Manitou ACCESS Platform 165 ATJ Repair Manual - PDF DOWNLOAD

R

BP 249 Z. I. 44 158 ANCENIS CEDEX FRANCE TEL : +33 (0)2 40 09 10 11

YOUR CONCESSIONARY

REF : 547 343 EN (01 / 02)

ACCESS PLATFORM

165 ATJ REPAIRS MANUAL

1st ISSUE DATE CATALOGUE INFORMATION

01 / 2002 ISSUE DATE

OBSERVATION

TABLE OF CONTENTS Groups

0 0-1-M.53 EN 10 10-2-12-M.53 EN 10-3-12 EN 30 30-2-43-M.53 EN 55

Chapters

General points Technical characteristics I.C. engine Removing 900 series engine Dismantling 900 series engine Axle Removing the front and rear axle assembly Arm - Platform

55-2-20-M.53 EN

Removing the hydraulic hoses situated in the arms, pads and telescope

55-8-23-M.53 EN

Adjusting the platform overload springs and the load detection unit

70

Hydraulics

70-2-44-M.53 EN

Removing the basket and turret rotation engine

70-2-60-M.53 EN

Removing the lifting cylinders

70-2-61-M.53 EN

Removing the tilt cylinder

70-2-63-M.53 EN

Removing the telescope cylinder

70-2-64-M.53 EN

Removing the compensation cylinder

70-2-70-M.53 EN

Removing the axle locking cylinder (oscillation)

70-2-73-M.53 EN

Removing the pendular cylinder

70-5-M.53 EN

Hydraulic pressure

70-6-M.53 EN

Hydraulic diagram

75 75-2-5-M.53 EN

Hydrostatic Removing the hydrostatic pump

TABLE OF CONTENTS Groups

Chapters

75-3-5 EN

Removing of the hydrostatic pump A10VG

75-3-24 EN

Dismantling of the hydrostatic motor A2F

75-8-5-M.53 EN 80

Adjusting the hydrostatic pump Electricity

80-2-10-M.53 EN

Replacing the electronic baseboard and microprocessor

80-8-81-M.53 EN

Position of the sensors

80-8-82-M.53 EN

Main electricity cabinet

80-8-84-M.53 EN

Parameterization of the machine

GROUPS 0

GENERAL POINTS

TECHNICAL CHARACTERISTICS 165 ATJ 0-1-M.53 EN

01 / 2002

1

CHARACTERISTICS ENGINE - Type - Number of cylinders - Number of strokes - Injection system - Ignition sequence - Rocker arm clearance (hot) . Inlet . Exhaust - Capacity - Bore - Stroke - Volumetric ratio - Nominal running speed - Idle speed - Full speed - Power BS.AU 141 to 1971 - Power ISO/TR 14396 - Power ISO 3046-1 : 1995 - Maximum torque - Air clearner

COOLING

PERKINS 903-27 diesel 3 in line 4 Direct 1.2.3.

0,20 mm 0,45 mm 2700 cm3 95 mm 127 mm 17.5:1 2100 rpm 1200 rpm 2310 rpm 39,5 kw (2100 rpm) 38,5 kw (2100 rpm) 37 kw (2100 rpm) 190 Nm (1200 rpm) Dry 3 microns

CIRCUIT

- Type - Fan

By water Suction 6 406,4 mm

. Number of blades . Diameter - Thermostat . Start opening . Full opening

ELECTRIC

80 / 84°C 96°C

CIRCUIT

- Earth - Battery - Alternator - Tension regulator - Starter

Négative 12 V - 105 A 14 V - 55 A Built into the alternator 12 V - 2,2 kw

HYDROSTATIC TRANSMISSION HYDROSTATIC PUMP

- Type

A10VG45 variable displacement automatic.power regulation 12V electromagnetic

- Gear reverser - Main pump . MAX. displacement . MINI. displacement . MAX. flow rate . Working pressure - Boost pump . Cubic capacity . MAX. flow rate . Boost pressure MAX. r.p.m.

- Filtration . Suction

45 cm3 0 cm3 94 L/min 350 Bar 8,4 cm3 17,64 L/min 25 Bar (Neutral transmission).

10 Microns

HYDROSTATIC ENGINE

A2FM à cylindrée fixe

- Type 2

with

AUXILIARY HYDRAULIC CIRCUIT - Pump type . Displacement - Lifting circuit, tilt, telescope, steering, rotation . Flow rate at full speed unladen . Pressure - Filtration . Pressure

Gear pump 22 cm3 46 L/min 200 Bar 10 Microns

BOARD FUSES BOARD 1 - F1 - F2 - F3 - F4 - F5 - F6

10A 10A 10A 10A 3A 1A

BOARD 2 - F1 - F2 - F3

16A 16A 3,15A

3

165 ATJ SPECIFICATIONS - Use

Interior and exterior

- Capacity

250 Kg including 2 persons

- Weight of on-board fittings allowed : . With one person in the basket . With two persons in the basket

170 kg 90 kg

- Hydrostatic transmission

4 drive wheels 4 steering wheels

- Turret rotation

Continuous

- Travel speed of the access platform . Forward . Reverse

0 to 6 km/h 0 to 6 km/h

- Working height - Floor height - Offset maxi

16 600 mm 14 600 mm 10 443 mm

- Access platform weight . Unladen . Rated load

8450 Kg 8700 Kg

- Number of speed

2

- Maximum slope

35%

- Ground clearance under chassis

447 mm

- Ground clearance under axle

375 mm

- Maximum authorized wind speed

45 km/h

- Admissible maximum tipping

9% or 5°

- Maximum allowed horizontal manual force

40 daN

- 1 daN = 1kg

FRONT AND REAR TYRES DIMENSIONS

PRESSURE

400 / 70 - 20

Mousse

LOADED BY PNEUMATIC UNLOADED

AR 4405Kg

AV 4045Kg

4

WITH MAX; LOAD +.

OFFCENTRING ON 1 WHEEL

5600 kg

DIMENSIONS 165 ATJ

L

G

H

J K

E

C

C1

A1

F

A A1 B C C1 D E F G H J K L

165 ATJ 7310 5450 2100 2342 2380 2360 447 375 1321 3667 3841 6476 2733

D B A

5

3

2

1

0

1

2

3

5

4

6

8

7

10

9

11

12 18 17 16

G1

15 14 I

13 H1

I

H2

12 11

G2

10 9 8 7 6

H3

G3

5 4 3 2 1 2

3

10 H4

3

G4

6

11

12

FILTERING ELEMENTS AND BELTS

1

2

3

4

5

DESIGNATION

6

REFERENCE

7

8

CLEAN

9

CHANGE

1 - Thermic engine oil filter

211 384

2 - Dry air filter cartridge

177 129

3 - Safety dry air filter cartridge

177 178

800 H

4 - Hydrostatic transmission oil filter cartridge (UP TO MACHINE 503 789)

519 856

800 H

518 250

800 H

5 - Auxiliary hydraulic oil filter cartridge

518 251

400 H

6 - Diesel Pre-filter

592 385

400 H

7 - Fuel filter cartrige

49 660

400 H

8 - Fan belt

561 299

9 - Suction strainer for hydraulic oil tank

77 402

Hydrostatic transmission oil filter cartridge (FROM MACHINE 503 790)

7

400 H 50 H

800 H

400 H

GROUPS 10

I.C. ENGINE

REMOVING 900 SERIES ENGINE 165ATJ 10-2-12-M.53 EN

01 / 2002

REMOVING OF ENGINE 903-27 - Put out the crankcase: · unscrew the nuts mark. 1 (Fig. A) of the hinges and of the pneumatic spring in order to free the crankcase.(10 mm wrench). · dismantle the reinforcing piece mark 3 (Fig. A) in order to free the place. (13 mm wrench)

A 2 3 1 1

- Cut out the power supply (batterie cut out).

- Mark and disconnect the electric power supply: · alternator, starter, water temperature sensor, preheating, engine oil pressure, engine stop...

- Plug out the earth wiremark 4 (Fig. B) near the alternator.

(13 mm wrench)

B

4

- Plug out the electric plug rep. 5 (Fig. C) of the hydrostatic pump with a screwdriver.

C

5 5

- Place a receptable under the frame und put out the water hoses mark 6 (Fig. D).

D

6

6

1

- Dismantle the clip mark. 7 (Fig. E) and and free the connection piece from its place.

E

7

- Mark the seven hoses mark 9 (Fig. F), plug them out and seal them.

8

F 9

9 9 9

9 9

9

- Mark the feed hoses and back on the tank rep. 10 (Fig. G).

G 10 10

- Plug them out and seal them. (17 mm wrench) - Put out the screw of the engine supports, 2 front (Fig. H) and 2 rear (Fig. I).

(24 mm wrench).

- Sling the engine on the support clips mark 11 (Fig. J) designed for that purpose.

- Lightly lift the engine, .move the whole in order to free the radiator fan propeller. The engine can be put down.

H

J

I

11

2

DISMANTLING 900 SERIES ENGINE 165ATJ 10-3-12 EN

01 / 2002

GROUPS 30

AXLE

REMOVING THE FRONT AND REAR AXLE ASSEMBLY 165ATJ 30-2-43-M.53 EN

01 / 2002

REMOVING THE FRONT AXLE ASSEMBLY A

- Switch off the electricity supply (battery cutout).

- Remove the front wheels (see instruction manual).

- Uncouple the cardan on a level with the axle (10 mm hexagonal wrench)

1

- Unscrew the four mountingscrews mark 1 (Fig. A) on the axle lock cylinder fitting (oscillation) . (30 mm wrench) 1

- Disconnect the two hydraulic hoses mark 2 (Fig. B) and seal. (19 mm wrench) - Disconnect the front axle assembly switch mark 3 (Fig. B).

- Use a hoist to hold the front axle assembly in complete safety. Front axle assembly weight : 290 Kg

B 3

4

- Unscrew the six front axle assembly mounting screws mark 4 (Fig. B) on the frame. (30 mm wrench) 2

- Remove the front axle assembly.

Refitting the front axle assembly

2

- Reassemble by following the above procedure in reverse order (wheel nut tightening torque : 34daNm) (front axle assembly tightening torque on the frame : 28.5 daNm)

4

REMOVING THE REAR AXLE ASSEMBLY C

- Switch off the electricity supply (battery cutout)

5

5

5

5

5

5

- Remove the rear wheels (see instruction manual) - Uncouple the cardan on a level with the axle. (18 mm wrench, 10 mm hex. wrench) - Disassemble the hydrostatic crankcase. (10 mm wrench) - Disconnect the eight hydraulic hoses mark 5 (Fig C) and seal. (19 mm wrench, 24 mm wrench and 10 mm hexagonal wrench) 5

- Disconnect the rear axle assembly switch mark 6 (Fig. C).

- Use a hoist to hold the rear axle assembly in complete safety. Rear axle assembly weight : 410 Kg - Unscrew the eight front axle assembly mounting screws mark 7 (Fig. D) on the frame. (30 mm wrench)

6

D

7

- Remove the rear axle assembly.

Refitting the rear axle assembly

7

- Reassemble by following the above procedure in reverse order. (wheel nut tightening torque : 34 daNm) (axle assembly tightening torque on the frame : 28.5 daNm) 1

GROUPS 55

ARMS - PLATFORM

REMOVING THE HYDRAULIC HOSES SITUATED IN THE ARMS, PADS AND TELESCOPE 165ATJ 55-2-20-M.53 EN

01 / 2002

INDEX

A – REMOVING THE HOSES FROM THE UPPER PART ....................................

2

B – REMOVING THE HOSES FROM THE LOWER PART ...................................

4

C – REMOVING THE GUIDE PADS FROM THE TELESCOPE CYLINDER.......

6

D – REMOVING THE PADS FROM THE TELESCOPE ARM ...............................

6

E – REMOVING THE PADS FROM THE MOBILE TUBE ......................................

6

F

7

– REMOVING THE TELESCOPE ...........................................................................

1

A - REMOVING THE HOSES FROM THE UPPER PART A1

A2

NOTE : For this operation, you will need guide wires.

- They must be resistant and flexible.

- Once attached onto the hoses, they will be covered with tape to form a type of cone that will facilitate the passage into the ducts.

2

A3 e.g : REMOVING THE PLATFORM ROTATION ENGINE HOSES 1

- Extend the telescope arm as far as possible.

- Cut off the power supply by means of a battery cutout.

- Dismantle the chain (foot and head) 1 (Fig. A3 ) (4 mm hex. wrench and 10 mm wrench ).

- Dismantle the flanges (34 and 38 page 5) in order to release the hoses (10 mm wrench).

- Dismantle the sheet metal flange 5 (page5) from the hose trough (10 mm wrench).

- Dismantle the telescope hose fixed cover 43 (page 5) (10 mm wrench).

- Remove the spiral from the hoses of the basket rotation motor 2 (Fig A4).

A4

- Locate the two hoses 3 (Fig. A4) on the rotation motor.

2

- Remove them and seal off with plugs.

3

- Fix a guide wire at the end of the damaged hose.

- Dismantle the cover 4 (Fig A5) from the upper articulation (10 mm wrench).

- Remove the spiral from the hoses located in the articulation.

- Disconnect the hose.

- Fix a guide wire and release the hose.

REASSEMBLY - Fix the guide wire onto the new hose.

A5

- Connect the new hose.

- Pass the other end of the hose into the duct by pulling it with the aid of the remaining guide wire.

- Position the hose along the fixed telescope arm and place on the chain.lower folded sheet metal. Then reasemble the fixed telescope hose cover.

- While continuing to pull with the aid of the guide wire, pass the hose into the chain.

- Reassemble the chain.

- Position the chain into the hose shoot and reassemble the sheet metal flange.

- Pull and reconnect to the rotation motor.

- Return the articulation ducts and the spirals to their original position.

- Reassemble the flanges.

- Before operating the platform, check the hydraulic oil level.

Note :

- The removal of the tilt cylinder hoses is identical to that of the platform rotation engine.

- The removal of the telescope cylinder hoses.calls for the exclusive dismantling of the telescopearm cover and of the articulation cover.

- Care must be taken to return the duct to the level of the articulations leaving curve important enough for the movement.

- The removal of the pendular cylinder is identical to that of the platform rotation engine.

3

4

B - REMOVING THE HOSES FROM THE LOWER PART B1

NOTE : For this operation , you will need guide wires.

- They must be resistant and flexible.

- Once attached onto the hoses, they will be covered with tape to form a type of conethat will facilitate the passage into the ducts.

- Position the arms in order to facilitate the work..

E.g : Removing the telescopic cylinder hoses.

- Cut off the power supply by means of a battery cutout.

- Dismantle the lower tie rod hose cover as well as the upper arm hose cover.

- Dismantle the right turret cowl.

- Dismantle the damaged hose at the articulation level.

- Fix a guide wire onto its end.

- Disconnect the damaged hose at the distributor level and remove it by pulling it.

REASSEMBLY - Proceed in the same way as for the reassembly of hoses from the upper part.

4

5

14 15 21 17 16

26 27 25 29 28 23

53

10 12 11

56 57 58

5 BA 203

6

7 9

35

34 36

31 33 32 30

18

8

5

41 40

20

3 4 2

25

30 26

42

37

1

23 22 24 27

38 39

44 45

FLECHE TELESCOPIQUE TELESKOPAUSLEGER AGUILON TELESCOPICO TELESCOPIC JIB

54

42

41

13 15 14

14 15 13 19

43

44 45

17 16 16 17

59 55

50 52 51 49 53

165 ATJ

06 / 12 / 00

46 48 47 18 53 59

P.A.O

C - REMOVING THE TELESCOPE CYLINDER GUIDE PADS - For the removal of the telescope cylinder guide pads1 (Fig C1) (12 mm wrench) , the telescopehas to be removed.

C1

- See removing the telescope cylinder.

- Remove the guide pads.

REASSEMBLY - Carry out the operations described above in the reverse order.

1

D - REMOVING THE TELESCOPE ARM PADS D1

- Extend the telescope arm to allow easy access.

- Dismantle the fixing device of the jib head pads 2 (Fig. D1) (4 mm hex. wrench, 13 mm wrench, 6 mm hex. wrench, 19 mm wrench).

- Care must be takenwith the positionning of the adjusment plates.

2 4

- Remove the pads.

2

REASSEMBLY 3

- Carry out the operations described above in the reverse order.

- If necessary, fit the adjustment plates : side plates 3 (Fig D1) : 516326 upper plates 4 (Fig D1) : 516327

E - REMOVING THE MOBILE TUBE PADS E1

- Remove the mobile tube.

- Dismantle the fixing device of the jib base pads 5 (Fig.E1) (6 mm hexagonal wrench, 19 mm wrench).

6

5

- Care must be taken with the positioning of the adjusment plates 6 (Fig E1).

- Remove the pads.

5

REASSEMBLY - Carry out the operations described above in the reverse order.

- If necessary, fit the adjustment plates : adjustment plates 6 (Fig E1) : 516325

6

F - REMOVING THE TELESCOPE F1

- Wedge the basket.

4

- Hold back the mobile tube with a rope.

- Remove the telescope cylinder (see removing the telescope cylinder).

- Dismantle the head axle1 (Fig. F1) of the tilt cylinder (12 mm wrench).

- Démonter l’axe de l’articulation 2 (Fig. F1) of the pendular (12 mm wrench and circlip pliers).

2 1

- Dismantle the tilt cylinder 3 (Fig. F2).

- Dismantle the hose trough4 (Fig. F1) (3 screws, 10 mm wrench).

F2 - Pull out the hoses.

- Dismantle the two closing covers 5 (Fig. F4) (8 screws, 10 mm wrench).

- Dismantle the chain 6 (Fig. F3) (2 screws, 4 mm hexagonal wrench).

- Dismantle the chain housing 7 (Fig. F3) (10 mm wrench).

- Dismantle the jib head upper pad 8 (Fig. F4) (13 mm wrench, 4 mm hexagonal wrench)

3

- Dismantle the jib head lower pad 9 (Fig. F4) (19 mm wrench, 6 mm hexagonal wrench) F3 - Remove the telescope mobile tube 10 (Fig. F3).

10

REASSEMBLY - Carry out the operations described above in the reverse order.

6

7

F4

5 8

9 7

ADJUSTING THE PLATFORM OVERLOAD SPRINGS AND THE LOAD DETECTION UNIT 165ATJ 55-8-23-M.53 EN

01 / 2002

ADJUSTING THE PLATFORM OVERLOAD SPRINGS This operation must be carried out when one or various springs have been dismantled.

- Adjust each spring in accordance with the dimensions given below. (30 mm wrench)

68

B

79

A

ADJUSTING THE LOAD DETECTION UNIT - Loosen the load detection screw as much as possible. (16 mm wrench) - Place a 250 kg load into the basket and adjust the load detection screw to allow it to operate : - with 250 kg the sound alarm must not be activated - with 260 kg the sound alarm must be activated.

C 1 2

- The four springs must have the same stress (see chapter : adjustment of the platform overload springs).

- The four connecting rods mark1 (Fig. C) must be subject to the same tension. This adjustment is carried out with the fitting mark 2 (Fig. C).The detection of the overload must be correct no matter where the load is placed in the basket.(18 mm wrench)

Further to these modifications, it is imperative that static and dynamic controls be carried out by a certification body.

1

load detection screw

GROUPS 70

HYDRAULICS

REMOVING THE BASKET AND TURRET ROTATION ENGINE 165ATJ 70-2-44-M.53 EN

01 / 2002

REMOVING THE BASKET ROTATION ENGINE - Locate the basket rotation engine hoses.

- Dismantle the ring gear case 1 (Fig. A)(3 screws, 10 mm wrench).

- Dismantle the two hydraulic hoses 2 (Fig. A) (19 mm wrench).

- Dismantle the two mounting screws 3 (Fig. A) of the engine (10 mm hex. wrench).

- Remove the engine 4 (Fig. A).

A

2

Nota : tightening torque of mountig screws 3 : 8 +- 10% daN.m 1

3

4

REMOVING THE TURRET ROTATION ENGINE - Position the platform in such a way as to gain access to the turret rotation engine.

B 8

- Disassemble the inner turret casing (4 screws, 10 mm wrench).

6

- Locate the hoses.

- Disassemble the lower turret polyester casing (7 screws, 10 mm wrench).

7

- Disassemble the two hydraulic hoses 5 (Fig. B) (19 mm wrench, 24 mm wrench).

- Disassemble from these two ends the hydraulic hose 6 (Fig. B) (19 mm wrench).

- Disassemble the two engine mounting screws 7 (Fig. B) (8 mm hexagonal wrench height 40).

- Remove the engine 8 (Fig. B).

When remounting the engine, use two new mounting screws 7 (Fig. B) (qualité 12.9) with average locking compound. (tightening torque : 13.5 +- 10% daN.m)

1

5

5

2

25 165 ATJS

150 ATS 2

REMOVING THE LIFTING CYLINDERS 165ATJ 70-2-60-M.53 EN

01 / 2002

REMOVING THE LIFTING CYLINDERS A

LIFTING CYLINDER OF LOWER ARM - Remove the right turret cowl.

- Locate the hydraulic hoses.

2

- Position the lower arm horizontally.

- Tightly block the lower arm using stays or a pulley.

- Dismantle the locking axles 1 (Fig. A) of the lower cylinder.

1

- Remove the cylinder 2 (Fig. A).

- Disconnect the hydraulic hoses (19 mm wrench).and seal them.

REASSEMBLY - Carry out the operations described above in the reverse order.

B 2

LIFTING CYLINDER OF UPPER ARM (Fig. B) - Lift the middle arm in order to release the access to the cylinder foot axle.

- Follow the same instructions described above while replacing “lower arm” by “upper arm”.

1

1

10 CA 157

LOWER LIFTING CYLINDER

2

10 CA 156

UPPER LIFTING CYLINDER

3

REMOVING THE TILT CYLINDER 165ATJ 70-2-61-M.53 EN

01 / 2002

REMOVING THE TILT CYLINDER A - Locate the hydraulic hoses.

- Wedge the basket with a hoisting device (lift as much as possible).

- Dismantle the locking axles 1 (Fig. A and B)(13 mm wrench, circlip pliers).

- Remove the cylinder.

- Disconnect the hydraulic hoses (19 mm wrench) and seal them.

1

REASSEMBLY - Carry out the operations described above in the reverse order.

B 1

1

10 CD 66

TILT CYLINDER

2

REMOVING THE TELESCOPE CYLINDER 165ATJ 70-2-63-M.53 EN

01 / 2002

REMOVING THE TELESCOPE CYLINDER A - Position the telescope arm horizontally.

1

- If necessary, hold back the basket-mobile tube assembly.

- Dismantle the telescope cylinder head axle 1 (Fig. A) (circlips pliers).

- Retract the telescope cylinder until it comes to a stop.

- Dismantle the telescope arm cover 2 (Fig. B) (2 screws, 10 mm wrench).

- Locate the hydraulic hoses.

- Disconnect the hydraulic hoses 3 (Fig. C) (24 mm wrench).and seal them.

- Dismantle the fixing device from the cylinder foot axle 4 (Fig. D) and drive it out (13 mm wrench).

B

- Remove the cylinder.

2

REASSEMBLY - Carry out the operations described above in the reverse order.

C

3

D

4

1

10 CC 71

TELESCOPE CYLINDER

2

REMOVING THE COMPENSATION CYLINDER 165ATJ 70-2-64-M.53 EN

01 / 2002

REMOVING THE COMPENSATION CYLINDER A - Locate the hydraulic hoses.

1

- Lift the middle arm in order to release the access to the compensation cylinder head and foot axles.

- Cut off the power supply.

- Dismantle the locking axles 1 (Fig. A) (13 mm wrench).

1

- Remove the cylinder.

- Disconnect the hydraulic hoses (19 mm wrench) and seal them.

REASSEMBLY - Carry out the operations described above in the reverse order.

1

10 CB 38

COMPENSATION CYLINDER

2

REMOVING THE AXLE LOCKING CYLINDER (OSCILLATION) 165ATJ 70-2-70-M.53 EN

01 / 2002

REMOVING THE AXLE LOCKING CYLINDER (OSCILLATION) - Position the platform (lower arm lift as much as possible) and orientate the right front wheel so as to obtain as much accessibility as possible.

A 2

- Cut off the power supply (battery cut out).

1 1

- Disconnect the safety valves 1 (Fig A) with a screwdriver.

- Disconnect the hydraulic hose 2 (Fig. A) and seal it. (19 mm wrench)

3

- Dismantle the shafts 3 (Fig. A and B). (circlip pliers) - Remove the cylinder.

B REASSEMBLY - Carry out the operations described above in the reverse order.

1

3

AXLE LOCKING CYLINDER (OSCILLATION)

2

REMOVING THE PENDULAR CYLINDER 165ATJ 70-2-73-M.53 EN

01 / 2002

REMOVING THE PENDULAR CYLINDER - Place the platform on the ground.

A

- Cut off the power supply (battery cut out).

1

- Disconnect the hydraulic hoses and seal them (19 mm wrench).

2

- Dismantle the axles 1 (Fig. A and B). (10 mm wrench and circlip pliers).

- Remove the lower arm 2 (Fig. A).

3

- Remove the cylinder 3 (Fig. A).

B REASSEMBLY - Carry out the operations described above in the reverse order.

1

1

10 CA 155

PENDULAR CYLINDER

2

HYDRAULIC PRESSURE 165ATJ 70-5-M.53 EN

01/ 2002

All the pressures are adjusted between 25 et 30°c

A 1

- Remove the turret right cowling.

MAIN CIRCUIT (240 BARS) - Required tooling • 1 pressure gauge (0-400 bar) ............549885 • 1 test hose .................................................549887 - Connect the pressure gauge onto the pressure tapping point 1 (Fig. A).

- Lower the lower arm as much as possible.

- Read the pressure on the pressure gauge.

- Main circuit pressure = 240 bar.

- If necessary, act upon the pressure limiter 2 (Fig. A) with a 1/4 mm hex. wrench (adjusting screw) after having removed the plug.

1

2

HYDRAULIC DIAGRAM 165ATJ 70-6-M.53 EN

01 / 2002

165 ATJ BASKET HYDRAULIC DIAGRAM

1

2

3

4

PRINCIPAL DISTRIBUTOR

5

DANFOSS DISTRIBUTOR

THERMIC ENGINE

6

BRAKE BLOCK

19

PERKINS 900 ENGINE

10

Rotating seal Opening 1 Right side

11

5

B

50% SLOPE OPTION

6

21

7 8

1

2

3

20

4

9

Screw delivered with coupling

18

12

7

13

18

15

14

Fuel filter

17

7

Rotating seal Opening 2 Left side

50% SLOPE OPTION

CANCELLED PARTS PART LISTS REF 520856

21 20 18 16 15 14 13 11 10 4 3 2 1 Rep.

-

1 1 1 2 2 1 1 1 1 1 1 2 1 1 1

Nbre

RAC CD ADA MA 20S / FE20SOR Oil filter support RAC UN MA8S 12X150 RL W14 RAC UN MA20S / MA3/4BSP JE Engine cowling support FLE H2S 19FC 20S 90FC 25S L 550 FLE H2S 16FC 20S 90FC 20S L 1800 Max suction filter FT1ASP25 SBP FLE H4S 19BR3/4” 30FC 25S90 L1050 FLE H4S 19BR3/4” 30FC 25S90 L940 Screw CHC M14-40 C8.8 Hydrostatic pump A10VG45 Flywheel casing Coupling Designation

217043 519600 518365 CI 42256 482664 518151 518288 203663 519596 518290 518292 CI 45631 518184 519115 517367 Reference

ADDED PARTS PART LISTS REF 520855 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

1 2 1 2 1 1 1 1 1 2 1 1 1 8 10 4 1 2 1 1 1

Rep.

Nbre

RAC UN MA8S 14X150 RL W16 RAC CD ADA MA25S FE25S OR RAC UN MA25S / MA1”1/4BSP JE RAC CD ADA MA20S FE20S OR Engine cowling support FLE H1S 19FC 25S 90FC 25S L 580 FLE H1S 19FC 25S 90FC 20S L 1800 Filter LPF BN/HC160DE10W1X/-KB Screw H M10-20 FLE H4S 19FC 25S 90° FC25S 90° L 950 FLE H4S 49FC 25S 90° FC25S 90° L 850 Flanked elbow connection Screw CHC M10-35 10.9 ZN8/C RL, W10 ZN12C Flange 600 psi Flanked straight connection Vis CHC M16-40 Hydrostatic pump A4VG56 Flywheel casing Coupling DX250/71

CI 175746 CI 42322 CI 216267 593878 CI 217043 593637 593582 593583 CI 593542 CI 63727 593856 593855 593860 CI 202250 CI 42232 593844 593859 CI54366 592406 592498 592499

Designation

Reference

8

GROUPS 75

HYDROSTATIC

REMOVING THE HYDROSTATIC PUMP 165ATJ 75-2-5-M.53 EN

01 / 2002

REMOVING THE A10VG PUMP - Unscrew the nuts mark 1 (Fig. A) on the hinges and pneumatic spring to free the crankcase mark 2 (Fig. A). (10 mm wrench).

A 2

1 1

- Switch off the electricity supply (battery cut out).

- Disconnect the electrical plugs mark. 3 (Fig. B) on the hydrostatic pump with a screwdriver.

B 3

3

6

- Locate the eight hoses mark 4 (Fig. C), disconnect and seal them.

(19, 30, 36 mm wrenches and 8 mm hexagonal wrench).

C 4

5

- Sling the hydrostatic pump 5 (Fig. C).

4

- Unscrew the two screws mark 6 (Fig. B). (21 mm wrench) 4

- Take down the unit with a screwdriver.

4

- You now have access to the ring gear.

4 4

- Place a receptacle under.the pump.

- Disconnect the lower drain hose mark 7 (Fig. C) then remove the pump.

(46 mm wrench) - To reassemble, follow the same procedure in the reverse order.

1

7 4

REMOVING THE HYDROSTATIC PUMP A10VG 165ATJ 75-3-5 EN

01 / 2002

Reparaturanleitung / Repair instructions A10VG ... 28-63 Baureihe/Series 10

RDE 92750-01-R/10.01 ersetzt/replaces 07.97

Mobile Hydraulics

RDE 92750-01-R/10.01

Hinweis / Inhalt Notice / Contents

Reparaturanleitung A10VG Repair Instructions A10VG

HINWEIS

NOTICE

Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage.

Specifications, descriptions and illustrative material shown herein were as accurate as known at the time this publication was approved for printing.

Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.

Methoden und Vorrichtungen sind Empfehlungen, für deren Resultat wir keine Haftung übernehmen können.

BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.

BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to change speci-fications, materials, or design without notice and with-out incurring obligation.

Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem Teststand vorzunehmen.

Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.

Optional equipment and accessories may add cost to the basic unit, and some options are available only in combination with certain models or other options.

For the available combinations refer to the relevant data sheet for the basic unit and the desired option.

Adjustment and tests have to be carried out on the test bench under operating temperatures.

Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermitteln wir in unseren Schulungskursen.

Protection of personnel and property has to be guaranteed by appropriate measures.

Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

Seite/ Page

A10VG

A10VG Schnittbild Allgemeine Reparaturhinweise Dichtsätze und Baugruppen Triebwelle abdichten Hilfspumpe abdichten Stellkolbendeckel abdichten Ventile abdichten Druckabschneidung abdichten Regelventil abdichten Steuergerät demontieren Ansteuergeräte Pumpe demontieren Triebwerk ausbauen Stellkolben demontieren Überprüfungshinweise Turcon-Glyd-Ring montieren Pumpe montieren Triebwerk einbauen Pumpe montieren Montageanweisung für Anziehdrehmomente Sicherheitsbestimmungen Einstellhinweise

2

Brueninghaus Hydromatik

CONTENTS

3-4 5 6-8 9 10-12 13 14 15 16 17 18-22 23-25 26 27-28 29-31 32 33-35 36-38 39 40-43 44-45 46-52

Sectional view General repair instructions Seal kits and sub assembly groups Sealing of the drive shaft Sealing of the boost pump Sealing of the control piston cover Sealing of the valves Sealing of the pressure cut-off valve Sealing of the regulator valve Removal of the control unit Control units Pump disassembly Removal of the rotary group Disassembly of the positioning piston Inspection notes Turcon-Glyd-ring Assembly of the pump Installation of the rotary group Assembly of the pump Assembly guidelines for tightening torques Safety regulations Adjustment instructions

RDE 92750-01-R/10.01

Schnittbild

Reparaturanleitung A10VG Repair Instructions A10VG

Sectional view

mit Druckabschneidung with pressure cut-off

HW

ohne Druckabschneidung without pressure cut-off

HDD

EPD

Brueninghaus Hydromatik

3

RDE 92750-01-R/10.01

Schnittbild Sectional view

DA

4

Brueninghaus Hydromatik

Reparaturanleitung A10VG Repair Instructions A10VG

RDE 92750-01-R/10.01

Allgemeine Reparaturhinweise General repair instructions

Reparaturanleitung A10VG Repair Instructions A10VG

Achtung!

Nachfolgend Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten!

Attention!

Please take into account the following guidelines when carrying out repair work on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close all openings on the hydraulic units.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK-Ersatzteile verwenden.

Replace all seals.

Use only original BRUENINGHAUS HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch Schleifpapier kann die Oberfläche beschädigen.

Check all sealing and sliding surfaces for wear.

Attention: Rework of the sealing areas, f. ex., with abrasive paper can cause damage to the surface.

Hydraulikaggregate vor Inbetriebnahme mit Betriebsmedium befüllen.

Fill the hydraulic units with the operating mediumbefore commissioning.

Brueninghaus Hydromatik

5

RDE 92750-01-R/10.01

Dichtsätze und Baugruppen Seal kits and sub-assemblies

Reparaturanleitung A10VG Repair Instructions A10VG

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben Positioning piston

2 1

3

1. Anschlußplatte Standard, 2. Anschlußplatte mit Druckabschneidung 3. Anschlußplatte DA mit Druckabschneidung 1. Standard connection plate 2. Connection plate with pressure cut-off 3. DA connection

6

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Dichtsätze und Baugruppen Seal kits and sub-assemblies

Reparaturanleitung A10VG Repair Instructions A10VG

Ansteuergerät HW Control unit HW

Ansteuergerät HW mit Nullagenanzeige Control unit HW with zero indicator

alt / old neu / new

Ansteuergerät HD Control unit HD

alt / old neu / new

Ansteuergerät EP Control unit EP

alt / old neu / new Ansteuergerät DA Control unit DA

Brueninghaus Hydromatik

7

RDE 92750-01-R/10.01

Dichtsätze und Baugruppen Seal kits and sub-assemblies

Reparaturanleitung A10VG Repair Instructions A10VG

Hilfspumpe mit Verschleißplatte Boost pump with wear plates

1

2

1. HD - Ventil 2. HD - Ventil mit Bypass 3. ND - Ventil 1. High pressure valve 2. High pressure valve with bypass function 3. Low pressure valve

3

Druckabschneidung Pressure cut-off

3 2 1

1. DA - Regelventil, verstellbar mit Hebel 2. DA - Regelventil, festeingestellt 3. Zuschaltventil 1. DA control valve, adjustable via a lever 2. DA control valve, fixed 3. Switching valve

8

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Triebwelle abdichten Sealing of the drive shaft

Reparaturanleitung A10VG Repair Instructions A10VG

Triebwelle abkleben.

Sicherungsring ausbauen.

Protect the drive shaft (e.g. masking tape).

Remove the retaining ring.

Blechschraube in die mit Gummi gefüllten Löcher eindrehen.

Mit Zange WDR herausziehen.

Screw the metal screws into the holes that are fitted with rubber.

Withdraw the shaft seal using pliers.

Wellendichtring mit Buchse auf Anschlag einpressen.

Press-in the shaft seal with a bush untilth end stop is reached.

Brueninghaus Hydromatik

9

RDE 92750-01-R/10.01

Hilfspumpe abdichten Sealing of the boost pump

Reparaturanleitung A10VG Repair Instructions A10VG

* * Achtung! * "Angefaste Seite" zum Deckel montieren.

Note! * Mount the "chamfered side" towards the cover.

Befestigungsschrauben ausbauen.

Remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Einbaulage kennzeichnen.

Mark position.

10

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Hilfspumpe abdichten Sealing of the boost pump

Reparaturanleitung A10VG Repair Instructions A10VG

O-Ring ausbauen.

Remove O-ring.

Hilfspumpe abdrücken.

Pry off the boost pump.

2 1. Verschleißplatte 2. Fixierstift 1

3

1 2

1. Wear plate 2. Locating pin

1. Kantsil-Ring 2. Entlastungsnut 3. Fixierstift 1. Kantsil-ring 2. Unloading channel 3. Locating pin

Verschleißplatte einsetzen.

Drehrichtung beachten!

Fit wear plate taking the direction of rotation account.

Brueninghaus Hydromatik

11

RDE 92750-01-R/10.01

Hilfspumpe abdichten Sealing of the boost pump

Reparaturanleitung A10VG Repair Instructions A10VG

Verschleißplatte einsetzen.

Drehrichtung "Rechts" bei Blick auf die Triebwelle.

Achtung! Fixierstift Fit wear plate.

Direction of rotation "clockwise" looking on the drive shaft.

Attention! Locating pin

*

Saugseite - suction side

Verschleißplatte einsetzen.

Drehrichtung "Links" bei Blick auf die Triebwelle.

Achtung! Fixierstift Fit wear plate.

Direction of rotation "anti-clockwise" looking on the drive shaft.

Attention! Locating pin

*

Saugseite - suction side

Linkslauf - anti-clockwise

Rechtslauf - clockwise

Hilfspumpe montieren.

Fit boost pump

O-Ring und Deckel montieren.

Fit O-ring andcover plate.

12

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Stellkolbendeckel abdichten Sealing of the control piston cover

Reparaturanleitung A10VG Repair Instructions A10VG

Achtung!

Korrekte mechanische 0-Lageneinstellung überprüfen!

Attention!

Check that the mechanical "0"-position is correct!

Kontermutter ausbauen, Stellschraube gegenhalten.

Deckel kennzeichnen. Maß festhalten, Kontermutter lösen.

Remove lock unit, whilst holding the adjustment screw, mark the cover plate, ascertain the dimension, loosen locknut.

Deckel von Stellschraube "abschrauben".

Remove the cover from the adjustment screw by unscrewing it from the adjustment screw.

Kontrolle! O-Ring (1), Nut (2), Gehäuse und Deckel (3).

Achtung!

Korrekte mechanische 0-Lageneinstellung muß nach Einbau im Gerät bzw. Prüfstand erfolgen.

Check! O-ring (1), groove (2), housing with cover (3).

Attention!

The correct mechanical "0" position has to be adjusted after the unit has been built into the machine or on a test rig.

Brueninghaus Hydromatik

13

RDE 92750-01-R/10.01

Ventile abdichten Sealing of the valves

Reparaturanleitung A10VG Repair Instructions A10VG

PHD -Ventil

mit Bypass

PHD -valve

with bypass-function

PSP-Ventil PSP -valve

Gewinde vor Montage des neuen O-Ringes abkleben.

(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

* Stützring

Ventilkegel mit Druckfeder ausbauen. * mit Bypassfunktion Remove valve poppet with compression spring. * with bypass function

* O-Ring

Gewinde vor Montage des neuen O-Ringes abkleben.

(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

14

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Druckabschneidung abdichten Sealing of the pressure cut-off valve

Reparaturanleitung A10VG Repair Instructions A10VG

*

Wechsel der Dichtmutter.

Einstellmaß festhalten (*).

Exchanging the sealing nut.

Ascertsion the adjustment dimension (*).

Achtung!

Nach Einbau "Ventileinstellung" überprüfen.

Attention!

After assembly check "valve setting".

Brueninghaus Hydromatik

15

RDE 92750-01-R/10.01

Regelventil abdichten Sealing of the control valve

Reparaturanleitung A10VG Repair Instructions A10VG

Regelventil ausbauen.

Remove control valve.

Blendendurchmesser nicht beschädigen.

Kontrolle: Blendendurchmesser Do not damage the orifice diameter.

Check: Orifice diameter.

Gewinde vor Montage des neuen O-Ringes abkleben.

Before fitting the new O-ring cover the threads (e.g. tape).

16

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Steuergerät demontieren Removing of the control unit

Reparaturanleitung A10VG Repair Instructions A10VG

HW alt / old DA

alt / old

neu / new HD neu / new

HW mit Nullagenschalter HW with zero position switch

*

EP neu / new

alt / old

* Befestigungsschrauben demontieren. * Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check Sealing surface (1), gasket (2), O-rings (3).

Brueninghaus Hydromatik

17

RDE 92750-01-R/10.01

Ansteuergeräte Control units

NG / Size 28

Reparaturanleitung A10VG Repair Instructions A10VG

Ansteuergerät HW HW control unit

NG / Size 45

Ansteuergerät DA DA control unit

18

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Ansteuergeräte Control units

Reparaturanleitung A10VG Repair Instructions A10VG

Ansteuergerät HD - EP alt HD - EP control unit old HD alt / old

EP alt / old

HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP New HD - EP control unit old

202,0 mm

131,0 mm 214,4 mm

77,4 mm

Brueninghaus Hydromatik

19

RDE 92750-01-R/10.01

Ansteuergeräte Control units

Ansteuergerät HD neu HD - control unit new

Ansteuergerät EP neu EP - control unit new

20

Brueninghaus Hydromatik

Reparaturanleitung A10VG Repair Instructions A10VG

RDE 92750-01-R/10.01

Ansteuergeräte Control units

Reparaturanleitung A10VG Repair Instructions A10VG

* Markierung Montageposition HD * Marking the assembly position HD

* *

*

*

* Markierung Montageposition HD

Wird von EP- auf HD-Ausführung umgebaut Deckelposition beachten siehe Markierung Leckölkanal offen wird geschlossen.

Zugfeder tauschen!

* Assembly position marker HD

Is converted from EP into the HD version take note of the cover position, see marker The open leakage port is plugged Exchange the tension spring!

Brueninghaus Hydromatik

21

RDE 92750-01-R/10.01

Ansteuergeräte Control units

Reparaturanleitung A10VG Repair Instructions A10VG

*

Markierung Montageposition EP Assembly position marker EP

Die neuen Proportionalmagnete müssen bei der Inbetriebnahme entlüftet werden. Wird die Luft nicht aus dem Ankerraum entfernt, kann es zum Schwingen der Ansteuerung kommen.

Zum Entlüften ist am Ende des Magneten, im Messingteil, ein kleiner Gewindestift M4, SW 2 vorhanden.

Dieser Gewindestift ist max. 2 Umdrehungen herauszudrehen und nach dem Entlüften mit 1 Nm wieder festzuziehen.

Bei der Ausführung mit Nothand mit Federrückzug muß zum Entlüften die Kunststoffmutter mit Gummibalg entfernt und nach dem Entlüften mit 5+1 Nm wieder angeschraubt werden.

Hydraulische Nullage Hydraulic zero position Klemmschraube Clamping screw

*

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen.

Bleed screw *. Unscrew by a max. of 2 turns

*

*

The new proportional solenoids must be bled during commissioning. If the air is not removed from the armature chamber oscillations at the control can occur.

For bleeding purposes there is, on the end of the solenoid, in the brass component a small set screw M4, 2A/F. This can be unscrewed by a maximum of 2 turns and then after completion of the bleeding tightened to a maximum of 2 Nm. For the version with hand override and spring return the plastic nut with rubber coating has to be removed for bleeding. After bleeding it has to be replaced and tightened with 5+1 Nm.

Polrohr Anziehmoment 19 Nm Pole tube Tightening torque 19 Nm

*

*

Markierung Montageposition EP Assembly position marker EP

Klemmschraube 6,1 Nm Clamping screw 6,1 Nm

Anziehmoment 5+1 Nm Steckschlüssel SW 26 Tightening torque 5+1 Nm 26 A/F socket spanner

Hydraulische Nullage Exzenterstift Hydraulic zero point Eccentric pin

Beim Lösen der Klemmschraube Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw Hold the eccentric pin - hydraulic zero point 22

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Pumpe demontieren Pump disassembly

Reparaturanleitung A10VG Repair Instructions A10VG

HD alt/old

EP alt/old

HD neu/new

EP neu/new

Druckabschneidung Pressure cut-off

DA alt/old DA neu/new

Excenterschraube Eccentric screw

Brueninghaus Hydromatik

23

RDE 92750-01-R/10.01

Pumpe demontieren Pump disassembly

Reparaturanleitung A10VG Repair Instructions A10VG

Lage der Hilfspumpe und Anschlußplatte markieren.

Hilfspumpe abbauen.

Mark position of the boost pump and the port plate.

Remove the boost pump.

DA-Ausführung: Lage der Verdrillschraube markieren (1).

Verdrillschraube auf Demontageposition stellen (2).

DA-design: Mark the position of the eccentric screw (1).

Set the eccentric screw to disassembly position (2).

Anschlußplattenbefestigung lösen. Anschlußplatte abheben.

Remove connecting plate fixing screws.

Lift off the connection plate.

Steuerplatte abdrücken.

Lage notieren.

Lift off control plate.

Note position.

2 3 1

24

Brueninghaus Hydromatik

4

Kontrolle!

O-Ring mit Nut (1) O-Ring mit Nut (2) Fixierstift - Steuerplatte (3) Bei DA - kein Stift T - Ablauf verschlossen (4) Check O-ring and groove (1) O-Ring and groove (2) Locating pin - control plate (3) type DA has no pin T drain plugged (4) open for type DA

RDE 92750-01-R/10.01

Pumpe demontieren Pump disassembly

Reparaturanleitung A10VG Repair Instructions A10VG

DA-Ausführung Zylinder nach unten drücken (1).

Verdrillschraube herausdrehen (2).

Triebwerk ausheben (3).

DA- version Press the cylinder downwards (1).

Remove the eccentric screw (2).

Lift out the rotary group (3).

"Ausbauen" 1. Zylinder 2. Schwenkwiege 3. Gelenkstift "Remove" 1. Cylinder 2. Swash plate 3. Joint pin

Sicherungsring, WDR ausbauen.

Remove retaining ring, remove drive shaft seal.

Brueninghaus Hydromatik

25

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Triebwerk ausbauen Removal of the rotary group

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with light hammer strokes.

Lagerschalen ausbauen.

Remove bearing shells.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Sicherungsring demontieren.

Feder und Druckstifte ausbauen.

Remove circlip.

Remove spring and pressure pins.

26

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Stellkolben demontieren - Gehäuse mit Buchse Disassembly of the positioning piston - housing with bush

Reparaturanleitung A10VG Repair Instructions A10VG

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen.

Disassemble the control piston.

Brueninghaus Hydromatik

27

RDE 92750-01-R/10.01

Stellkolben demontieren - Gehäuse mit Turcon-Glyd-Ring Disassembly of the positioning piston - housing with Turcon-Glyd-ring

Reparaturanleitung A10VG Repair Instructions A10VG

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen (Gehäuse Turcon-Glyd-Ring Abdichtung).

Disassemble the control piston (Housing Turcon-Glyd-ring).

28

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Überprüfungshinweise Inspection notes

Reparaturanleitung A10VG Repair Instructions A10VG

Alle Lager erneuern.

Replace all bearings.

Kontrolle!

1. Verzahnung, ausgeschlagen, Passungsrost.

2. Lauffläche.

3. Einlaufrillen vom Wellendichtring.

Check!

1. Splines, wear steps, corrosion.

2. Running surfaces.

3. Grooves made by the shaft seal.

Stellkolbenlaufbüchse (1) riefenfrei, nicht ausgelaufen.

1 1

Check that the control piston guide bush (1) is free of grooves and is free of wear.

Kontrolle!

Stellkolben (1) riefenfrei.

Check!

Control piston (1) is not scored.

Brueninghaus Hydromatik

29

RDE 92750-01-R/10.01

Überprüfungshinweise Inspection notes

Reparaturanleitung A10VG Repair Instructions A10VG

Kontrolle!

Gleitfläche riefenfrei.

Check!

Sliding surface free of grooves.

Kontrolle!

Verbindung Gleitstein/Schwenkzapfen spielfrei.

Check!

That the connection of slide ring/swivel pin is free of play.

Kontrolle!

Rückzugeinrichtung riefenfrei (1), keine Einlaufspuren (2) im Gleitschuhbereich.

Check!

That the retaining plate is free of grooves (1) and that there is no wear (2) in the slipper pad area.

Kontrolle!

Lauffläche (1) keine Kratzer, keine Metalleinlagerungen, kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!

Check to see that there are no scratches or metal deposits on the sliding surface (1), and that there is no axial play (2), (pistons must only be replaced as a set).

Kontrolle!

Zylinderbohrungen (1), Verzahnungen (2).

Check!

Cylinder bores (1), splines (2).

30

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Überprüfungshinweise Inspection notes

Reparaturanleitung A10VG Repair Instructions A10VG

Kontrolle!

Zylindergleitfläche (1) riefenfrei, nicht eingelaufen, keine Einlagerungen, Steuerplatte (2) nicht riefig (nur satzweise austauschen).

Check!

Cylinder sliding surface (1) free of grooves, no wear, no embedded foreign particles. That there are no scratches on the control plate (2). (Only replace them as a set).

Kontrolle!

Auflagefläche - Steuerplatte ohne Beschädigung.

Check!

Mounting surface - control plate undamaged

Hinweis: Bohrung bei DA-Regelung offen. (gültig nur bei A10VG 45).

Information: Hole for DA-control is open, without DA control valve it is plugged.

Kontrolle!

Lagerbahnen (1) Check!

Bearing surfaces (1)

Riefenfrei, keine Einlaufspuren Free of grooves, no wear.

Brueninghaus Hydromatik

31

RDE 92750-01-R/10.01

Gehäuse - Turcon-Glyd-Ring montieren Assemble housing - Turcon-Glyd-ring

Reparaturanleitung A10VG Repair Instructions A10VG

Dichtring in die Montagezange einlegen.

Fit the seal ring into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig zusammendrücken. Die Verformung von Turcon-Dichtungen ist sorgfältig vorzunehmen, damit die Dichtkanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the assembly tool. The deformation of the Turcon seal has to be done with care so as not to damage the sealing edges.

O-Ring in Nut einlegen.

Dichtring ins Gehäuse einführen und in der Aufnahmenut plazieren. Dann Spannung lösen und Montagezange heraus ziehen. Lage des Dichtringes prüfen - eventuell mit dem Finger egalisieren.

Position the seal ring into the groove.

Position the seal ring into the housing and place it into the groove. Release the tension and withdraw the assembly tool.

Check the position of the seal ring if necessary straighten using a finger.

Kalibrieren des Dichtringes mit einem Kalibrierdorn (Stello o kolben) - mit langer Schräge 10 bis 15 .

Calibrate the seal ring using a cylindrical plug gauge o o (positioning piston) at an angle of 10 to 15 .

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Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Pumpe montieren Assembly of the pump

Reparaturanleitung A10VG Repair Instructions A10VG

Lagerschalenpaar einsetzen.

Insert bearing shells.

Stellkolben ins Gehäuse einsetzen.

Hinweis: Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction: Oil positioning piston before assembly.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett Assemble the bearing, wire, slide ring and joint pin .

Assemble aids: e.g. - clips / rubber rings / grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse "achten".

Montagehilfe ausbauen.

Insert the swash plate into the housing.

Ensure that the swivel-bearing is correctly located in the housing.

Remove assembly aid.

Brueninghaus Hydromatik

33

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Pumpe montieren Assembly of the pump

Kontrolle:

Sitz der Schwenklager in der Lagerbahn.

Schwenkwiege mit Stellkolben verschwenken "Leichtgängig".

Mittig stellen mit Meßvorrichtung (Uhr oder Tiefenmaß) Punkt 1 und 2 kontrollieren - gleiches Maß.

Check:

Location of the swivel-bearing in the bearing.

Swivel the swivel bearing by using the control piston "it should move easily".

Centralise by using a measuring device (dial gauge or depth measurement).

Check points 1 and 2 - they should have the same dimension.

Gelenkstift montieren.

Fit joint pin.

34

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Pumpe montieren Assembly of the pump

Reparaturanleitung A10VG Repair Instructions A10VG

Haltevorrichtung montieren.

Mit Gewindestift Schwenkwiege festhalten.

Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.

Do not use force.

Haltevorrichtung "Schwenkwiege" A4V Holding device "swivel cradle" A4V Teil/Part 3 6, 7, 8, 9

Teil/Part 4

∅

∅

∅

∅

∅

∅

3, 4, 5

Teil/Part 5 ∅

2 1

∅

∅

Pos./Item 1 2 3 4 5 6 7 8 9

Benennung/Designation Winkel/Angle Gewindestift/Threaded pin Scheibe/Shim Scheibe/Shim Scheibe/Shim Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912

Stck./Qty. 2 2 2 2 2 2 2 2 2

Brueninghaus Hydromatik

35

RDE 92750-01-R/10.01

Triebwerk einbauen Installation of the rotary group

Reparaturanleitung A10VG Repair Instructions A10VG

Neue Montageposition!

Triebwelle mit Lager und Wellendichtring einbauen.

Assemble drive shaft with bearings and radial seal rings.

Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Kolben mit Rückzugeinrichtung montieren.

Hinweis: Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note: Oil piston and piston pad.

36

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Triebwerk einbauen Installation of the rotary group

Reparaturanleitung A10VG Repair Instructions A10VG

Vorrichtung ausbauen.

Zylinder mit Kolben und Rückzugeinrichtung einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

Montagehilfe: Mit O-Ring Kolben festhalten.

Assembly aid: Hold the pistons by using an O-ring.

*

Bei Ausführung mit Verdrillschraube: Zylinder nach unten drücken - Verdrillschraube auf Maß x einschrauben. * Kerbe in Montageposition.

For the version with eccentric screw: Push the cylinder down - screw in the eccentric screw in the eccentric screw until dimension x is reached. * groove in assembled position.

* NG / Size 28 = 31 ± 0,75 mm NG / Size 45 = 32 ± 0,75 mm

Brueninghaus Hydromatik

37

RDE 92750-01-R/10.01

Triebwerk einbauen Installation of the rotary group

Reparaturanleitung A10VG Repair Instructions A10VG

Fixierstift für Steuerplatte einsetzen.

Bei DA - Ausführung mit Verdrillschraube ohne Fixierstift.

Fit locating pin for control plate.

For the DA version with eccentric screw without locating pin.

Steuerplatte Rechtslauf

*

* Fixierstift Control plate, clockwise rotation

* Locating pin

Steuerplatte Linkslauf

*

* Fixierstift Control plate, anti-clockwise rotation

* Locating pin

Steuerplatte Rechtslauf mit Verdrillschraube

*

Control plate, clockwise rotation with eccentric screw

Max. Einschraubtiefe beachten.

Max. depth - take into account!

38

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Pumpe montieren Assembly of the pump

Reparaturanleitung A10VG Repair Instructions A10VG

Zylinderflächen einölen, neue O-Ringe mit Fett einreiben und einsetzen.

Oil the cylinder surfaces, grease the new O-rings and fit into place.

HW, HD, EP

DA

Lagerichtig aufsetzen.

Hinweis: HW, HD, EP Steuerplatte mit Fett auf Anschlußplatte.

Bei DA Steuerplatte auf Zylinderfläche legen.

Place in correct position.

Note: HW, HD, EP - Locate the control plate on the connection plate using grease.

For the DA version, place control plate on the cylinder surface.

Schrauben über Kreuz anziehen.

Verdrillschraube auf Markierung drehen.

Tighten the screws aross corners.

Turn the eccentric screw until the marker is reached.

Hilfspumpe montieren.

Fit boost pump.

Ansteuergerät mit Dichtung montieren.

Fit control device with seal.

Brueninghaus Hydromatik

39

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) Die Werte gelten für Schaftschrauben mit metrischem ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen nach DIN 912 Zylinderschrauben, DIN 931 Sechskantschrauben mit Schaft bzw. DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Gewinde / Thread M 3 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24

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Brueninghaus Hydromatik

1. Bolts (to N 08.001) The values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class 8.8 10.9 12.9 Anziehdrehmoment / Tightening torque M A in Nm 1,1 1,6 1,9 3,1 4,5 5,3 6,1 8,9 10,4 10,4 15,5 18 25 37 43 51 75 87 87 130 150 140 205 240 215 310 370 300 430 510 430 620 720 580 830 970 740 1060 1240

RDE 92750-01-R/10.01

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

Reparaturanleitung A10VG Repair Instructions A10VG

2. Plugs with internal hexagon and profile seal ring (to N 02.009).

G

2. Verschlußschrauben mit Innensechskant und Profildichtring (nach N 02.009).

EOLASTICDichtung / Seal

Gewinde / Thread M8 x 1 M10 x 1 M12 x 1,5 M14 x 1,5 M16 x 1,5 M18 x 1,5 M20 x 1,5 M22 x 1,5 M26 x 1,5 M27 x 2 M30 x 1,5 M33 x 2 M42 x 2 M48 x 2

Anziehdrehmoment / Tightening torque MA in Nm 5 10 20 30 35 40 50 60 70 90 100 140 240 300

Gewinde / Thread G 1/8 A G 1/4 A G 3/8 A G 1/2 A G 3/4 A G 1 A G 1 1/4 A G 1 1/2 A

Anziehdrehmoment Tightening torque MA in Nm 10 30 35 60 90 140 240 300

Brueninghaus Hydromatik

41

RDE 92750-01-R/10.01

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

5. Plugs with internal hexagon, O-ring and UNF-, UN- threads to SAE J 514 (nach N 02.106)

G

5. Verschlußschrauben mit Innensechskant, O-Ring und UNF-, UN-Gewinde nach SAE J 514 (nach N 02.106)

Reparaturanleitung A10VG Repair Instructions A10VG

O-Ring / O-ring seal Dichtung / Thread

Gewinde / Thread 7/16 - 20 UNF 1/2 - 20 UNF 9/16 - 18 UNF 3/4 - 16 UNF 7/8 - 14 UN 1 1/16 - 12 UN 1 3/16 - 12 UN 1 5/16 - 12 UN 1 5/8 - 12 UN 1 7/8 - 12 UN

Anziehdrehmoment MA in Nm Tightening torque MA in Nm 15 20 25 72 127 147 173 198 320 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100)

Gewinde / Thread M6 M6 x 0,5 M8 M8 x 1 M10 M10 x 1 M12 M12 x 1,5 M14 M14 x 1,5 M16 M16 x 1,5

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Brueninghaus Hydromatik

Anziehdrehmoment MA in Nm Tightening torque MA in Nm 10 11 22 24 40 44 69 72 110 120 170 180

Gewinde / Thread M12 x 1,5 M14 x 1,5 M27 x 1,5

Anziehdrehmoment MA in Nm Tightening torque MA in Nm 20 30 90

6. SEAL-LOCK - sealing nuts (to N 02.100)

RDE 92750-01-R/10.01

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

Reparaturanleitung A10VG Repair Instructions A10VG

A10V - Düsen / orifices

Gewinde / Thread M6 M10

Anziehdremomente Nm / Tightening torques Nm bisher / up to neu / new 6,5 3 28 12

Brueninghaus Hydromatik

43

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Sicherheitsbestimmungen Safety regulations

Allgemein

General advice

· Machen Sie sich mit der Ausstattung der Maschine vertraut. · Fahren Sie die Maschine nur, wenn Sie sich völlig mit den Bedien- und Steuerelementen sowie der Arbeitsweise der Maschine vertraut gemacht haben. · Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, Sicherheitsschuhe und Gehörschutz. · Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. · Benutzen Sie die Maschine nur für den ihr zugedachten Zweck.

· Familiarise yourself with the equipment which the machine is fitted. · Only operate the machine if your are completely familiar with the operating and control elements as well as the function of the machine. · Use your safety equipment, such as safety helmet, safety shoes and ear protectors. · Make yourself familiar with your work area. · Only operate the machine for its intended purpose.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

Please observe the guidelines of the Professional Association and the machine manufacturer.

Vor dem Start

Before starting

· Beachten Sie die Bedienungshinweise vor dem Starten. · Prüfen Sie die Maschine aut auffällige Fehler. · Fahren Sie die Maschine nicht mit defekten Instrumenten, Kontrolleuchten oder Steuerorganen. · Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. · Nehmen Sie keine losen Gegenstände mit bzw. befestigen Sie diese an der Maschine. · Halten Sie die Maschine von öligem und zündfähigem Material frei. · Prüfen Sie vor dem Besteigen der Maschine, ob sich Personen oder Hindernisse neben oder unter der Maschine befinden. · Vorsicht beim Besteigen der Maschine, benützen Sie Treppen und Griffe. · Stellen Sie vor dem Start Ihren Sitz ein.

· Observe the operating instructions before starting. · Check the machine for obvious faults. · Do not operate the machine with defective instruments, warning lights or control elements. · All safety devices must be in place and secure. · Do not carry with you loose objects, if necessary fix them to the machine. · Keep the machine free of oily and inflammable material. · Before entering thc driver’s cabin, check if persons or obstacles are beside or beneath the machine. · Be careful when entering the driver’s cabin, use steps and handles. · Adjust your seat before starting.

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Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Sicherheitsbestimmungen Safety regulations

Reparaturanleitung A10VG Repair Instructions A10VG

Starten · Beim Starten müssen alle Bedienhebel in “Neutralstellung” stehen. · Die Maschine nur vom Fahrersitz aus Starten. · Prüfen Sie die Anzeigeinstrumente nach dem Start, um sicher zu gehen, daß alles ordnungsgemäß funktioniert. · Lassen Sie die Maschine nicht unbewacht, während der Motor läuft. · Beim Start mit Batterieverbindungskabeln verbinden Sie Plus mit Plus und Minus mit Minus. Massekabel (Minus) immer zuletzt anschliesen und zuerst abtrennen.

Start · When starting all operating levers must be in “neutral position”. · Only start the machine from the driver’s seat · Check the indicating instruments after start-up to assure that all functions are in order. · Do not leave the machine unattended when the motor is running. · When starting with battery jumper cables connect plus with plus and minus with minus.

Always connect negative (-) cable last and disconnect negative cable first.

Vorsicht · Auspuffgase sind lebensgefährlich. Bei Start in geschlossenen Räumen für ausreichende Luftzufuhr sorgen!

Attention · Exhaust gas is life threatening. Ensure that there is sufficient fresh air when starting in closed rooms!

Hydraulikanlage 1. Hydraulikanlage steht unter hohem Druck!

Hydraulic equipment 1. Hydraulic equipment is under high pressure.

Unter hohem Druck austretende Hochdruck-

2.

3.

4.

5.

6.

7.

Flüssigkeiten (Kraftstoff, Hydrauliköl) können die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen Arzt aufsuchen, da anderenfalls schwere Infektionen entstehen können!

Bei der Suche nach Leckstellen wegen Ver letzungsgefahr geeignete Hilfsmittel verwenden!

Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Geräte absenken!

Bei Arbeiten an der Hydraulikanlage unbedingt Motor abstellen und Traktor gegen Wegrollen sichern (Feststellbremse, Unterlegkeil)!

Beim Anschließen von Hydraulikzylindern und -motoren ist auf vorgeschriebenen Anschluß der Hydraulikschläuche zu achten!

Bei Vertauschen der Anschlüsse umgekehrte Funktionen (z.B. Heben/Senken) - Unfallgefahr!

Hydraulikschlauchleitungen regelmäßig kontrollieren und bei Beschädigung und Alterung austauschen! Die Austauschschlauchleitungen müssen den technischen Anforderungen des Geräteherstellers entsprechen!

High pressure fluids (fuel, hydraulic oil) which

2.

3.

4.

5.

6.

7.

escapes under high pressure can penetrate the skin and cause serious injuries.

Therefore, immediately consult a doctor otherwise serious infections could result.

When searching for leaks use the appropriate aids due to the danger of accidents.

Before working at the hydraulic equipment, always de-pressurise the system and lower the working elements.

When working on the hydraulic equipment, always stop motor and secure tractor to prevent rolling away (parking brake, wedges)!

When connecting hydraulic cylinders and motor pay close attention to correct connection of hydraulic flexible hoses.

If the ports are exchanged, then the functions are reversed (i.e.. lifting/lowering) - hazardous situation!

Check the hydraulic flexible hoses regularly and replace them in case of dammage, wear or ageing!

The new hose pipes must comply with the technical requirements of the machine manufacturer!

Ensure orderly disposal or recycling of oil, fuel and filters!

Öle, Kraftstoffe und Filter ordnungsgemäß entsorgen!

Brueninghaus Hydromatik

45

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Einstellhinweise - Mechanische "Nullage" Adjustment instructions - Mechanical "zero position"

HW alt / old

alt / old DA neu / new

HD

neu / new

EP

alt / old

neu / new HW mit Nullagenschalter HW with zero position switch

Achtung!

Sicherheitsbestimmungen beachten!

Mit Schlauch NW6 beide Stellkammern verbinden. Vermeidung von Restsignal aus hydraulischer Nullage.

Manometer an MA und MB anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Totband der Nullage - vermitteln.

Attention!

Observe safety regulations!

Connect both control chambers with a nominal size 6 hose. Avoidance of residual signals from hydraulic zero position.

Connect pressure gauges to MA and MB. Adjust the zero position so that with at blocked drive both pressure gauges indicate the same pressure valve.

Note: Ascertain the zero position dead band.

46

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Einstellhinweise - Hydraulische "Nullage" Adjustment instructions - Hydraulic "zero position"

Reparaturanleitung A10VG Repair Instructions A10VG

HD neu/new HW HD alt/old

Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

HW mit Nullagenschalter HW with zero position switch

EP alt/old EP neu/new

Manometer an X1 und X2 anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Excenterjustierung - nicht über ±90° verdrehen.

Connect pressure gauges to X1 and X2.

Adjust the zero position so that with a block drive both pressure gauges indicate the same pressure value.

Note: Eccentric adjusting - Do not turn more than ±90°.

Brueninghaus Hydromatik

47

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Einstellhinweise - ND-Ventil (Speisedruck) Adjustment instructions - Low pressure valve (Boost pressure)

Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

Hinweis: Nachjustierung nur bei Betriebstemperatur.

Note: Readjusting only at operating temperature.

Manometer an "G" anschließen.

Connect pressure gauge to "G".

Achtung! * Speisedruckeinstellung!

Nenndruck pH - 18 bar Höchstdruck pH - 40 bar Bei Max.-Drehzahl.

Attention! * Boost pressure setting!

Nominal pressure pH - 18 bar Peak pressure pH - 40 bar at max. speed.

Hinweis: Einstelldaten nach Werksauftrag.

Note: Setting data is in accordance to the works order.

* bei DA-Ausführung

* with the DA version

"G" *

*

48

Brueninghaus Hydromatik

RDE 92750-01-R/10.01

Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Zum Blockieren der Druckabschneidung beim Überprüfen der Hochdruckventile die Einstellschraube Pos. 1 mit gelöster Kontermutter Pos. 2 bis zum Anschlag mit max.

2 Nm im drucklosen Zustand eindrehen!

To block the pressure cut-off when testing the high pressure valves, the adjustment screw (item 1), with the lock-nut (item 2) loosened, has to be screwed in with a max. torque of 2 Nm in the depressurised condition until the end stop is reached.

Reparaturanleitung A10VG Repair Instructions A10VG

Achtung!

Sicherheitsbestimmungen beachten!

HD-Ventil ohne Bypass 1 . HD- Ventile sind immer 10% höher eingestellt als die Druckabschneidung.

Bei Veränderung eines Einsteilwertes immer beide kontrollieren.

2. Nachjustierung nur bei Betriebstemperatur Manometer an MA und MB anschließen.

Druckabschneidung: Maß X Einstellschrauben notieren!

Einstellschraube auf Block drehen.

HD- Ventile: Mit geringer Pumpenmenge über Ventile fahren. Einstellwert kontrollieren.

(Nur kurzzeitig "Temperatur“.)

Drucklos "Einstellwert“ verändern - Kontrolle

Druckabschneidung Pressure cut-off

Druckabschneidung: Einstellschraube auf Maß (*) zurückdrehen.

Druckwert kontrollieren bzw. nachjustieren.

Achtung! Differenz von 10% HD- Ventile und Druckabschneidung beachten!

Hinweis: Einstelldaten nach Werksauftrag.

Attention!

Observe safety regulations.

HP valve without bypass-function

HD- Ventile HP- valves

1 . HP valves are always adjusted 10% higher than the pressure cut-off.

If one setting value is changed, always check both values.

2. Readjusting only at operating temperature.

Connect pressure gauge MA and MB. Pressure cut-off: Note measurement X for setting screw!

Turn setting screw to the blocked position.

HP valves: Operate the valves with small pump flow over the valves.

Check setting value. (only for a short time "temperature“).

Change zero pressure "setting value“ - then check.

Pressure cut-off: Turn back setting screw to measurement (*).

Check pressure value and readjust if necessary.

Attention! Observe the 10% pressure difference between the HP valves and the pressure cut-off!

Note: Setting data is in accordance with the works order.

Brueninghaus Hydromatik

49

RDE 92750-01-R/10.01

Reparaturanleitung A10VG Repair Instructions A10VG

Einstellhinweise - Bypassventil Adjustment instructions - Bypass valve

1 1

1

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung (Freilauf).

Vehicle with a pure hydrostatic transmission or with a hydrostatic drive with gear box without free wheel position.

Hydrostatischer Antrieb / Bypaß-Schaltung

Hydrostatic transmission / Bypass condition

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. Zu diesem Zweck haben die in der Verstellpumpe integrierten Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion.

D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich ist.

Bypass:Pos.1 einschrauben bis eben mit Mutter.

Mutter wieder anziehen.

In this case the travel drive is switched on to the free wheel position. For this purpose the high pressure valves of the variable displacement pump have a so-called bypass function.

By turning the relevant screw (item 1) the valve is so released that free oil circulation is made possible.

Bypass: Screw in item1 until it is level with the nut.

Schleppgeschwindigkeit Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht überschreiten.

-

Höhere zulässige Schleppgeschwindigkeiten sind abhängig von der Hydromotordrehzahl bzw. dem eingelegten Gang.

Abschleppdistanz Die Schleppentfernung sollte 1 km nicht überschreiten.

-

Bei fehlender Einspeisung entleert sich der Hydraulik-Kreislauf.

Zu beachten ist die Wärmeentwicklung im Hydromotor-Triebwerk.

Abschleppvorgang beendet Nach beendetem Abschleppvorgang Pos.1 zurückdrehen. Der ursprüngliche Einstellwert der Hochdruckventile liegt somit wieder vor.

Ventilfunktion: Pos.1 zurückschrauben bis Anschlag. Mutter anziehen.

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Brueninghaus Hydromatik

Towing speed The max. towing speed of 2 km/h should not be exceeded.

-

Higher permissible speeds are depended on the hydraulic motor speed or the selected gear.

Towing distance The towing distance should not exceed 1 km.

-

With no boost avaiable the hydraulic circuit drains.

The heat generation in the hydraulic motor rotary group has to be taken into account.

Termination of the towing operation After termination of the towing operation turn back item 1. The original set pressure value is thereby avaiable.

Valve function: Screw back item 1 up to stop.

Screw up the nut.

RDE 92750-01-R/10.01

Einstellhinweise - DA- Regelung Adjustment instructions - DA control

Reparaturanleitung A10VG Repair Instructions A10VG

Achtung!

Sicherheitsbestimmungen beachten! Überprüfung der Einstelldaten Betriebstemperatur soll während des Überprüfungsvorgangs weitgehend konstant gehalten werden.

Antriebsmotor starten, Leerlaufdrehzahl Blockzustand Fahrtrichtungsschalter "0“ Motordrehzahl langsam steigern bis zur max.

Motordrehzahl, dabei Meßgeräte beobachten.

Speisedruck: Leerlaufdrehzahl Psp = ca. 15-20 bar max. Motordrehzahl Psp = . . . . . . . . bar*

*

Blockzustand Fahrtrichtungsschalter - vorwärts (Straßengang und Festgebremst) Einstelldaten Pumpe A4V/DA überprüfen

* Regelbeginn Verdrillung

Regelbeginn

HD 40 - 50 bar Motordrehzahl . min.1 * Psp . . . . . bar* HD . . . . . . bar Nachjustierung - Regelbeginnschraube Regelende HD . . . . . bar* Motordrehzahl . . . . . min.1 * Psp . . . . . bar* Nachjustierung - Verdrillschraube Hinweis: Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

Brueninghaus Hydromatik

51

RDE 92750-01-R/10.01

Einstellhinweise - DA- Regelung Adjustment instructions - DA control

Reparaturanleitung A10VG Repair Instructions A10VG

Attention!

Observe safety regulations!

Check setting data.

Operating temperature should be generally kept constant during the checking procedure.

Start prime mover, idle speed.

Block position Drive direction switch - "0“.

Slowly increase motor speed up to the max. motor speed and observe measuring instruments.

*

Boost pressure: Idle speed of prime mover Psp = approx. 15 - 20 bar max. motor speed Psp = . . . . . . . . . bar* Block position Drive direction switch - forwards (Road gear and fully applied brake) Check setting data pump A4VIDA

Begin of control Timing adjustment screw

* Start of control: HD 40 - 50 bar Motor speed . . . . . rpm* Psp . . . . . . . bar* HD . . . . . . . bar* Readjustment of start of control screw End of control HD . . . . . . . . bar Motor speed . . . . . . rpm* Psp . . . . . . . bar* Readjustment of the indexing screw Note: Eccentric adjusting - observe direction of rotation.

Note: * Setting data is in accordance to the order work!

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: service.elchingen@bru-hyd.com Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Fax (07451) 8221, E-Mail: service.horb@bru-hyd.com

52

Brueninghaus Hydromatik

DISMANTLING OF THE HYDROSTATIC MOTOR A2F 165ATJ 75-3-24 EN

01 / 2002

engineering

mannesmann Rexroth

RDE 91001-03-R / 04.00 ersetzt / replaces 07.98

Reparaturanleitung Repair instructions

-

A2F Baureihe 61

-

A2F Series 61

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Inhalt / Hinweis Contents / Notice

HINWEIS Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage. Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.

Methoden und Vorrichtungen sind Empfehlungen, für deren Resultat wir keine Haftung übernehmen können.

BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.

Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem Teststand vorzunehmen.

Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.

Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermitteln wir in unseren Schulungskursen.

NOTICE Specifications, descriptions and illustrative material shown herein were as accurate as known at the time this publication was approved for printing.

Changes can influence the service of the products. We do not accept any obligations due to this.

Methods and tooling are suggestions, we cannot accept any liability for their results.

BRUENINGHAUS HYDROMATIK sub-assemblies ordered using the serial no. are the basis for good repairs.

Adjustments and tests have to be carried out on the test bench under operating temperatures.

Protection of personnel and property has to be guaranteed by appropriate measures.

Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

CONTENTS

Seite/ Page

A2F

A2F Schnittbild Allgemeine Reparaturhinweise Dichtsätze und Baugruppen Triebwelle abdichten Anschlußplatte abdichten Triebwerk ausbauen Überprüfungshinweise Triebwerk einbauen Anziehdrehmomente Sicherheitsbestimmungen

2

Brueninghaus Hydromatik

3 4 5 6-7 8-10 11-12 13-14 15-17 18 19-20

Sectional view General repair instructions Seal kits and sub-assemblies Sealing of the drive shaft Sealing of the cover plate Removal the rotary group Inspection guidelines Installing rotary group Tightening torques Safety regulations

RDE 91001-03-R/04.00

Schnittbild

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Sectional view

B

D

A

Meßpunkte: Siehe Serviceinfo

Measuring points: See service information

Brueninghaus Hydromatik

3

RDE 91001-03-R/04.00

Allgemeine Reparaturhinweise General repair instructions

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Achtung!

Nachfolgende Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten!

Attention!

Please take into account the following guidelines when carrying out repair work on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close off all of the ports of the hydraulic unit.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK Ersatzteile verwenden!

Replace all seals.

Use only original BRUENINGHAUS HYDROMATIK spare parts!

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of the sealing surfaces, using for example abrasive paper, can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit Hydrauliköl befüllen.

Fill the hydraulic unit with hydraulic oil before commissioning.

4

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Dichtsätze und Baugruppen

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Seal kits and sub-assemblies

Dichtsatz.

Seal kit.

Triebwerk, mechanischer Teil; mit Dichtsatz, muß abgestimmt werden auf Maß "A". (siehe Serviceinfo) (a) Rotary group, mechanical part; with seal kit, has to be adjusted to dimension "A". (see service info)

Lagersatz, komplett abgestimmt.

Maß B (Stützscheibe und Sicherungsring nicht tauschbar) Abstimmung Maß "A". (siehe Serviceinfo) (b)

Bearing set, matched Dimension B (support disc and circlip are not exchangeable) Adjustment to dimension "A". (see service info)

Triebwerk, hydraulischer Teil; mit Dichtsatz, Abstimmung hydraulischer Teil Pos. "D". (siehe Serviceinfo) (c)

Rotary group, hydraulic part; with seal kit, Adjustment of the hydraulic part Pos. "D". (see service info)

Triebwerk komplett; mit Dichtsatz, fertig vorabgestimmt.

Abstimmung hydraulischer Teil Pos. "D". (siehe Serviceinfo) (d)

Complete rotary group, with seal kit, preadjusted.

Adjustment of the hydraulic part Pos. "D". (see service info) Brueninghaus Hydromatik

5

RDE 91001-03-R/04.00

Triebwelle abdichten Sealing of the drive shaft

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Bei nicht verzahnten Triebwellen: Paßfeder abnehmen. Triebwelle abkleben, For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).

Sicherungsring ausbauen, Verschlußring abdrücken Remove circlip, prise off cover.

Sichtkontrolle Wellendichtring (1), Verschlußring (2), Triebwelle (3), Gehäuse (4), O-Ring (5).

Visual check Shaft seal (1), cover (2), drive shaft (3), housing (4), O-ring (5).

6

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Triebwelle abdichten Sealing of the drive shaft

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Wellendichtring demontieren.

Remove shaft seal.

Neuen Wellendichtring lagerichtig mit passender Büchse einpressen.

Press in the new shaft seal,ensuring that it is correctly orientated, using a suitable bush.

Bei tiefer Laufrille Scheibe vor den Wellendichtring einlegen (max. 1 mm).

If the drive shaft is deeply grooved, insert a shim in front of the shaft seal (max. 1 mm).

Neuen O-Ring einlegen, auf bündiges Anliegen achten. O-Ring sowie Dicht- und Staublippe des Wellendichtringes einfetten. (siehe Serviceinfo) Fit new O-ring, ensure that it is correctly located. Grease the O-ring as well as the seal and dust lips of the shaft seal. (see service information)

Sicherungsring einbauen.

Sitzkontrolle des Sicherungsringes in der Nut. Fit circlip.

Check to ensure that the circlip is correctly located within the groove.

Brueninghaus Hydromatik

7

RDE 91001-03-R/04.00

Anschlußplatte abdichten Sealing of the cover plate

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Lage der Anschlußplatte zum Gehäuse kennzeichnen (Pfeil), Befestigungsschrauben lösen.

Mark the position of the cover plate with regard to the housing (arrow), loosen the fixing screws.

Anschlußplatte um Verdrillstift schwenken (1) und abheben (2).

Swing the connection plate about the locating pin (1) and lift off (2).

8

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Anschlußplatte abdichten

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Sealing of the cover plate

Auf Montagestellung des Verdrillstiftes achten (Pfeile).

Take the assembly position of the locating pin (arrow) into account.

Saugseite / Suction side

Druckseite / Pressure side

Pumpe, Drehrichtung rechts.

(Blick auf sphärische Fläche.)

Druckseite / Pressure side

Saugseite / Suction side

Pump, clockwise rotation. (viewed on spherical surface.)

Pumpe, Drehrichtung links.

(Blick auf sphärische Fläche.)

Pump, anti-clockwise rotation. (viewed on spherical surface.)

Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)

Motor, bi-directional.

(Viewed on spherical surface.)

Brueninghaus Hydromatik

9

RDE 91001-03-R/04.00

Anschlußplatte abdichten Sealing of the cover plate

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Sichtkontrolle O-Ring (1), Einstich (2), Platte (3).

Visual check O-ring (1), Groove (2), Plate (3).

Neuen O-Ring einlegen, zuvor leicht einfetten.

Lightly grease and fit O-ring.

Anschlußplatte aufsetzen, auf Kennzeichnung und Lage des Verdrillstiftes achten.

Place the cover plate onto the housing taking into account the location mark and position of the locating pin.

Befestigungsschrauben mit Drehmomentenschlüsselanziehen.

Tighten fixing screws using a torque wrench.

10

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Triebwerk ausbauen

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Removal the rotary group

Lagersatz / Bearing set

Demontage der Anschlußplatte. Steuerplatte abheben.

Zylinder am Mittelzapfen mit Schraube befestigen.

Removal of the connection plate. Lift off the control plate.

Secure the cylinder to the centre pin using a screw.

Gewindestift,Zylinderschraube / Threaded pin,socket head screw NG / Size

(mm)

10; 12; 16

M3 x 35

23; 28; 32

M5 x 45

45

M5 x 50

56; 63

M5 x 55

80; 90

M5 x 60

107; 125; 131 160; 180

M6 x 70 M6 x 85

Brueninghaus Hydromatik

11

RDE 91001-03-R/04.00

Triebwerk ausbauen Removal the rotary group

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Verschlußring, O-Ring und Paßscheibe ausbauen.

Remove the cover, O-ring and shim.

Triebwerk mit Vorrichtung ausbauen.

Withdraw the rotary group using an extractor.

Befestigungsschraube ausbauen.

Zylinder abheben.

Remove the fixing screw.

Lift off the cylinder.

Rückzugplatte demontieren, Schrauben sind eingeklebt. o Komplettes Triebwerk bei ca. 120 C im Ölbad erwärmen. Danach Befestigungsschrauben lösen!

Disassemble the retaining plate, screws are locked with an adhesive.

Heat up the complete rotary group in an oil o bath to approx 120 C, then remove the fixing screws.

12

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Überprüfungshinweise

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Inspection guidelines

1

2

4

4

3 3

Triebwelle 1. kein Passungsrost, nicht ausgeschlagen.

2. keine Einlaufspuren, riefenfrei.

3. Kalotten riefenfrei und keine Pittings.

4. Keine Laufspuren (Lagerdreher) Drive shaft 1. No wear, or fretting 2. No traces of wear, free of scratches.

3. Cups free of wear and no pitting.

4. No traces of wear, (bearing rotation).

1 1. Axiales Kolbenspiel 1. Axial play of piston.

Alt / Old Kolben Riefenfrei, keine Pittings.

Piston Free of scratches, no pitting.

Neu / New

1

2 Mittelzapfen 1. Riefenfrei, ohne Pittings.

2. Riefenfrei.

Center pin 1. Free of scratches, no pittings.

2. Free of scratches.

Rückzugplatte Riefenfrei, keine Ausbrüche.

Retaining plate Free of scratches, no wear.

Brueninghaus Hydromatik

13

RDE 91001-03-R/04.00

Überprüfungshinweise Inspection guidelines

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Zylinder/Steuerplatte 1. Bohrungen riefenfrei, nicht ausgelaufen.

2. Gleichmäßiges Tragbild, riß- und riefenfrei.

3. Mindesthärte 700 HV 10.

Cylinder / control plate 1. Bores unscratched, and no traces of wear.

2. Even load distribution, free of cracks and grooves.

3. Min. hardness 700 HV 10.

Gehäuse Im Lagerbereich riefenfrei und keine Einlaufspuren.

Housing No traces of wear in the bearing area.

Nur kompletten Kolbensatz austauschen.

Only exchange the pistons as a complete set.

Zylinder und Steuerplatte nur gemeinsam austauschen.

Only replace the cylinder and control plate as a pair.

14

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Triebwerk einbauen

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Installing rotary group

Triebwelle mit Lager vormontiert verwenden.

Use a pre-assembled drive shaft with bearings.

Rückzugplatte mit Kolben und Mittelzapfen einsetzen.

Schrauben mit Precote-Beschichtung verwenden.

Fit retaining plate complete with pistons and centre pin.

Uses screws with a Precote coating.

1

Druckfeder (1) und Abstimmscheibe (2) einbauen.

Fit the compression spring (1) and shim(2).

2

Zylinder in Neutralposition befestigen.

Fix the cylinder in the neutral position.

Brueninghaus Hydromatik

15

RDE 91001-03-R/04.00

Triebwerk einbauen Installing rotary group

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Triebwerk max. ausschwenken.

Swivel the rotary group to max.

Neuer Radialwellendichtring montiert?

Is the new shaft seal fitted?

o

Gehäuse auf ca. 80 C erwärmen. o

Heat the housing to approx. 80 C.

Heißes Gehäuse bis zum Anschlag aufsetzen.

Push on the hot housing until the stop is reached.

Neue Montagestellung.

New assembly position.

16

Brueninghaus Hydromatik

RDE 91001-03-R/04.00

Triebwerk einbauen

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Installing rotary group

Paßscheibe, O-Ring einlegen. Verschlußring montieren.

O-Ring, Zwischenraum Wellendichtring einfetten (siehe Serviceinfo).

Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust lipsof the shaft seal.

Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.

Pull the rotary group against the cover.

Check: to see that the cover is free of play.

Befestigungsschraube ausbauen.

Steuerplatte lagerichtig aufsetzen.

Fertigmontage Abstimmung Pos. D - siehe Serviceinfo Remove fixing screw. Fit the control plate into its correct location.

Final assembly For adjustment of Pos. D - see service info

* * Pos.D

Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!

Seal connections to protect against dust.

Corrosion proctection (internal/external).

Assembly complete.

Brueninghaus Hydromatik

17

RDE 91001-03-R/04.00

Montageanweisung für Anziehdrehmomente

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) Die Werte gelten für Schaftschrauben mit metrischem ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen nach DIN 912 Zylinderschrauben, DIN 931 Sechskantschrauben mit Schaft bzw. DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Gewinde / Thread M 3 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24

18

Brueninghaus Hydromatik

1. Bolts (to N 08.001) The values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class 8.8 10.9 12.9 Anziehdrehmoment / Tightening torque MA in Nm 1,1 1,6 1,9 3,1 4,5 5,3 6,1 8,9 10,4 10,4 15,5 18 25 37 43 51 75 87 87 130 150 140 205 240 215 310 370 300 430 510 430 620 720 580 830 970 740 1060 1240

RDE 91001-03-R/04.00

Montageanweisung für Anziehdrehmomente

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Assembly guidelines for tightening torques

G

2. Verschlußschrauben mit Innensechskant und Profildichtring (nach N 02.009).

Plugs with internal hexagon and profile seal ring (to N 02.009).

EOLASTICDichtung / Seal Gewinde / Thread M8 x 1 M10 x 1 M12 x 1,5 M14 x 1,5 M16 x 1,5

Anziehdrehmoment / Tightening torque MA in Nm 5 10 20 30 35

M18 x 1,5 M20 x 1,5 M22 x 1,5 M26 x 1,5 M27 x 2 M30 x 1,5 M33 x 2 M42 x 2 M48 x 2

40 50 60 70 90 100 140 240 300

M3 M4 M5 M6 M8

Anziehdrehmoment Tightening torque MA in Nm 10 30 35 60 90

G 1 A G 1 1/4 A G 1 1/2 A

7. Linsenschrauben mit Innen-TORX, Gewindevorbeschichtung mit "precote 8O" (nach N 02.119) Oval head screw with inner TORX, thread precoated with "precote 8O" (to N 02.119)

Gewinde / Thread

Gewinde / Thread G 1/8 A G 1/4 A G 3/8 A G 1/2 A G 3/4 A

140 240 300

precote 80

Festigkeitsklasse / Tensile strength class 10.9 11.9 Anziehdrehmoment MA in Nm Tightening torque M A in Nm 2,1 -4,7 -9,1 9,5 15,8 -37,7 --

Brueninghaus Hydromatik

19

RDE 91001-03-R/04.00

Sicherheitsbestimmungen

Reparaturanleitung A2F/61 Repair Instructions A2F/61

Safety regulations

Allgemein

General advice

· Machen Sie sich mit der Ausstattung der Maschine vertraut. · Fahren Sie die Maschine nur, wenn Sie sich völlig mit den Bedien- und Steuerelementen sowie der Arbeitsweise der Maschine vertraut gemacht haben. · Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, Sicherheitsschuhe und Gehörschutz. · Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. · Benutzen Sie die Maschine nur für den ihr zugedachten Zweck.

· Make yourself familiar with the equipment of the machine. · Only operate the machine if your are completely familiar with the operating and control elements as well as the functioning of the machine. · Use your safety equipment like helmet, safety shoes and hearing protection. · Make yourself familiar with your working field. · Only operate the machine for its intended purpose.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

Please observe the guidelines of the Professional Association and the machine manufacturer.

Hydraulikanlage 1. Hydraulikanlage steht unter hohem Druck!

Hydraulic equipment 1. Hydraulic equipment is standing under high pressure.

Unter hohem Druck austretende Hochdruck-

2.

3.

4.

5.

6.

7.

Flüssigkeiten (Kraftstoff, Hydrauliköl) können die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen Arzt aufsuchen, da anderenfalls schwere Infektionen entstehen können!

Bei der Suche nach Leckstellen wegen Ver letzungsgefahr geeignete Hilfsmittel verwenden!

Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Geräte absenken!

Bei Arbeiten an der Hydraulikanlage unbedingt Motor abstellen und Traktor gegen Wegrollen sichern (Feststellbremse, Unterlegkeil)!

Beim Anschließen von Hydraulikzylindern und -motoren ist auf vorgeschriebenen Anschluß der Hydraulikschläuche zu achten!

Bei Vertauschen der Anschlüsse umgekehrte Funktionen (z.B. Heben/Senken) - Unfallgefahr!

Hydraulikschlauchleitungen regelmäßig kontrollieren und bei Beschädigung und Alterung austauschen! Die Austauschschlauchleitungen müssen den technischen Anforderungen des Geräteherstellers entsprechen! Öle, Kraftstoffe und Filter ordnungsgemäß entsorgen!

High pressure fluids (fuel, hydraulic oil) which escape under high pressure can penetrate the skin and cause heavy injuries.

Therefore immediately consult a doctor as otherwise heavy infections can be caused.

2. When searching leakages use appropriate auxiliary devices because of the danger of accidents.

3. Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the rnachine.

4. When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away (parking brake, shim)!

5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible hoses.

6. In case of exchanging the ports, the tunctions are vice versa (f. ex. lift-up/lower) - danger of accidents!

7. Check hydraulic flexible hoses regularly and replace them in case of dammage or wear! The new hose pipes must comply with the technical requirements of the machine manufacturer!

Orderly disposal or recycling of oil, fuel and filters!

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: service.elchingen@bru-hyd.com Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Fax (07451) 8221, E-Mail: service.horb@bru-hyd.com

20

Brueninghaus Hydromatik

ADJUSTING THE HYDROSTATIC PUMP 165ATJ 75-8-5-M.53 EN

01 / 2002

ADJUSTING THE A 10 VG HYDROSTATIC PUMP Fig. A

- Required tooling

1

• 1 tachometer .............................................490165 • 1 pressure port .......................................477484 • 1 pressure gauge .....................................58179 - Fit the tachometer ref. 490165 mark.1 (Fig.A) onto the platform.

- Mount the pressure port part ref. 477484 mark.2 in B (see Fig.B), and the pressure gauge part ref. 58179 mark.3 (Fig.B). 6 mm hex. wrench (cap connector) and 17 mm wrench (pressure port) - Place the hooks in the purpose-designed anchor points C. (See Fig. C)

Fig. B

- Start up the platform.

3

- Read off the engine rotation speed on the tachometer = 1200 tr/mn ± 20.

- If necessary, adjust the adjusting screw mark.4 (Fig.D) with a 10 mm wrench B

- Move the platform up to tighten the webbing. Hold the control lever forwards.

- Read off the pressure on the pressure gauge = 330 bar ± 10.

- If necessary, adjust the regulator cardrige mark. 5 (Fig. B) with a 13 mm wrench (lock nut) and a 4 mm hex. wrench (adjusting screw).

5

Fig. C

C

Fig. D

C

4 C

1

2

GROUPS 80

ELECTRICITY

REPLACING THE ELECTRONIC BASEBOARD AND MICROPROCESSOR 165ATJ 80-2-10-M.53 EN

01 / 2002

REPLACING THE ELECTRONIC BASEBOARD AND THE MICROPROCESSOR A

REPLACING THE ELECTRONIC BASEBOARD

2

- Cut off the power supply.

- Open the righthand turret bonnet.

1

- Open the electric box.

- Disconnect the eighteen connectors 1 (Fig. A).

- Dismantle the 4 locking screws.

- Change the electronic baseboard 2 (Fig. A).

NOTA : The electronic baseboard is delivered without a microprocessor, you must collect it from the old baseboard or if necessary, order a new one. For the set up, follow the directions described below.

B

REPLACING THE MICROPROCESSOR - This operation must be carried out with great care since the microprocessor pins are very fragile.

4 3

- Lift one side of the microprocessor 3 (Fig. B) by means of a small screwdriver 4 (Fig. B) - Finish disengaging it by taking it between your fingers and by pulling it slowly towards you ( place your thumbs behind to avoid its slipping out).

- Before its fitting, care must be taken with the direction of assembly. The polarizing slot (a half moon) 5 (Fig. C) of the microprocessor must fit into the serigraph slot 6 (Fig. C) on the electronic baseboard.

C

- Present and slightly engage the lower pins into the bracket.

- Then, while tilting the microprocessor upwards, push in the upper pins.

6

- Finish the operation by exerting a light pressure with the thumbs.

NOTE : In case of order, please, indicate the complete designation noted on the microprocessor together with the reference MANITOU. ex :

MAN 6.4.3 10/07/95

1

5

POSITION OF THE SENSORS 165ATJ 80-8-81-M.53 EN

01 / 2002

POSITION OF THE SENSORS

foot switch : deadman pedal

Basket overload detection switch

Telescope retracted detection switch

Telescope folded detection switch

Lower and middle arms folded detection switch

Slope sensor

Fuel tank level gauge

Engine compartment : Water temperature, oil pressure, air filter clogging sensor

Wheel alignment sensor

1

MAIN ELECTRICITY CABINET 165ATJ 80-8-82-M.53 EN

01 / 2002

MAIN ELECTRICITY CABINET

Card1 (mark 1) : On/off component control card. It includes 25 logical inputs with LED display (marked from A to Y) and 23 mechanical relay outputs with LED display (R1 to R23). A programm microcontroller (mark 7) ensures logical operation (programm version MAN X.X). A flashing “RUN” LED indicates that the card is operating correctly.

Card 2 (mark 8) : Proportional component control card. It handles 4 proportional electrovalves (hydrostatic pump and DANFOSS PVG 32 electrovalve) and the manipulator. It includes 24 logical inputs and 12 mechanical outputs. The card is protected by 1 fuse (mark 10). Electronic is protected by 1 fuse. EPROM type memory (mark 9) ensures logical operation (programm version CIMM VX). A flashing “RUN” LED indicates that the card is operating correctly.

Card 3 (mark 2) : Fuse card. Card 1 (inputs and outputs) is protected by 6 fuses. The card also includes the starter motor relay (mark3).

1

INDEX

A – CARD 1 : ON/OFF .................................................................................................

4

A1 - Diagram ................................................................................................................

4

A2 - Correspondence of input/output LEDS.............................................................

5

A3 - Table of LED status by movement ....................................................................

6

B – CARD 2 : PROPORTIONAL ................................................................................ 23 B1 - Diagram ................................................................................................................ 23

C – CARD 3 : FUSES ................................................................................................... 25 C1 - Diagram ................................................................................................................ 25

D – GENERAL ELECTRICAL DIAGRAM................................................................. 26 D1 - Schematic diagram ............................................................................................. 26 D2 - Electrical circuit - Parts catalogue ..................................................................... 27

2

A - CARD 1 : ON/OFF A1 - Diagram

v12 m3 v9

EV Engine max. speed (R19)

14

flashing alarm lamp (R17)

Cad 2 - I24 - Speed stop (R15) Card 2 - I23 - Lowered arm (R14) EV differential locking (R13) EV oscillation x 2 (R12) EV brake x 2 (R11) ro36 Card 2 - I19 - Lifting pendular ro37 Card 2 - I20 - Lowering pendular

EV lowering pendular EV lifting pendular

EV right steering EV slope tilting EV cavage tilting EV turret right rotation EV turret left rotation EV turret right rotation EV left steering EV right steering EV basket left rotationr EV basket right rotation

+12v Card 3 - Fuse 4 +12v Card 3 - Fuse 3 +12v Card 3 - Fuse 2

Base emergency stop Battery cutout Basket control

16

ro70 ro28 ro16 ro15 ro14 ro13 ro12

v24 v25 v26

v20 v20 v20 ro32/29 ro9 ro8 ro30/7 ro6 ro5 ro4 ro3 ro2 ro1 ro43 ro42 ro41 ro40 ro39 ro38 ro7 ro52 ro53 ro29

+ 12v - Card 3 - Fuse 5

10

Buzzer output (R20)

v55 v54 4 2 7 6

Turret left rotation S5 Turret right rotation S7 Pedal Overload security Left steering Right steering

3 5 3 4 12 11 6 10 9

Pedal Hare select.

Basket left rotation select.

Basket right rotation select.

Cavage tilting select.

Slope tilting select.

Bp differential locking Lifting pendular select.

Lowering pendular select.

2 3

+ 12v - Slope sensor Slope

Slope (Card 2 - I2)

OK transmission regulation (card 2 - S1) +12v -Control selec. basebasket OK telescope regulation (card 2 - S6) OKarm 1/2 regulation (card 2 - S3) OK proportio. regulation N°4 (card 2 - S4) digicode predisposition (pin 5) OK arm 3 regulation (card 2 - S2)

+ 12v FC lowered arm

+ 12v FC arm 3

+12v - Card 3 - Fuse F6

3

v28 v29

v52 v5

v1 v62 v61 v53 v60

1 2

1 2

v27 v30

Card 2 - I13 - basket right rotation Card 2 - I14 - basket left rotation Card 2 - I15 -right steering Card 2 - I16 - left steering Card 2 - I21 -turret right rotation Card 2 - I22 -turret left rotation EV basket right rotation Card 2 - I17 -cavage tilting Card 2 - I18 -slope tilting EVcavage tilting

BASE

BASKET

+ 12v - Emergency stop Assistance pump

A2 - Correspondence of the inputs and outputs LEDS

ABREVIATION AND CORRESPONDENCE OF THE INPUTS LEDS

ABREVIATION AND CORRESPONDENCE OF THE RELAYS AND OUTPUTS LEDS R1 = R2 = R3 = R4 = R5 = R6 = R7 = R8 = R9 = R10 = R11 = R12 = R13 = R14 = R15 = R16= R17 = R18 = R19 = R20 = R21 = R22 =

BASKET RIGHT ROTATION EV BASKET LEFT ROTATION EV RIGHT STEERING EV LEFT STEERING EV TURRET RIGHT ROTATION EV TURRET LEFT ROTATION EV CAVAGE TILTING EV SLOPE TILTING EV TILTING PENDULAR EV LOWERING PENDULAR EV BRAKE X2 EV OSCILLATION X2 EV DIFFERENTIAL LOCKING EV HIGH SPEED ARM LOWERED STOP PROPORTIONAL SPEED N°4 FREE FLASHING ALARM LAMP FREE EV MAX ENGINE SPEED BUZZER FREE BASKET EMMERGENCY CANCELLATION R23 = FREE

4

A B C D E

= = = = =

F

=

G

=

H

=

I

=

J K L M N O P Q R S T U V W X Y

= = = = = = = = = = = = = = = =

SLOPE SENSOR ARM3 FC/ANGULAR LOWER ARM FC FREE (S6) SPEED REGULATION PLATE OK ARM 1/2 (S3) SPEED REGULATION PLATE OK PROPORTIONAL N°4 (S4) SPEED REGULATION PLATE OK TRANSLATION (S1) SPEED REGULATION PLATE OK ARM 3 (S2) SPEED REGULATION PLATE OK FREE PENDULAR LOWERING PENDULAR LIFTING PB DIFFERENTIAL LOCKING SLOPE TILTING CAVAGE TILTING BASKET RIGHT ROTATION BASKET LEFT ROTATION HARE SELECTOR RIGHT STEERING LEFT STEERING OVERLOAD SAFETY DEVICE BASKET CONTROL (S7) TURRET RIGHT ROTATION (S5) TURRET LEFT ROTATION FREE

A3 - Leds state table per movement of card on/ off

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

RIGHT ROTATION ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Basket drive 1 X X X X X X X X X 0 0 X 0 0 1 0 X 0 0 1 1 0 0 X

Output CI Movement

EV Right rotation

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

1

X X X X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

5

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

LEFT ROTATION ELECTROVALVE

Input CI Movement

Basket Control

Output CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

1 X X X X X X X X X 0 0 X 0 0 0 1 X 0 0 1 1 0 0 X

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Left Rotation X EV

1

X X X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

6

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

RIGHT STEERING ELECTROVALVE

Input CI Movement

Basket Control

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X X X X X X X X X X 0 0 X 0 0 0 0 X 1 0 1 1 0 0 X X 1 1 X X X X X X X 0 0 X 0 0 0 0 X 1 0 X 1 0 0 X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Right X X Steering EV

1

X X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

7

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

LEFT STEERING ELECTROVALVE

Entrée CI Movement

Basket Control

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X X X X X X X X X X 0 0 X 0 0 0 0 X 0 1 1 1 0 0 X X 1 1 X X X X X X X 0 0 X 0 0 0 0 X 0 1 X 1 0 0 X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Left Steering X X X EV

1

X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

8

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

TURRET RIGHT ROTATION ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 0 0 X 0 0 X X X X X 1 0 1 0 X Basket Control X X X X X X X X X X 0 0 X 0 0 0 0 X 0 0 1 1 1 0 X

Output CI Movement

Turret right rotation EV

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X

1

X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

9

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

TURRET LEFT ROTATION ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 0 0 X 0 0 X X X X X 1 0 0 1 X Basket Control X X X X X X X X X X 0 0 X 0 0 0 0 X 0 0 1 1 0 1 X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Turret left X X X X X rotation EV

1

X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

10

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

CAVAGE TILTING ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 0 0 X 0 1 X X X X X X 0 0 0 X Basket Control 1 X X X X X X X X X 0 0 X 0 1 0 0 X 0 0 X 1 0 0 X

Output CI Movement

Cavage tilting EV

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X X X

1

X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

11

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

SLOPE TILTING ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 0 0 X 1 0 X X X X X X 0 0 0 X Basket Control 1 X X X X X X X X X 0 0 X 1 0 0 0 X 0 0 X 1 0 0 X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Slope tilting X X X X X X X EV

1

X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

12

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

PENDULAR LIFTING ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 0 1 X 0 0 X X X X X 1 0 0 0 X Basket Control X X X X X X X X X X 0 1 X 0 0 0 0 X 0 0 1 1 0 0 X

Output CI Movement

Pendular lifting EV

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X X X X X

1

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

13

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

PENDULAR LOWERING ELECTROVALVE

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Base Control X X X X X X X X X X 1 0 X 0 0 X X X X X 1 0 0 0 X Basket Control X X X X X X X X X X 1 0 X 0 0 0 0 X 0 0 1 1 0 0 X

Output CI Movement

Pendular lowering EV

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X X X X X X

1

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

14

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

BRAKE X2 ELECTROVALVE

Input CI Movement

Basket control

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

1 X X X X X X 1 X X X X X X X X X X X X X 1 X X X X 1 1 X X X X 1 X X X X X X X X X X X X X 1 X X X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Brake X2 EV X X X X X X X X X

X

1

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

15

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

OSCILLATION X2 EV

Input CI Movement

Basket Control

Output CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X 1 1 X X X X 1 X X X X X X X X X X X X X 1 X X X

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Oscillation X2 X X X X X X X X X EV

X

X

1

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

16

X

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

DIFFERENTIAL LOCKING ELECTROVALVE

Input CI Movement

Basket Control

Output CI Movement

Differential locking EV

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X X X X X X X 1 X X X X 1 X X X X X X X X 1 X X X

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

17

1

X

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

LOWERED ARM FAST SPEED

Input CI Movement

Basket Control

Output CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X 1 1 X X X X 1 X X X X X X X X X X X X X 1 X X X

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Lowered arm X X X X X X X X X fast speed

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

18

X

1

X

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

PROPORTIONAL SPEED N°4 STOP

If leds state tables of inputs from R1 to R10 are not the asked conditions, then R15 = 1 during 2 seconds maxi.

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Speed stop X X X X X X X X X

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

19

X

X

1

X

X

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

FLASHING ALARM LAMP

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Flashing 1 X X X X X X 1 X X X X X X X X X X X X X 1 X X X alarm lamp X 1 1 X X X X 1 X X X X X X X X X X X X X 1 X X X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Flashing X X X X X X X X X alarm lamp

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

20

X

X

X

X

1

X

X

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

MAXI ENGINE SPEED ELECTROVALVE

Input CI Movement

Basket control

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

X X X X 1 1 X 0 X X X X X X X X X X X X X 1 X X X X X X X 1 X X 0 1 X X X X X X X X X X X X 1 X X X X X X X X 1 X 0 1 X X X X X X X X X X X X 1 X X X X 1 1 X X X X 1 X X X X X X X X X 1 X X X 1 X X X

Output CI Movement

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

Maxi engine X X X X X X X X X speed EV

X

X

X

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

21

X

X

X

X

X

X

1

X

X

LEDS STATE TABLE PER POSSIBLE MOVEMENT Ref. MICRO W.517700-007

BUZZER CUT OFF

Input CI Movement

A B C D E F G H I

J K L M N O P Q R S T U V W X Y

Intermittent 0 X X X X X X X X X X X X X X X X X X X X X X X X slope default Permanent X X X X X X X X X X X X X X X X X X X X 0 X X X X overload def.

Output CI Movement

Buzzer

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

X X X X X X X X X

X

X

X

If absence of A = R20 , 1 sec. at 1 and then 1 sec. at 0 on alternate.

0 = Plate led switched off in order to have the movement 1 = Plate led switched on in order to have the movement X = No taking into account of the state0-1 in order to have the movement

22

X

X

X

X

X

X

X

1

X

B - CARD 2 : PROPORTIONAL

+12 v

MANIPULATOR

FWD/REV LONGITUDINAL

RIGHT STEERING

LEFT STEERING

DICE

MANIPULATOR

TELESCOPE SIDE

ARM 1/2 LONGITUDINAL

TURRET SIDE ROTATION

MANIPULATOR

ARM 3 LONGITUDINAL

B1 - Diagram

v

1

7

m

11

n g bc

ro bl

5

r

6

m

13

j

8

g bc

m

9

j

12

DANFOSS SECURITY EV

1

LED E

2 1 PROPORTIONAL FWD GEAR EV

B

9 8 14 12 LED W

m 13

A

SIGNAL ARM 1/2 SIGNAL TELESCOPE SIGNAL ARM 3 I SIGNAL TURRET ROTATION FREE S7 TURRET RIGHT ROTATION I

I

I

v 54 m 15 m 14 m 13

m 14 12

REV GEAR EV

+ 12 VDC MANIP +12 VDC - 12 VDC MANIP -12 VDC I SIGNAL TRANSLATION FWD/REV -12 VDC S6 OK REGUL TELESCOPE S8 EV SECURITY DANFOSS

2

REXROTH ON HYDROSTATIC PUMP EV PROPORTIONAL

13 v 31 11 v 34 5 v 34 v1

m 19

EV PWM FWD EV PWM REVERSE COM EV PWM FREE FREE FREE

m 15 2

14

g bc

+12 v LED H LED I LED F

4 TELESCOPE EV

1 4

ARM 3 EV

1 4

ARM1/2 EV

LED G LED X

yellow blue white

v 52 v 38

S1

OK REGUL TRANS

v 60

S2

OK REGUL ARM 3

v 62

S3

OK REGUL ARM 1/2

v 61 v 55

S5

S4 OK REGUL PROPO n 4 TURRET LEFT ROTATION FREE FREE

blue blue white white yellow yellow

yellow blue white

+ 12 PVG + 12 PVG SIGNAL TELESCOPE SIGNAL ARM 3 -12 VDC -12 VDC

1

blue blue white white yellow yellow

yellow blue white

+ 12 PVG + 12 PVG SIGNAL PROPOR N 4 SIGNAL ARM 1/2 -12 VDC -12 VDC ro 43

v 15 ro 42 4 1

= TURRET ROTATION = BASKET ROTATION = STEERING = PENDULAR = TILTING

0.4/1.15Amp

v 14

yellow blue white

ro 41 m 27 ro 40 v 69 ro 52 V 51 ro 53 (INPUTS) A MOVEMENT SELECTION

v6 ro 37 v7 ro 36 v 64 ro 39 v 65 ro 38 v 66 ro 28 v 67 ro 70

23

I13 BASKET RIGHT ROTATION BASE CTRL I14 BASKET LEFT ROTATION SLOPE I2 I15 RIGHT STEERING MAX. SPEED I3 I16 LEFT STEERING I4 Basket ctrl I17 CAVAGE TILT I5 OVERLOAD I18 SLOPE TILTING I6 TELESCOPE OUT I19 LIFTING PENDULAR I7 TELESCOPE IN I20 LOWERING PENDULAR I8 ARM 1/2 LIFTING I21 TURRET RIGHT ROTATION I9 ARM 1/2 LOWERING I22 TURRET LEFT ROTATION I10 ARM 3 LIFTING I23 LOWERED ARM I11 ARM 3 LOWERING I24 SPEED STOP I12 FREE I1

C - CARD 3 : FUSES C1 - Diagram F1 : Base engine default lights supply. Emergency stop.

F2 : Relays R1 to R6 card 1 supply.

F3 : Relays R7 to R13 card 1 supply.

F4 : Relays R14 to R17 and R19, R20 card 1 supply.

F5 : Inputs cad 1 supply, and alignment axles sensor and excitation alternator supply.

F6 : Card 1 supply.

RD : Engine starter relays.

RD

F1 F2 F3 F4 F5 F6

518055

F1 : 10 AMP F2 : 10 AMP F3 : 10 AMP F4 : 10 AMP F5 : 3.15 AMP F6 : 1 AMP

C1 1

C2 3

C3 6

C4 6

6 + battery after :

Starter engine signal (basket)

NEMAN position 1 NEMAN position 2

Basket light of engine default (-)

Horameter run on

Card 2 supply

Engine starter signal NEMAN position 3

Starting motor signal

Alternator excitation

Card 1-C18 supply

Signal of engine temperature + light

Card 1-C10 inputs supply + Axles alignment sensors

Signal of oil pressure + light

Relays R14 to R17 and R19, R20 card 1-C3 supply

Signal of air filter clogging + light

Relays R7 to R13 card 1-C3 supply

Lights supply of engine / base default + emergency stop Relays supply R1 to R6 card 1-C3

24

D - GENERAL POWER SUPPLY DIAGRAM D1 - Schematic diagram

25

1/2 ARM SPEED REGULATION PLATE OK

PENDULAR LIFTING

LEFT STEERING

Y = FREE

W = TURRET RIGHT ROTATION X = TURRET LEFT ROTATON

V = BASKET CONTROL

U = OVERLOAD SAFETY

T=

S = RIGHT STEERING

R = HARE SELECTOR

Q = BASKET LEFT ROTATION

P = BASKET RIGHT ROTATION

O = CAVAGE TILTING

N = SLOPE TILTING

M = BP DIFFERENTIAL LOCKING

L=

AB CDE

3

4

17

7

( S2 )

m1

m6

ENGINE WATER

m 12

m4

m 2/27

v9

m2

m3

( S4 ) ( S1 )

m5

+

( S6 )

( S3 )

OIL ENGINE PRESSURE

AIR FILTER COLMATING

MAXI SPEED ENGINE EV

( S5 )

( S7 )

FREE

J=

K = PENDULAR LOWERING

ARM 3 SPEED REGULATION PLATE OK

I=

2

G = PROPORTIO N 4 SPEED REGULATI ON PLATE OK H = TRANSLATION SPEED REGULATION PLATE OK

F=

E = TELESCOPE SPEED REGULATION PLATE OK

2

2

8

ro 17 ro 18

v 22

ro 19

1

1

1

BUZZER

C5

C6

C7

C8

4

1

3 2

R18

R19

R20

R21

R22

R23

g bc

j

ARM 3 INNER CONNECTION

RUN

MICRO W.517700-007

V

D = FREE

R8

SLOPE SENSOR

2

ro 20 ro 50

16

18 17

jvt 16

11

16

15

18 17

ro 70

24

R17

2

FLASHING RM LAMP

R15

11

ro 28

ro 24

50

20

R16

16

ro 13/36

R12 ro 12/37

19

v 12

ASSISTANCE PUMP

15

PUPITRE PANIER

14

14

16

13

13

15

12

v 26

1

ro 51

HORAMETER

11

12

R14

11

R13

ro 16 ro 15

ro 11 ro 11

51

ro 14

10 9

18

FUEL LEVEL 8

10 9 v 28

8 v 29

7

14

14

1

THERMIC ENGINE DEFECT 6

15 5

7 R10 17

Y X R11 18 15

W

6

14

5

+ -

1

EMMERGENCY STOP BP STARTING UP 13

4 10

3 v 55 T

v 63 v 54 S

v 92 4 R

v 69

4

17

MANIPULATOR

2 1

16

ARM 3 LONGITUDINAL R7 v 20

2 7

C = LOWER FC ARM m

ro 9/53

B = ARM 3 FC / ANGULAR

ro 32/29

+

g bc

j m

v

C1

215681

C14

C13

DICE r

2

1

2

1

v 60

v 53

v 61

v 62

v1

v 52

ro bl

RIGHT STEERING v 30

v 27

v 20

v 21

v 15

v 23

v 22

v5

v6

v7

v 92

v 63

v 64

v 65

v 66

v 67

n g bc

LIFTING PENDULAR SELEC.

SLOPE TILTING SELEC.

12 NEMAN

10

LOWERING PENDULAR SELEC.

REAR AXLE INDICATOR FRONT AXLE INDICATOR

BP DIFFERENTIAL LOCKING HARE SELEC.

5

7 3 2 1 OP

6

8

BASKET RIGHT ROTATION SELEC.

4

2

1

2

1

3 1

C2

RD

DETECTEUR ANGULAIRE Black

6 1

C3 6 1

C4

F1 F2 F3 F4 F5 F6

DANFOSS SECURITY EV

FC BRAS N 3

FC BRAS EN BAS

1

C1

1

Brown Black

Blue

Brown Blue

INCLIN. DEVERSEMENT

INCLIN. CAVAGE

LOWERING PENDULAR

LIFTING PENDULAR

BASKET CONTROL BASE CONTROL

EXIT TELESCOPE

INDENT TELESCOPE

BASKET LEFT ROTATION SELEC.

3

TURRET RIGHT ROTATION

TURRET LEFT ROTATION

LIFTING ARM 1/2

LOWERING ARM 1/2

LIFTING ARM 3

LOWERING ARM 3

30 30 17 17 50 19 19 54 15 58

m

4 WHEELS STEERING SELEC. g 42

6

OF THE INPUTS LED

ro 8/52

U R9

v 24 v 25 16

R3 ro 7/30

v 51

3

N R5

2 1

5

M L R4

20

3 K

20

4 J R2

14 13

TURRET SIDE ROTATION 12

12 v 20 11

I H

19

G ro 4/40

19

F

R1

Q P

16 16

6 v 22 10 v 23 E

17

R6

15 14

11

13

15 14

3

12

13

D

ro 3/41 ro 2/42

18

BUZZER 11

12

10

10

11

v 21

10

7 ro 1/43

ro 6/38

C

18

1/2 ARM LONGITUDINAL 9

9 8

9 9

8

3 2 B

17

TELESCOPE SIDE

7 6 6

ro 5/39

6 O

v 20 v 20

MANIPULATOR 5 5

8 4 4

White Red 3

Black v 14

2

3

1

2

3 SLOPE

LEFT STEERING 7

FWD/REV LONGITUDINAL

5

V LOWERING ENDULAR

CRABWISE STEERING SELEC.

2 518055

CAVAGE TILTING SELEC. bc 36

2

A

2 2 4 15

13

1 1

1

1

PEDAL 2 2

1 3

18

MANIPULATOR V LEFT TEERING

m 23

A=

bc 9 bc 17 v 129 V TURRET LEFT OTATION

v129

11

V BASKET LEFT OTATION

v127

OVERLOAD SAFETY 1 1

2 m 6/26

m 5/25

m8

v 97 v 26

m 30 m 4/24

BUZZER 1 v 25 v 24

9

bc 18 V SLOPE LTING

15

16

v 31

m7

v127 2

1

v 90

v 28/22 v 27

v127

v 98 v127 1 2

ABREVIATION AND CORRESPONDENCE

v 38 v 53

v 12

m 24

m 26 m 25

P

2

1

F6 = 1AMP

F5 = 3.15A

v10/11/13

6

F4 = 10AMP

F3 = 10AMP

F1 = 10AMP F2 = 10AMP

FUSE PLATE

v 91

26

2

1

2

1

KM1

F7

m 15 m 14 m 13

v 54

9 8 14 12

13 v 31 11 v 34 5 v 34 v1

pin 9 pin 11 pin 12

+ BATTERY

PWM FWD EV PWM REVERSE EV COM EV PWM

I

I

0.4/1.15Amp

SIGNAL ARM 1/2 SIGNAL TELESCOPE SIGNAL ARM 3 SIGNAL TURRET ROTATION FREE S7 TURRET RIGHT ROTATION I

I

+ 12 VDC MANIP +12 VDC - 12 VDC MANIP -12 VDC I SIGNAL TRANSLATION FWD/REV -12 VDC S6 OK REGUL TELESCOPE S8 EV SECURITY DANFOSS

ASSISTANCE PUMP ENGINE

ASSISTANCE PUMP SWITCH

FUSE 6.3 Amp

BP ASSISTANCE PUMP

AIR FILTER COLMATION INDICATOR

ENGINE OIL PRESSURE INDICATOR

EMERGENCY STOP WATER TEMPERATURE INDICATOR

pin 5

pin 8

PREDISPOSITION CONNECTOR DIGICODE

(masse)

pin 6 pin 10

pin 4 pin 3 pin 7

pin 1 pin 2

(libre)

(+ 12V) (+ 12V)

1

2

m 12

m4

A

B

-

R2 = BASKET LEFT ROTATION EV R3 = RIGHT STEERING EV R4 = LEFT STEERING EV R5 = TURRET RIGHT ROTATION EV R6 = TURRET LEFT ROTATION EV R7 = CAVAGE TILTING EV R8 = SLOPE TILTING EV R9 = LIFTING PENDULAR EV R10 = LOWERING PENDULAR EV R11 = BRAKE x2 EV R12 = OSCILLATION x2 EV

R1 = BASKET RIGHT ROTATION EV

OF THE RELAYS AND OUTPUT LEDS

m7

m3

m 11

m 21

n

bc 17

bc 10

bc 9

m8

m 12 m 11

m1 jvt 16

bc 10

C5

C6

OSCILLATION EV

DETECTOR

REAR AXLE

4 WHEELS STEERING EV

ro 12

ro 11

CRABWISE STEERING EV

R18

R19

R20

R12

V

RUN

B

ro 27

ro 26

C

ro 25

ro 15

A

ro 17

ro 20

ro 11

ro 16

R

N

DETECTOR

FRONT AXLE

GAZOLE GAUGE

BRAKE EV

m = BROWN bc = WHITE

OSCILLATION EV

ro 11

ro 14

ro 11

ro 14

COLLECTOR

DIFFERENTIAL LOCKING EV

ro 15

ro 24 ro 18

C A

U

MICRO W.517700-007

W

ro 26

ro 19

B

ro 13

ro 11

R13 = DIFFERENTIAL LOCKING EV R14 = HIGH SPEED ARM LOWERED R15 = PROPORTIONAL SPEED STOP n° 4 R16 = FREE R17 = FLASHING ALARM LAMP R18 = FREE R19 = EV MAX. ENGINE SPEED R20 = BUZZER R21 = FREE R22 = BASKET EMMERGENCY CANCELLATION R23 = FREE

m 15

m 19

m 14

m 13

bc 18

m 20 T m 21

m 22

+

D

ABREVIATION ET CORRESPONDENCE

FORWARD GEAR EV

PROPORTIONAL

REVERSE GEAR EV

PROPORTIONAL

PREHEATING

EV FROM COLD STARTING

ENGINE INJECTION EV

BATTERY CUTOUT

BATTERY

STARTER

ALTERNATOR

m6

n

m1

m 2/27

ENGINE WATER TEMPERATURE

G

+

m5

n

OIL ENGINE PRESSURE

AIR FILTER COLMATING

MAXI SPEED ENGINE EV

BUZZER

AB CDE

1

R17

2

R21

1

ro 26/26/25

M L

R5 ro 32/29

S

R8

R22 B

C C1

215681

A

F

D ro 1/43

E

ro 3/41 ro 2/42

v = VIOLET ro = PINK

n = BLACK g = GREY

2

1

2

1

v 60

v 53

v 61

v 62

v1

jvt = YELLOW/GREEN

ABREVIATION OF THE STRAND COLOURS

BRAKE EV

ro 5/39

T v 26

3

m2

2

ro 11/11/24

1

R14

ro 11

3

ro 11/11/11

ro 12

2

ro 28

ro 20

ro 50

4

ro 20

+ -

FLASHING ALARM LAMP

R16

jvt 16

ro 11

R15

ro 70

ro 24

R13

ro 16 ro 15

ro 24

ro 14

ro 19

ro 13/36 ro 14

ro 13

ro 51

ro 19/27

6 ro 14/14

7

ro 12/37 8

ro 11 ro 11

5

1

9 ro 18

Q P

R7 v 20

Y X R11 ro 18 ro 15

ro 17

10 11

R10 ro 16 12

ro 15/15 ro 17

R9 v 24 v 25

ro 16

O

R6 v 20 v 20

K ro 8/52

R4 ro 9/53

J

R3 ro 7/30

I H R2 ro 6/38

G R1 ro 4/40

v 52

v 30

v 27

v 20

v 21

v 15

v 23

v 22

v5

v6

2

1

1 2

DETECTEUR ANGULAIRE

Black

= TURRET ROTATION = BASKET ROTATION = STEERING = PENDULAR = TILTING

ARM 1/2 EV

ARM 3 EV

TELESCOPE EV

yellow blue white

yellow blue white

2

1

yellow blue white

15

16

yellow blue white

DANFOSS SECURITY EV

FC BRAS N 3

FC BRAS EN BAS

Brown Black

Blue

Brown Blue

INCLIN. DEVERSEMENT

INCLIN. CAVAGE

LOWERING PENDULAR

LIFTING PENDULAR

BASKET CONTROL BASE CONTROL

m 24

m 25

v 91

EXIT TELESCOPE

ro 13 ro 34

R23

EV LOWERING PENDULAR ro 34 ro 12

C7

ro 4

m3

EV LEFT STEERING ro 31 ro 3

ro 31/32

EV LIFTING PENDULAR

4

1

12

2

4

1

2

ro 6

v 90 4

1

2

EV TURRET LEFT ROTATION ro 33 ro 5

ro 33/30

ro8

1 2 4

1

1

ro 2

EV RIGHT STEERING

EV BASKET LEFT ROTATION

ro 35 ro 1

EV TURRET RIGHT ROTATION

ro 35 /7 EVBASKET RIGHT ROTATION

EV SLOPE TILTING ro 9 ro 34 ro 34 /29 EV CAVAGE TILTING

27

4 1

P

2

1

2

1

2

1

KM1

F7

ro 43

v 67

v 66

v 65

v 64

v7

v6

V 51

v 69

m 27

v 14

v 15

blue blue white white yellow yellow

blue blue white white yellow yellow

ro 70

ro 28

ro 38

ro 39

ro 36

ro 37

ro 53

ro 52

ro 40

ro 41

ro 42

OK REGUL ARM 1/2

S3 v 62

I13 BASKET RIGHT ROTATION BASE CTRL I14 BASKET LEFT ROTATION SLOPE I15 RIGHT STEERING I3 MAX. SPEED I16 LEFT STEERING I4 Basket ctrl I17 CAVAGE TILT I5 OVERLOAD I18 SLOPE TILTING I6 TELESCOPE OUT I19 LIFTING PENDULAR I7 TELESCOPE IN I20 LOWERING PENDULAR I8 ARM 1/2 LIFTING I21 TURRET RIGHT ROTATION I9 ARM 1/2 LOWERING I22 TURRET LEFT ROTATION I10 ARM 3 LIFTING I23 LOWERED ARM I11 ARM 3 LOWERING I24 SPEED STOP I12 FREE I2

I1

+ 12 PVG + 12 PVG SIGNAL PROPOR n° 4 SIGNAL ARM 1/2 -12 VDC -12 VDC

+ 12 PVG + 12 PVG SIGNAL TELESCOPE SIGNAL ARM 3 -12 VDC -12 VDC

FREE

S4 OK REGUL PROPO n° 4 S5 TURRET LEFT ROTATION FREE

OK REGUL ARM 3

S2

v 61 v 55

OK REGUL TRANS

S1

0.4/1.15Amp

v 60

PWM FWD EV PWM REVERSE EV COM EV PWM FREE FREE FREE

I

I

SIGNAL ARM 1/2 SIGNAL TELESCOPE SIGNAL ARM 3 SIGNAL TURRET ROTATION FREE S7 TURRET RIGHT ROTATION I

I

+ 12 VDC MANIP +12 VDC - 12 VDC MANIP -12 VDC I SIGNAL TRANSLATION FWD/REV -12 VDC S6 OK REGUL TELESCOPE S8 EV SECURITY DANFOSS

v 52 v 38

m 15 m 14 m 13

v 54

9 8 14 12

13 v 31 11 v 34 5 v 34 v1

+ BATTERY

ASSISTANCE PUMP ENGINE

ASSISTANCE PUMP SWITCH

FUSE 6.3 Amp

BP ASSISTANCE PUMP

AIR FILTER COLMATION INDICATOR

ENGINE OIL PRESSURE INDICATOR

28

m 21 m 20

18 bc

54

ro14 ro11

ro14 ro11

ro16 ro11

m 2/27 m1

m 20

48

m 21 m11 m 22

AUX

-

+

45

44

43

11 AA 399

49

ro20

55

46

41

30

38

m5

47

m6

50

42

m1 9 m1 5

m1 3 m1 4

ro11 ro13

ro11 ro12

1 - 3 2

1 - 3 2

m7 bc10

m4 m1 2

35 37 36

57

56

n

53

j/vt16 m1 2 m 8 bc10 m1 m11 bc9 bc17

31

n

39

B

A

B

A

ro17 C ro25 ro27

ro18 C ro24 ro19

63

33

32 40

CIRCUIT ELECTRIQUE STROMKREIS CIRCUITO ELECTRICO ELECTRIC CIRCUIT

ro15 ro26

2 3 1

34

23

58

1 - 3 2

n1 n2

1

2 - 3 1

61 62

jaune bleu blanc jaune bleu blanc jaune bleu blanc jaune bleu blanc

60 59

52

51

29

28

ro15 ro26

26

11

17

16

3

4

2

C B

A

27

ro2 ro35

ro34/29 ro8

ro35/7 ro1

ro6 ro33

ro9 ro34

ro31/32 ro3 ro33/30 ro5

ro4 ro31

23 / 01 / 01

22

19 21 25

15

ro34 ro12

24 19

20

18

14

10

ro13 ro34

12 13

9

6 5

8

7

165 ATJ

P.A.O

29

319 165 ATJS

150 ATS2

30

23

22

21

24

20

11 CB 321

15 13

14

23

22

21

19

11

12

10 12

16 17 18

8

7

6

1

9

10

5

12

4

10

10

3

12

12

4

10 12

2

10 12

18 / 01 / 01

150 ATS2 165 ATJ 165 ATJS

P.A.O

PARAMETERIZATION OF THE MACHINE 165ATJ 80-8-84-M.53 EN

01 / 2002

PARAMETERIZATION OF THE MACHINE Main Parameterization All platform movements are parameterizable.Each movement is defined by three parameters :

Speed :

Expressed in percentage (%) of total power. This parameter defines the maximum authorized speed. The hydraulic movement can thus be anything between 0% and the maximum speed.

Gradient + : This is the acceleration gradient. A user using the manipulator in on/off mode (moving suddenly from zero position.to maximum position) will accelerate gradually according to the value defined for this “gradient+” parameter.

Gradient - : This is the deceleration gradient. A user using the manipulator in on/off mode(moving suddenly from maximum position to zero position) will decelerate gradually according to the value defined for this “gradient -” parameter.

The parameters of the MANITOU platform have been calculated in such a way as to ensure maximum safety to users whilst offering maximum performance. The parameters table shown overleaf corresponds to the factory settings and should be taken as a benchmark when making any adjustments.

We draw the reader’s attention to the fact that any change you may make to the speed may have serious consequences in terms of machine stability for which you will be entirely liable.

1

2

FWD Gear lowered arm FWD Gear slow low. arm FWD Gear lifted arm REV Gear lowered arm REV Gear slow low. arm REV Gear lifted arm Lower arms lifting Lower arms lowering Upper arms lifting Bras supérieur lowering Pendular lifting Pendular lowering Telescope retracted Telescope out Turret rotation right Turret rotation left Basket rotation right Basket rotation left Right steering Left steering Tilting cavage Tilting slope

Movement

-3

40 40 100 100 52

on / off on / off

basket

basket basket base basket base on / off

on / off 42

35

35

65

50

20

35

45

55

65

on / off

lateral

lateral

lateral

lateral

on / off

on / off

longitudinal

longitudinal

longitudinal

=

=

-3

-3

=

=

-3

-3

-3

-3

-3

2 0 0

2 0 0 4

4

4

2

2

4

35

35

10

13

2

2

15

12

12

20

20

13

15

2

2

15

12

40

12

18

20

50 65

longitudinal 15

15

8

100

longitudinal

longitudinal

13

8

100

longitudinal

18

20

50

15

8

100

longitudinal longitudinal

13

8

100

longitudinal

; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 50 ; - 30 ; - 30 ; - 50 ; - 50 ; - 50 ; - 50 ; - 30 ; - 30 ; - 30 ; - 30 ; - 30 + 20 ; - 30 + 0 ; - 20 + 0 ; - 20 + 20 ; - 30 + 20 ; - 30 + 20 ; - 30 + 20 ; - 30

+ 25 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20 + 20

+ 0 ; - 80

+ 0 ; - 80

+ 25 ; - 50

+ 0 ; - 80

+ 0 ; - 80

Manipulator Limitation(%) Gradient + Gradient - Tolerance

basket base basket base basket base basket base basket base basket base basket base basket base basket base basket base basket

basket

Control

Because of the repetition of some components, ther can be speed differences (between forward and reverse or right and left) In this case, the machine should be parameterized in order to find the balance. You must not pass : - Lifted arms transfer : 0.9 Km/h 165 ATJ - Turret rotation (complete) 95 s - Lifting/lowering : Base and basket 32 sec.

hydraulic

hydrostatic

Pump

12 s 4s 4s s s s s

0.85 Km/h 20 s s 20 s s 30 s s 30 s s 20 s s 20 s s 18 s s 19 s s 85 s s 85 s s 12 s

3.3 Km/h

6 Km/h

0.85 Km/h

3.3 Km/h

6 Km/h

Speed

W592900.004.C microprocessor - Standart parameters

12 s to 14 s -

42 à 46 s on 10m 20 s to 24 s 22 s to 26 s 20 s to 24 s 22 s to 26 s 32 s to 35 s 34 s to 40 s 32 s to 35 s 34 s to 40 s 20 s to 24 s 22 s to 26 s 20 s to 24 s 22 s to 26 s 18 s to 20s 18 s to 20s 18 s to 20s 18 s to 20s 95 s to 100s 100 s to 105 s 95 s to 100s 100 s to 105 s 12 s to 14 s

11 s on 10m

6 s on 10m

42 à 46 s on10m

11 s on 10m

6 s on 10m

Speed Tolerance

Parameterization list

.

PARAMETERIZATION TERMINAL REF. : 563102

Parameterization terminal

CARD 2 PROPORTIONAL CARD

3

Instructions for using the parameterization terminal I - START UP Connect the terminal onto the RJ45 connector.

Press the terminal “0” key in order to indicate the presence of the computer to the terminal.

The following mesage is displayed on the configuration terminal screen :

CIMM ATJ 165

Description of the menus : - F1 key : Speed and gradient parameter data - F2 key : annex data - F2 to F5 key : Visualization data.

II - F1 PARAMETER MENU This menu is accessible by pressing the “F1” key.

To reach the data you want to modify, press the menus.

(= Shift 8) or

(= Shift 2) keys to obtain the pull-down

Once you have reached the data, you can modify it by pressing + or - keys in the predefined and gathered limits in the “Error, reference source not find” paragraph.

Speed and gradient data These values let you modify (according to the selected movement) : - The max. speed - The acceleration gradient (R+) and deceleration gradient (R-).

The data you want modify is accessible by pressing the “space” key.

4

III - ANNEX DATA MENU F2 III.1 - LANGUAGE CONFIGURATION In this menu, you can toggle between French and English by pressing the“ + ou -” keys.

IV - VISUALIZATION MENU IV.1 - PWM OUPUTS VISUALIZATION (ADVANCING PUMP CONTROL) This menu is accessible by pressing the” F3” key.

The datas are expressed in mA. IV.2 -PVG OUTPUTS VISUALIZATION This menu is accessible by pressing the” F4” and it is divided into two parts. The second one is accessible by pressing the key.

The PVG control analog outputs are expressed in % of the power supply tension. (50%=PVG in the neutral).

IV. 3 - ANALOG INPUTS VISUALIZATION This menu is accessible by pressing the “ F5” and it is divided into two parts. The second one is accessible by pressing the key.

The manipulators analog inputs are expressed in % of the power supply tension.

(50% = manipulator in the neutral).

IV. 4 - ON/OFF OUTPUTS VISUALIZATION This menu is accessible by pressing the” F6” key.

The displayed datas represent the state of thePVG power supply outputs and of the information conveyed to the “on/off” card.

IV. 5 - ON/OFF INPUTS VISUALIZATION This menu is accessible by pressing the” F7” key.

The displayed data represent the on/off outputs that are conveyed to the proportional card.

These inputs are numbered from the left to the right and from 0 to 23 .

5

V - MODIFICATION END At the end of the parameter modification, you shall press on Shift + End keys in order to indicate the modification end to the calculator.

6