Manitou Rexroth Hydrostatic Motor A2FM Repair Manual 647256EN - PDF DOWNLOAD

647256EN (18/04/2013)

MOTOR A2FM HYDROSTATIC REXROTH Repair manual

MANITOU BF B.P 10249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

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1st Date of Issue : 18 / 04 / 2013

647256EN

DATE OF ISSUE 18 / 04 / 2013

OBSERVATION - 1ST ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

MOTOR AF2M - REXROTH

Pages - Set of seals / Sub - assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - Shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 - Cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7 - Rotor removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - Checking the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 10 - Rotor installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 13 - Tools/Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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ENGINE A2FM - REXROTH

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JEU SETDE OFJOINTS SEALS // SOUS-ENSEMBLES SUB-ASSEMBLIES

01

Set of external seals with fitting device.

-HX GH MRLQWV H[WpULHXUV DYHF GLVSRVLWLI GH PRQWDJH

5RWRU SDUWLH PpFDQLTXHV SUpDMXVWp DYHF MHX GH MRLQWV 02 Rotor; mechanical part; pre-adjusted with a set of HW FROOH seals and glue.

03

5RWRU SDUWLH K\GUDXOLTXHV SUpDMXVWp DYHF MHX GH MRLQWV Rotor; hydraulic part; pre-adjusted with a set of HW FROOH seals and glue.

04

5RWRU FRPSOHW SUpDMXVWp DYHF MHX GH MRLQWV HW FROOH Complete rotor; pre-adjusted with a set of seals and glue.

PAGES

32 44 56 88 99 11 11 12 (18/04/2013)

JEUOF DESEALS JOINTS SET JOINTSSEALS D'ARBRE SHAFT CULASSE COVER CYLINDER DEMONTAGE DU ROTOR ROTOR REMOVAL CHECKING CONTROLETHE DESCOMPONENTS COMPOSANTS ROTOR INSTALLATION MONTAGE DU ROTOR TOOLS/TIGHTENING TORQUES 647256EN

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ENGINE A2FM - REXROTH

JOINTS D'ARBRE SHAFT SEALS

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3RXU OHV DUEUHV QRQ FDQQHOpV GpJDJHU OD FODYHWWH For ungrooved shafts: release the cotter pin. Retrieve 5HFRXYULU OH ERXW G¶DUEUH the end of the shaft.

2

Remove the circlips.

(QOHYHU OH FLUFOLSV

3

Push back the sealing ring.

5HSRXVVHU OD EDJXH GH IHUPHWXUH

4

Visual inspection: CONTROLE VISUEL: 1 MRLQW G – Shaft DUEUH seal 2 EDJXH GH IHUPHWXUH – Sealing ring DUEUH G¶HQWUpH 3 FDUWHU – Inlet shaft 4 MRLQW WRULTXH – Protective cover 5 – O-ring

5

Remove the shaft seal. 'pPRQWHU OH MRLQW G¶DUEUH

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JOINTS D'ARBRE SHAFT SEALS

6

3RVLWLRQQHU FRUUHFWHPHQW OD EDJXH GX MRLQW G DUEUH DYHF Position the shaft seal ring correctly with a suitable XQH GRXLOOH DSSURSULpH guide bush.

7

If6L Othe shaft is deeply grooved, insert a shim behind DUEUH HVW SURIRQGpPHQW UDLQXUp LQVpUHU XQH FDOH GHUULqUH OH MRLQW the seal.

8

Fit a new o-ring, ensuring it is fitted correctly.

Grease 0RQWHU QRXYHDX MRLQW WRULTXH V DVVXUHU G XQ PRQWDJH FRUUHFW *UDLVVHU OH MRLQW WRULTXH HW OHV OqYUHV GX MRLQW the o-ring and the lips of the shaft seal.

G¶DUEUH

9

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0RQWHU OH FLUFOLSV HQ XWLOLVDQW XQ SRLQWHDX Fit the circlips using a point.

9pULILHU TXH OH FLUFOLSV VRLW ELHQ GDQV VRQ ORJHPHQW Check that the circlips are correctly in their housing.

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ENGINE A2FM - REXROTH

CULASSE CYLINDER COVER/ JOINTS / SEALS

11

0DUTXHU OD SRVLWLRQ GH OD FXODVVH VXU OH FRUSV VXLYDQW Mark the position of the cylinder cover on the body IOqFKH

(according to the arrow). Remove the fixing screw. 'pPRQWHU OHV YLV GH IL[DWLRQ

12

)DLUH SLYRWHU OD FXODVVH DXWRXU GX SLRQ GH FHQWUDJH HW Swivel the cylinder cover around the centring pin O HQOHYHU and remove it.

13

5HSpUHU OD SRVLWLRQ GX SLRQ GH FHQWUDJH VXLYDQW IOqFKH Mark the position of the centring pin (according to the arrow).

14

3RPSH 5RWDWLRQ GURLWH 9XH JODFH FRWp VXUIDFH Pump: rotation right (mirror view spherical surface VSKpULTXH side).

15

3RPSH 5RWDWLRQ JDXFKH Remove the shaft seal. 9XH JODFH FRWp VXUIDFH VSKpULTXH

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CULASSE CYLINDER COVER//JOINTS SEALS

16

0RWHXU VHQV GH URWDWLRQ 9XH JODFH FRWp VXUIDFH Motor: 2 directions of rotation (mirror view spherical VSKpULTXH surface side).

17

9pULILHU YLVXHOOHPHQW Visually inspect MRLQW WRULTXH O-ring (1) UDLQXUH Groove FXODVVH (2)

Cylinder cover (3)

18

0HWWUH OH MRLQW HQ SODFH DSUqV O Lightly grease the seal andDYRLU OpJqUHPHQW insert it.

JUDLVVp

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19

5HPRQWHU OD FXODVVH GDQV VD SRVLWLRQ SUHPLqUH )LJ Refi t the cylinder cover in its initial position (Fig.

$WWHQWLRQ j OD SRVLWLRQ GH OD JODFH 11). Pay attention to the position of the mirror.

20

5HPRQWHU OHV YLV DYHF OH FRXSOH GpVLUp YRLU 3 Refi t the screw with the desired torque, see P. 14

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ENGINE A2FM - REXROTH

DEMONTAGE DU ROTOR ROTOR REMOVAL

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(QOHYHU OD FXODVVH SDJH cover 7RXUQHU OD SODTXH GH Remove the cylinder (Page 6). Turn the FRQWU{OH SRXU O control plate HQOHYHU to remove it.

22

'pPRQWHU OD EDJXH GH IHUPHWXUH Remove the sealing ring (PageSDJH 4)

23

(QOHYHU OHV FDOHV Remove the shims.

24

'pPRQWHU OH URWRU DYHF XQ H[WUDFWHXU )LJ Remove the rotor with an extractor (Fig 50)

25

(QOHYHU OD SODTXH GH UHWHQXH OHV YLV VRQW PDLQWHQXHV Remove the retaining plate; the screws are held DYHF GX ORFWLWH with LOCTITE.

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CONTROLETHE DESCOMPONENTS COMPOSANTS CHECKING

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$UEUH Gshaft HQWUDvQHPHQW Drive

([HPSW GH FRUURVLRQ RX G 1RQ DEvPpV DX[ 1) Free from corrosion orpURVLRQ erosion.

Not damaged FDQQHOXUHV on the channels.

3DV GH WUDFHV G XVXUH VDQV UD\XUHV ILJ 2) No trace of wear, no scoring (Fig 7) 6DQV FRXSXUHV LPSDFWV HW SLT UHV 3) No cuts, impacts and pitting.

27

-HX D[LDO DX SLVWRQ 1) Piston axial play

(SDXOHPHQW 2) Shoulder

28

3LVWRQV Pistons ([HPSW GH WUDFHV SDV GH SLT UHV 1H SDV GpPRQWHU Free from marks, no pitting (Do not remove the O DUWLFXODWLRQ joint)

29

7rWH GH FHQWUDJH Centring head

([HPSW GH WUDFHV SDV GH SLT UHV 1) Free from marks, no pitting (Do not remove 1H SDV GpPRQWHU O DUWLFXODWLRQ the joint) ([HPSW GH WUDFH 2) Free from marks

30

3ODTXH GH UHWHQXH Retaining plate ([HPSW GH WUDFHV HW G Free from marks andXVXUHV wear

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ENGINE A2FM - REXROTH

CONTROLETHE DESCOMPONENTS COMPOSANTS CHECKING

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%ORF F\OLQGUH 3ODTXH GH FRQWU{OH Cylinder block / control plate

$OHVDJH VDQV WUDFHV VDQV XVXUH 1) Bore without marks or wear )DFHV OLVVHV HW SODQHV VDQV WUDFHV RX VDQV 2) Smooth, flat surfaces without marks PDUTXDJHV 3) Minimum hardness 'XUHWp 0LQL +9 700 HV 10

32

&DUWHU Protective cover 3DV DEvPp RX XVp VXU OHV SRUWpHV GH URXOHPHQWV Not damaged or worn on the bearing supports.

33

&KDQJHU O HQVHPEOH SLVWRQ Changing the piston assembly. /RUVTX LO \ D OLHX GH FKDQJHU G DXWUHV FRPSRVDQWV XQ When other components require to be changed, UHFDOLEUDJH HVW QpFHVVDLUH recalibration is required.

34

%ORF F\OLQGUH HW SODTXH GH FRQWU{OH j FKDQJHU SDU SDLUH Cylinder block and control plate to be changed as a pair.

35

,QVpUHU XQ D[H GH FHQWUDJH DYHF DQQHDX GH UHWHQX Insert a centring shaft with a retaining ring. Fit the 0RQWHU FRUUHFWHPHQW OD SODTXH GH UHWHQXH retaining plate correctly.

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MONTAGE DU ROTOR ROTOR INSTALLATION

36

0HWWUH XQ SHX GH ORFWLWH SRXU OHV YLV VHXOHPHQW Use a little LOCTITE on the screw only.

37

0RQWHU j OD JUDLVVH OHV SDWLQV HW OHV URQGHOOHV %HOOHYLOOH Grease and fit the skids and the BELLEVILLE washer XWLOLVHU XQ WRXUQHYLV (use a screwdriver).

38

6 DVVXUHU TXH WRXWHV OHV SLqFHV VRQW FRUUHFWHPHQW Ensure that all the parts are correctly fitted.

PRQWpHV

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39

0RQWHU OHV SLVWRQV Fit the pistons.

40

$SSX\HU IHUPHPHQW VXU OHV SLVWRQV GDQV OHV FRXSHOOHV Press firmly on the pistons in the cup with the DYHF OH EORF F\OLQGUH PDLQWHQX HQ SRVLWLRQ FHQWUDOH cylinder block held in a central position.

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MONTAGE DU ROTOR ROTOR INSTALLATION

%DVFXOHU OH EORF F\OLQGUH DX 0D[L )LJ 41 Tip the cylinder block to the max (Fig. 40). Fasten )L[HU O¶RXWLO GH PRQWDJH SURWHFWHXU GH WUDQVSRUW )LJ the mounting tool and transport protector (Fig. 51)

pWDQFKpLWp" 42 Is(VW FH XQ QRXYHDX MRLQW G the seal new? (Comparison with Fig. 7) &RPSDUDLVRQ DYHF )LJ

HW RX

&KDXIIHU OH FDUWHU j & 43 Heat the protective cover to 80°C – 'LVSRVLWLI ILJ Device Fig. 52

0RQWHU OH FDUWHU SUpFKDXIIp 44 Fit the pre-heated cover.

8WLOLVHU XQH SODTXH j WURX SRXU IDFLOLWHU O¶RSpUDWLRQ Use a perforated plate to facilitate the operation /¶RXWLO GH PRQWDJH ILJ GpSDVVH GX FDUWHU ORUVTXH The mounting tool (Fig. 51) extends beyond the OH URWRU HVW LQVWDOOp protective cover when the rotor is installed.

0RQWHU OHV FDOHV HW DVVHPEOHU ILJ 45 Fit the shim and assemble Fig. 7-10

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MOTAGE DU ROTOR ROTOR INSTALLATION

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46

3RXVVHU OH URWRU FRQWUH OD EDJXH GH IHUPHWXUH Push the rotor against the sealing ring.

9pULILHU TXH OD EDJXH GH IHUPHWXUH QH ERXJH SDV Check that the sealing ring does not move.

47

5HWLUHU O¶RXWLO GH PRQWDJH Remove the mounting tool.

48

$VVHPEODJH FRPSOHW

Assembly completeYRLU )LJ (see Figs.

18-20)

49

0RQWHU GHV ERXFKRQV SRXU SURWpJHU GH OD SRXVVLqUH Fit the stoppers to protect from dust.

3URWHFWLRQ j OD FRUURVLRQ LQWHUQH H[WHUQH Protection from corrosion (internal & external).

50

([WUDFWHXU SRXU URWRU Extractor for the rotor.

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OUTILLAGE DE SERRAGE TOOLS // COUPLES TIGHTENING TORQUE

51

Protector / mounting tool.

3URWHFWHXU RXWLO GH PRQWDJH

52

'LVSRVLWLI GH FKDXIIDJH Heating device.

53

&RXSOHV GH VHUUDJH Tightening torque )LOHWDJH Threading 0 0 0 0 0

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&RXSOH 1P Torque Nm

*UDQGHXU Size 6: 6: 6: 6: 6:

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