Manitou Perkins New 1000 Series AJ-AS & YG-YK Workshop Manual - PDF DOWNLOAD

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REF : 47981 EN (07 / 03 / 2001)

HYDROMATIK TRANSMISSION PUMP A 4VG-DA MOTOR A 6VM-DA MOTOR A 2 FE

2

CONTENTS

-

-

Specific Advantages of Hydromatik Transmission Units............................................................................

4 Basic Diagram of Hydrostatic Transmission Systems ..................................................................................

5 Description of Hydromatik A4VG..DA/A6VM..DA Transmission Unit Operation ................................

6 Kinematic Chain of the Transmission Unit....................................................................................................

7 Hydraulic and Hydrostatic Diagrams MSI 40/50-MSI 20/25/30-MSI 20D/25D/30D..........................

8 à 65 BT 420/425-MA 460/470 MT 845 H / 940 HL / 1332 HSL / 1637 HSL / 1645 H MRT 1432 / 1542 / 1650 /1850 / 2145 TMT 315 / 317 / 320 / 322 / 325 Nacelles 150 / 170 ATT - 165 ATJ Maniloader AL70e/85t/100t - AS 45/70/90/14/200 - AF 60 Pump A4VG/DA ............................................................................................................................................

67 Sectional view of Pump A4VG/DA...............................................................................................................

69 Motor A6VM/DA ...........................................................................................................................................

70 - 76 Motor A2FE ......................................................................................................................................................

77 Colour Transmission Diagrams......................................................................................................................

Pump A4VG 40-56 (Front 3/4 View) .............................................................................................................

94 Pump A4VG 40-56 (Rear 3/4 View)...............................................................................................................

95 Operation of Pump A4VG..DA.......................................................................................................................

96 Pilot Circuit A4VG 56 DA (MSI 40/50)..........................................................................................................

97 Pilot Circuit A4VG 90 DA (MSI 20/25/30)....................................................................................................

98 Inching Valve Operation .................................................................................................................................

99 Control Cartridge Operation........................................................................................................................... 100 à 101 DR Valve ........................................................................................................................................................... 102 à 104 HP Valve with Haulage By-pass A 4VG 40 - 56 DA.....................................................................................

106 HP Valve with Haulage By-pass A 4VG 71 - 180 DA...................................................................................

107 Pump and Motor Pressure Measuring Points ............................................................................................... 108 - 109 Transmission Adjustment Points....................................................................................................................

111 Transmission A4VG - A6VM (Inspection before Start-up) ..........................................................................

112 Transmission Inspection and Adjustments ................................................................................................... 113 à 121 Adjusting the TH7 Valve on the Accelerator MSI 40/50..............................................................................

122 Adjusting the Pedals and TH7 Valves on MSI 20/25/30............................................................................. 123 à 127 Adjusting the Pedals and TH7 Valves on MSI 20D/25D/30D.................................................................... 128 à 132 Hydrostatic Motor and Pump Identification................................................................................................. 134 à 142 Hydrostatic Transmission Adjustment Sheet................................................................................................

143 Pump A4VG 40 - 56 Repairs Serial 3 ................................................................................................(chapter 75-3-10 EN) Pump A4VG 40 - 56 Repairs Serial 3.2 .............................................................................................(chapter 75-3-11 EN) Pump A4VG 71 - 180 Repairs Serial 3 ..............................................................................................(chapter 75-3-15 EN) Pump A4VG 71 - 180 Repairs Serial 3.2 ...........................................................................................(chapter 75-3-16 EN) Pump A10VG 28-45 Repairs Serial 3.2 ............................................................................................(chapter 75-3-5 EN) Motor A6VM Repairs Serial 60.........................................................................................................(chapter 75-3-20 EN) Motor A6VM Repairs Serial 63.........................................................................................................(chapter 75-3-35 EN) Motor A2F Repairs.............................................................................................................................(chapter 75-3-24 EN) Motor A2FE Repairs ..........................................................................................................................(chapter 75-3-25 EN) Inspection, adjustments and disassembly MANILOADER........................................................

(9-1/11-26)

3

SPECIFIC ADVANTAGES OF HYDROMATIK TRANSMISSION UNITS

In addition to the traditional features of hydrostatic transmission systems (freedom of transmission installation, minimum space requirement, instant drive reversal, no clutches, dynamic braking), HYDROMATIK transmission units have the following advantages : 1) 2) 3) 4) 5) 6)

7)

8)

9) 10) 11) 12) 13)

14) 15)

Specific output of A 4 VG pumps is the highest on the market.

High speed A 4 VG pumps and A 6 VM motors.

Bent axis design of A 6 VM motors, the pistons have no shoes, this allows 90% of the rated load torque to be transmitted on start-up and produces a wide control range.

Continuous automatic variation of transmission ratio, controlled by the operator (accelerator pedal) or according to the load, and consequently a better use of the installed capacity.

Conventional drive with accelerator pedal and brake and inching pedal.

The DA control acts as a “maximum load power control”. Pumps with DA control are used universally on diesel engines and do not require any power calibration, thus making the corresponding settings easier.

The DA control allows peak pressure and maximum displacement to be reached well before the maximum diesel engine speed (1600 - 2000 rpm), and therefore maximum machine power or 75% of the travel speed are achieved within a favourable fuel consumption range and a restricted noise level range.

When used on loaders, a high average travel speed and maximum propulsive force for a favourable diesel engine speed is possible. The efficiency of the machine (hourly capacity : hourly consumption) is also very high.

The TH 7 valve coupled up to the brake pedal clearance stroke allows the driver to reduce the machine travel speed whilst increasing the IC engine speed, and, consequently, the delivery of the pump supplying the various hydraulic movements.

It is therefore possible to achieve maximum lifting speed at low travel speed, hence more efficient handling.

Thanks to the TH 7 (inching) valve, when the driver brakes, firstly hydrostatic braking of the machine occurs, then the brakes are activated, giving economy and long life to the braking system.

Limited negative impact on diesel engine speed at full load.

No diesel engine overload.

When immobilized, diesel power is not transformed into heat ; the HP relief valves are not activated due to the combined restoring force-DR valve system.

Displacement of the A 6 VM variable motor controlled by the same pilot pressure as the pump (still the only system of this type on the market).

The installation of the DA controlled variable motor allows the pump module to be better adapted to the power of the IC engine (and not to the apparent power of the machine).

Thus, the constant power delivery range of the pump is maximized and is still satisfactory with the transfer of power to the working hydraulics.

HP locking system on the A 6 VM motor permitting detection of the torque direction in relation to the direction of travel, thus avoiding untimely braking in stoppage.

The A 6 VM motor is equipped with an exchange system allowing a certain quantity of oil to be drawn from the low pressure circuit. This oil is directed to the reservoir via the cooler. The booster flow therefore compensates for this exchange.

4

IC ENGINE

Control & Reversal

BASIC DIAGRAM OF HYDROSTATIC TRANSMISSION SYSTEMS

5

DESCRIPTION OF HYDROMATIK A 4 VG..DA/A 6 VM..DA TRANSMISSION UNIT OPERATION

GENERAL By its principle, hydrostatic transmission adapts the torque provided by the IC engine to the wheels according to the resistance encountered by the vehicle and the speed at which the driver wishes to travel.

The transmission ratio varies continuously and automatically.

The agent enabling the power to be transmitted is mineral oil which is practically incompressible and which is able to withstand substantial loads.

The HYDROMATIK A 4 VG..DA/A 6 VM..DA transmission system consists of two separate organs.

1°

An A 4 VG axial piston pump of a plate design, flange-mounted on to the diesel engine and driven directly by the flywheel by means of a flexible coupling.

2°

An A 6 VM hydraulic axial piston motor of bent axis design, flange-mounted on to a coupling case and a transfer case and driving the two axle shafts via a differential.

The pump and the hydraulic motor are linked together by a series of hoses, as are various accessories required for operation of the system: reservoir, filter, drain return to the cooler, etc.

The pump absorbs the maximum power supplied by the IC engine and converts it into hydraulic power (product of the pressure generated and the delivery rate).

The hydraulic motor receives the hydraulic power and absorbs it completely. The output shaft is then given a torque and speed which is transferred to the axle and distributed to the wheels.

The variation in the transmission ratio is obtained by the variation in the displacement of the pump and the hydraulic motor.

The pilot pressure acts against the high pressure on the servo positioner in a set ratio (1/3).

The preponderance of one in relation to the other determines whether the motor is controlled or not.

The minimum motor displacement is limited by a butt screw.

A control system sets the motor switching time.

6

7

VARIABLE CAPACITY PUMP

IC ENGINE

BOOSTER PUMP

FILTER

HP HOSE

RESERVOIR

HP HOSE

By-PASS

OIL COOLER

VARIABLE DISPLACEMENT MOTOR

CASE

TRANSFER

T R A N S M I S S I O N

F I N A L

Brake

Brake

KINEMATIC CHAIN OF THE TRANSMISSION UNIT

9

FILTER

VARIABLE DISPLACEMENT PUMP A 4 VG 56 DA

PERKINS ENGINE 1004-4

TH7 VALVE

FILTER

BRAKE TH7 VALVE

RESERVOIR

HYDRAULIC

COOLER

REVERSER

A 6 VM 107 DA / 60 W VARIABLE DISPLACEMENT MOTOR

ACCELERATOR

HYDRAULIC DIAGRAM MSI 40 - MSI 50 WITH MOTOR A6VM 107 DA/SERIAL 60

11

FILTER

VARIABLE DISPLACEMENT PUMP A 4 VG 56 DA

PERKINS ENGINE 1004-4

TH7 VALVE

FILTER

BRAKE TH7 VALVE

RESERVOIR

HYDRAULIC

COOLER

REVERSER

A 6 VM 107 DA / 63 W VARIABLE DISPLACEMENT MOTOR

ACCELERATOR

HYDRAULIC DIAGRAM MSI 40 - MSI 50 WITH MOTOR A6VM 107 DA/SERIAL 63

12

HIDROSTATIC TRANSMISSION CIRCUIT MSI 20/25/30

13

REDUCER C/W BRAKE Ratio 1:35

HYDRAULIC WHEEL MOTOR

HYDRAULIC WHEEL MOTOR

REDUCER C/W BRAKE Ratio 1:35

EV

FRONT

LIFT CYLINDERS

CF

VF

RETURN FILTER

HYDRAULIC RESERVOIR

SUCTION FILTER

VALVE BANK

VF - Brake valve CF - Brake switch - cuts supply to forward-rear drive solenoid valve bank on braking EV - Brake solenoid valve (power - parking brake released)

ACCELERATION VALVE

TILT CYLINDERS

FLOW REDUCER

STEERING PUMP

IC ENGINE

RADIATOR

NON-RETURN VALVE

MAIN PUMP

STEERING CYLINDER

STEERING UNIT

REAR

HYDRAULIC DIAGRAM MSI 20 / 25 / 30

CS

16

F

T

B

MR

B

2

3

1

r=1/32.15

28.1cm3/t 470b

EV

3

r=1/32.15

28.1cm /t 470b

150 MICRONS

MR

B

T

RA

RA

CS

A

T

PP

T

A

VF

A

P

T

RR

RR

A

VA

P

T

B

T

T

T

RD

B

RD

RA

B

VERSION TRIPLE MAST SANS LEVEE LIBRE

CS

VERSION MASTIL D VT

B

- FRONT AXLE -

CS

VERSION MASTIL D LL

CS

VERSION MASTIL T LL

100 µ

CR

VI

EF

CF

F

A

P1

B

32.6 cm3/t

LS

25 µ

10 µ

MB Fe

MA Fs S

FA

Valve bank, 140 bar MSI 20 D 160 bar MSI 25 D 185 bar MSI 30 D

B

RD 16 l/min

A B A B MH

Fa1

B

MATS: VL

R

20 µ

Fa

PS

(DR) 470b

3b

FR

T

P

G

D 80 l/min

EE

EL

EI

EA

a

X2

PH

Y

500b

b

RA : ø1

X1

P

T1

T2

R

2b

C

LS

175-190b

120-125b

L

M

T

DD

RF

- HYDRAULIC WHEEL MOTOR - MAIN PUMP - HYDROSTATIC PUMP - CONNECTION TEST - HYDRAULIC RESERVOIR - RESTRICTOR - REDUCING - RADIATOR - REDUCER C/W BRAKE - ACCELERATION VALVE - STEERING CYLINDER - BRAKE VALVE - TILT CYLINDER - LIFT CYLINDER - MR - P1 - PH - PP -R - RA - RD - RF - RR - VA - VD - VF - VI - VL

VD

- REAR AXLE -

- DD - EV -F - FA - FR -M

- NON RETURN VALVE - SUCTION STRAINER - SAFETY VALVE - VALVE BANK 3 SECTION - EA ATTACHMENTS SECTION - EE INLET MEMBER - EI TILTING SECTION - EL LIFTING SECTION - STEERING UNIT - BRAKE SOLENOID VALVE - FILTER - SUCTION FILTER - RETURN FILTER - IC ENGINE 903.27 PERKINS - IDLE RPM_____________900 - RATED RPM__________2100 - MAX. UNLOADED RPM -2240

-C - CR - CS -D

- LEGEND -

HYDRAULIC DIAGRAM MSI 20 / 25 / 30 D

17

PILOT SAFETY VALVE

19

STEERING CYLINDER

RATIO

1 2.80

1

MOTOR

5.333

VALVE

HYDRAULIC RESERVOIR

SUCTION FILTER

LIFT CYLINDER

RETURN FILTER

8.25

HYDRAULIC PUMPS

PRESSURE CONNECTION

VALVE BANK

COMPENSATING CYLINDER ATTACHMENT CONNECTIONS

HYDROSTATIC PUMP

PILOT SAFETY VALVE

RADIATOR

TILT CYLINDER

STEERING UNIT

RATIO

REAR AXLE

TELESCOPE CYLINDER

8.25

12

PRESSURE SELECTOR

PILOT SAFETY VALVE

HYDROSTATIC MOTOR

INCHING

RATIO

RATIO

BRAKE

1 1.424

RATIO

1 3.875

FRONT AXLE

1 4.923

HYDRAULIC DIAGRAM BT 420 / 425 FIRST MOUNTING - WITH MOTOR A6VM 80 DA / SERIAL 60

20

PILOT SAFETY VALVE

21

STEERING CYLINDER

RATIO

1 2.80

MOTOR

1 5.333

VALVE

HYDRAULIC RESERVOIR

SUCTION FILTER

LIFT CYLINDER

RETURN FILTER

8.25

HYDRAULIC PUMPS

PRESSURE CONNECTION

VALVE BANK

COMPENSATING CYLINDER ATTACHMENT CONNECTIONS

HYDROSTATIC PUMP

PILOT SAFETY VALVE

RADIATOR

TILT CYLINDER

STEERING UNIT

RATIO

REAR AXLE

TELESCOPE CYLINDER

8.25

12

PRESSURE SELECTOR

PILOT SAFETY VALVE

HYDROSTATIC MOTOR

INCHING

RATIO

1 1.424

BRAKE

RATIO

RATIO

1 3.875

FRONT AXLE

1 4.923

HYDRAULIC DIAGRAM BT 420 / 425 SECOND MOUNTING - WITH MOTOR A6VM 80 DA / SERIAL 63

FLOW CONTROLLER

23

HYDROSTATIC MOTOR A6 VM 107 DA

SOLENOID VALVE

NON-RETURN VALVE

ACCUMULATOR

COOLER

LIFT CYLINDERS

BALANCING VALVE

TRANSFER CASE

TH 7 VALVE

MASTER CYLINDER

TILT CYLINDERS FLOW CONTROLLER

FILTER 10 µ

HYDROSTATIC PUMP A4 VG 71 DA

IC ENGINE

HYDRAULIC PUMP

RETURN FILTER

VALVE BANK

STEERING CYLINDERS

STEERING PUMP

HYDRAULIC DIAGRAM MA 460 / 470 FIRST MOUNTING - WITH MOTOR A6VM 107 DA / SERIAL 60

24

25

COOLER

NON-RETURN VALVE

ACCUMULATOR

SOLENOID VALVE

HYDROSTATIC MOTOR A6VM107DA Sérial 63

FLOW CONTROLLER

LIFT CYLINDERS

BALANCING VALVE

TRANSFER CASE

TH 7 VALVE

MASTER CYLINDER

TILT CYLINDERS

FLOW CONTROLLER

FILTER 10 M

HYDROSTATIC PUMP A4 VG 71 DA

I.C.ENGINE

HYDRAULIC PUMP

RETURN FILTER

VALVE BANK

STEERING CYLINDER

STEERING CYLINDERS

HYDRAULIC DIAGRAM MA 460 / 470 SECOND MOUNTING - WITH MOTOR A6VM 107 DA / SERIAL 63

26

6

4

2.1mm 39.1mm

2.5mm 32mm

13

11

POUR FLEXIBLE ET RACCORD FÜR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION PER FLESSIBILE E RACCORDO

4 AB 50

2mm 12mm

1.6mm 16mm

37

27

10 EA 87

2mm 26mm

1.6mm 24.1mm

48

2,9mm 23.6mm

BC 119

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT CIRCUITO TRASMISIONE IDROSTATICO

BC 129

MT 1645 H SL T M.U.

10 / 10 / 00

P.A.O

A

Fs MA S

PH

X2

a

X1

B

T P

T M1

MH

0,7 LITRE

12 BARS

AC

LEGEND

MC

Brake Front axle

B2

B1

A2

A1

A3

TH7

T

A

P

supply RLF

Manipulator

T

G

b

a

X1

X3

B

A

U

VPV

A

BT

EVPV

CAR

R

T1 T2

b

2b

N

CAR

Y

B2

B1

10 Microns 150 L/mn

3 bars

2b VA

FR

R

G

6 bars

PS

MH

Fa

Fa1

Fe

MB

B

RF

M

HYDRAULIC DIAGRAM MT 845 / 940 / 1332 / 1637 / 1645 H PUMP A4 VG 71 DA1 / MOTOR A6 VM 107 DA2 / 63 W

27

AC BT CAR EVPV FR M MC MH N PH R RF RLF TH7 VPV

-

Accumulator Transfer Box Back pressure valve Gear changing solenoid valve Return filter I.C engine Master cylinder Hydrostatic Motor Level Hydrostatic pumpe Hydraulic tank Cooler Brake fluid tank TH7 manipulator Gear changing actuator

HYDRAULIC DIAGRAM MRT 1432

28

HYDRAULIC DIAGRAM MRT 1542 / 1650 / 1850 / 2145

29

30

HYDROSTATIC DIAGRAM TMT

31

valve DR

cartouche de régulation

1 - Pump A4 VG 40 DA 2 - Hydraulic motor 3 - Braked hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 27 - Suction filter 28 - I.C engine

HYDROSTATIC DIAGRAM TMT 322 / 325 / 320 / 320 FL / 320-3 / 320-3FL

32

valve DR

cartouche de régulation

1 - Pump A4 VG 40 DA 2 - Braked hydraulic motor 3 - Hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 25 - Suction filter 26 - I.C engine

HYDROSTATIC DIAGRAM TMT 320 SI / 320 SIFL / 315 SIFL / 320-3SI / 320-3SIFL / 315-3SFIL

33

valve DR

cartouche de régulation

1 - Pump A4 VG 40 DA 2 - Hydraulic motor 3 - Braked hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 27 - Suction filter 28 - I.C engine

HYDROSTATIC DIAGRAM TMT 320 FL HT

34

valve DR

cartouche de régulation

1 - Pump A4 VG 56 DA 2 - Hydraulic motor 3 - Braked hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 27 - Suction filter 28 - I.C engine

HYDROSTATIC DIAGRAM TMT 320 FL TURBO HT

35

valve DR

cartouche de régulation

1 - Pump A4 VG 40 DA 2 - Hydraulic motor 3 - Braked hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 27 - Suction filter 28 - I.C engine

HYDROSTATIC DIAGRAM TMT 315

36

valve

cartouche de régulati

1 - Pump A4 VG 40 DA 2 - Braked hydraulic motor 3 - Hydraulic motor 4 - Flow divider 5 - Distribution block 7 - Brake solenoid valve block assembly 8 - TH7 valve (inching) 9 - Non-return valve 10 - Fanned oil cooler 11 - Hydraulic reservoir 25 - Suction filter 26 - I.C engine

HYDROSTATIC DIAGRAM TMT 317 SI

37

38

4 AB 18

N° : 112 812

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 322

P.A.O.

25

15mm

POUR TUBE - FÜR RACCORD PARA TUBO - FOR TUBE

09 / 02 / 99

39

34

25

8

2

1.5mm 6mm

37

1.5mm 9mm

23

2mm 12mm

6

3.53mm 25mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 19

1.5mm 11.7mm

1.5mm 14.8mm

1.5mm 18.6mm

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 322

P.A.O.

TMT 325

03 / 10 / 2000

40

4 AB 22

N° : 113 439

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 320 TMT 320 FL

P.A.O.

25

15mm

POUR TUBE - FÜR RACCORD PARA TUBO - FOR TUBE

41

37

23

6

1.5mm 11.7mm

2

1.5mm 14.8mm

57

1.5mm 18.6mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 23

34

3.53mm 25mm

25

1.5mm 24mm

8

1.5mm 6mm

1.5mm 9mm

2mm 12mm

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 320 TMT 320 FL

P.A.O.

TMT 320 FL

29 / 08 / 2000

42

33

29

23

11

9

2.95mm 29.74mm

13

2mm 20mm

72

2mm 12mm

41

2mm 26mm

34

2.9mm 29.6mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 29

62

2mm 29.9mm

44

2.2mm 11.3mm

39

1.5mm 6mm

21

3.53mm 25mm

19

1.5mm 24mm

1.5mm 10mm

1.5mm 11.7mm

1.5mm 15.8mm

1.5mm 19.8mm

N° : 112 813

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

25

15mm

POUR TUBE - FUR RACCORD PARA TUBO - FOR TUBE

Ref.: 524 841 Ref.: 225 420

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 325

P.A.O.

VOIR PLANCHE SUIVANTE SEHEN DIE FOLGEDE ZEICHNUNG VER SEGUN DIBUJO SEE FOLLOWING DRAWING

TMT 322

29 / 09 / 2000

43

N° : 113 440

VOIR PLANCHE SUIVANTE SEHEN DIE FOLGEDE ZEICHNUNG VER SEGUN DIBUJO SEE FOLLOWING DRAWING

4 AB 30

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

Ref.: 524 841 Ref.: 225 420

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

39

19

13

1.5mm 11.7mm

72

1.5mm 19.8mm

44

2mm 29.9mm

29

2.1mm 11.4mm

11

1.5mm 10mm

9

TMT 320 TMT 320 FL

41

2mm 20mm

34

2mm 26mm

33

2.9mm 29.6mm

P.A.O.

1.5mm 6mm

3.53mm 25mm

2.95mm 29.74mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

TMT 320 FL

29 / 08 / 2000

44

28

20

11

9

13

2.95mm 29.74mm

50

2mm 20mm

35

2mm 26mm

30

2.9mm 29.6mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 31

2mm 29.9mm

2.2mm 11.3mm

43

1.5mm 6mm

20

3.53mm 25mm

18

1.5mm 10mm

1.5mm 11.7mm

1.5mm 19.8mm

Ref.: 524 841 Ref.: 225 420

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 315 SIFL

P.A.O.

VOIR PLANCHE SUIVANTE SEHEN DIE FOLGEDE ZEICHNUNG VER SEGUN DIBUJO SEE FOLLOWING DRAWING

TMT 320 SI TMT 320 SIFL

02 / 10 / 2000

45

40

23

8

2

36

1.5mm 6mm

32

1.5mm 9mm

21

2mm 12mm

6

3.53mm 25mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

27

12mm

POUR TUBE - FUR RACCORD PARA TUBO - FOR TUBE

4 AB 32

1.5mm 11.7mm

1.5mm 19.8mm

1.5mm 14.8mm

1.5mm 18.6mm

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 320 SI TMT 320 SIFL

P.A.O.

SUIVANT MONTAGE NACH MONTAGE SEGUN MONTAJE AS MOUNTING

TMT 315 SIFL

03 / 10 / 2000

46

55

54

51

27

25

10

8

56

53

52

67

66

7

8

57

1.5mm 24mm

4

1.5mm 14.8mm

2

1.5mm 18.6mm

36

1.5mm 11.7mm

3

4

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 52

6

57

27

26

5

6

2

11

37

26 14 24 6

1.5mm 6mm

40

2mm 12mm

32

1.5mm 9.9mm

6

5

19

6

57

2.2mm 19.3mm

2mm 13mm

42

1.5mm 9mm

18

59

58

52

6 19

38 6

64

65

3.53mm 25mm

25 24 2 12

38

40

56

59

18

13

62

4

8

65

54

53

27 26 27 26

60

6

61

6 39

6 20

58 59

57

51

55

29 30

64

15

7

29 30

2 13

50

2 22 21 2 26 27

2 1

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

2

1

2 14

23 6

28

64

9

26 27

24 25

20 6

2 1

10 9

31 9 10 41 42

62

32 31

49

48

64

4

65

2

63

11

10

7 4

8

65

9

12

9

43 44

31 32

17

4 34

4 33

60

61

58

59

4 3

4 16

34 35 36

2 1

17 4 7 8 34 4

15

4

7

8

7 8

16

P.A.O.

47 46 45

4

TMT 320 FL TURBO HT

25 / 08 / 2000

47

28

23

21

13

2.1mm 11.4mm

11

1.5mm 11.7mm

9

1.5mm 19.8mm

36

2mm 29.9mm

POUR FLEXIBLE ET RACCORD FUR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

4 AB 53

2mm 26mm

41

2.9mm 29.6mm

25

1.5mm 10mm

15

3.53mm 25mm

1.5mm 6mm

2mm 20mm

17

16

24

25

27

28

29

44

1

4

18

15

31

30

14

25 32

28 27

32

28

23

26

33

25

25

15

25

24

27

5

17

18

19

7

6

15

21

37

2

3

9

10

11

12

13

20

Ref. : 605 210

11

8 10

34

38 39 40 43 23 25

23

22

25 24

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

26

33

25

25 22

42

26 25

41

34

23

36 35 25

34 34

24

P.A.O.

TMT 320 FL TURBO HT

28 / 08 / 2000

48

6

54

5

21 22 23 24

27

22

16

6

35

1.5mm 20mm

23

1.5mm 15mm

19

1.5mm 12mm

8

1.5mm 18.7mm

POUR FLEXIBLE ET RACCORD FÜR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

53

40

42

41

4 AB 38

20

2,2mm 19,3mm

1,5mm 9mm

1.5mm 6mm

2mm 12mm

8

6 5

50

8 20

49

45

24

8

7

7

7

39

8

44

40

42

41

8

8

30

8

23 33

10

20 11 8 20

22 21 6 5

34 35

8 20

45 44 52

20 46

8

6 5

46

46

8 7

7

45

45

39 7

23 24

8

44

11

44

8

15

11

9

5 6

5 6

28

32

18 19

5 6

7

5 6

8

51

45

44

18

9

19

50 8 49 5 48 6 47

30

43

3 4

9

TMT 320-3SI TMT 320-3SIFL TMT 315-3SIFL

14 23 21 22

23 14

23

23 26 27

5 6

29

1 2

12

8

7 8

10 8

28 23 25 23 24

12 8

20

7 8

13 19

8

9

8

8 20

31

15 19 17 16

31

11

8 20

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

36

20 8

16

5 6

17

37

P.A.O.

38

17 / 09 / 99

49

50 49 35 48 50 49 20 47

125 667

136 139

N° :

52 53 51 50 49 20 46

134 889

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

N° :

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

N° :

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

4 AB 39

125 784

38

1

4 44

34 22 20

26

143 193

48 24 35 25

N° :

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

N° :

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

5

6 7

3 2

9

8 11

11 10

13 12

10

54

14

Réf.: 524 841 Réf.: 225 420

23

30 32 33

45 20

15 17

16

22 19

43 42 35 46 45 20 20 20 20 21 18

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

18

13

43

1.5mm 20mm

20

33

32

1,5mm 10mm

11

1,5mm 12mm

9

30

36 37 35 35 35 35 36 34 20

2mm 30.2mm

31

35 41 35 42 43

40

28

34

35 36

27

20

20 35

34

36

50

2mm 26mm

35

2.9mm 29,6mm

25

P.A.O.

2,2mm 11,3mm

1.5mm 6mm

2mm 20mm

POUR FLEXIBLE ET RACCORD FÜR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

29

35 36

34 20

35 40 39

TMT 320-3SI TMT 320-3SIFL TMT 315-3SIFL

22 / 09 / 99

50

22 21

16 17

19

26

28

6 5

23 24

8

22

16

6

2mm 12mm

35

1.5mm 15mm

23

1.5mm 12mm

19

1.5mm 18.7mm

POUR FLEXIBLE ET RACCORD FÜR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

27

40

42

41

4 AB 40

2,2mm 19,3mm

1,5mm 9mm

1.5mm 6mm

8 20

6 5

8 20

8

8 11

7

7

46

46

30

30

11

8 20

24

8

8

45

44

40

42

41

8

50

47

35

48

34

52

51

6 5

23 24 19 25

44

16 17

23 33

20

45

22 21

43

8 20

44

44

46 45

50

8 20

6 5

8 7 46 45

8 11

7

44

8

8

11

11

32

8

31

11

8 20

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

8

9

13

8 20

31

23 24

10 23

5 6

12 8

7 8

1 2

12

9

7 8

30 8

10

5 6

6 5 6

8

48 14 47 23 21 22 5 6

29

23 14

23

50

15

5

7

30

39

3 4

9

8

49

5

45

44

19

6

9

25

32 8

26

19

36

18

16

5 6

17

38

P.A.O.

37

TMT 320-3 TMT 320-3FL

27 / 09 / 99

51

50 49 35 48 50 49 20 47

125 667

136 139

N° :

52 53 51 50 49 20 46

134 889

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

N° :

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

N° :

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

4 AB 41

125 784

38

1

4 44

34 22 20

26

143 193

48 24 35 25

N° :

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

N° :

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

5

6 7

3 2

9

11 10

13 12

22

8 11

20 21

10

19 18 54 20

55

14

Ref.: 524 841 Ref.: 225 420

23

30 32 33

45 20

15 17

16

43 42 35 46 45 20 20 20

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

18

13

43

1.5mm 20mm

20

33

32

1,5mm 10mm

11

1,5mm 12mm

9

30

36 37 35 35 35 35 36 34 20

2mm 30.2mm

31

35 41 35 42 43

40

28

34

35 36

27

20

20 35

34

36

50

2mm 26mm

35

2.9mm 29,6mm

25

P.A.O.

2,2mm 11,3mm

1.5mm 6mm

2mm 20mm

POUR FLEXIBLE ET RACCORD FÜR SCHLAUCH UND VERSCHRAUBUNG PARA FLEXIBLE Y RACOR FOR HOSE AND CONNECTION

29

35 36

34 20

35 40 39

TMT 320-3 TMT 320-3FL

24 / 09 / 99

52

4 AB 35

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

TMT 315

P.A.O.

08 / 04 / 99

53

4 AB 36 N° : 225 421

CIRCUIT TRANSMISSION HYDROSTATIQUE HYDROSTATIK GETRIEBKREIS CIRCUITO TRANSMISION HIDROSTATICO HYDROSTATIC TRANSMISSION CIRCUIT

N° : 139 064

JUSQU' A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO MACHINE

TMT 315

N° : 139 065

P.A.O.

A PARTIR DE LA MACHINE AB DER MASCHINE A PARTIR DE LA MAQUINA FROM MACHINE

08 / 04 / 99

54

10 BA 74

HYDRAULIQUE (Circuit translation) HYDRAULIK (Fortschreitende kreis) HIDRAULICO (Circuito traslaciòn) HYDRAULIC (Translation circuit)

13 / 11 / 00

150 ATT

P.A.O

HYDRAULIC DIAGRAM 150 / 170 ATT - 165 ATJ PUMP A10 VG 45 EP 1D2 / MOTOR A2F

2b a

b T1

K

MB

PS

B 365 b

L

3 1

I.C Moteur engine

thermique Ralenti : 1200 tr/mn Maxi : 2100 tr/mn

Emergency ELECTRO-POMPE de SECOURS electric pump 45cm3

8,4cm3

1.25cm3

22cm3

365 b 25 b

800 W S2 : 16 mn ‡ 100 b S3 : 30 % ‡ 100 b

2 A

E

X1

X2

G

S

MA

J

0.5 b

M 0.5 b

I 7b T

D P

B

1 2 3 4 5 9

T2

F

LEGEND A B C D E F H I J K L M

-

Oil tank 12 track rotary seal Suction strainer 100 µm Proportional valve bank Variable displacement pump Bent axis motor Brake system Pressure 10 µm abs . filter Suction filter 10 µm nom.

Cooler Emergency electric pump Safety electrovalve

80cm3 (ATT) 90cm3 (ATJ)

H P

T

To oscillation Vers Blocage lock oscillation

C A

55

EP

Electrical Control with Proportional

Electroproportional bondage system

In relation to the preselected current, control pressure is applied to the positioning cylinder of the pump via two proportional solenoids on control device EP.The displacement of the pump is thus steplessly variable. One solenoid is assigned to each direction of flow.

Operating curve EP2 Courbe caractéristique EP2

EP2 (24V CC)

cal.

18

28

45

63

Start of control

mA

200

200

200

200

End of control

mA

525

530

560

560

EP1 (12V CC)

cal.

18

28

45

63

Start of control

mA

400

400

400

400

End of control

mA

1050

1060

1115

1115

Correspondance Graph direction of rotation - Control - Direction of through flow

proportional solenoid a anticlockwise

EP Control

Direction of rotation Solenoid

clockwise

anti-clockwise

a

b

a

b

Control pressure

X1

X2

X1

X2

Direction of flow

A vers B

B vers A

B vers A

A vers B

MB

MA

MA

MB

Operating pressure clockwise proportional solenoid b

56

PRESSURE TO BRAKING

PRESSURE TO CONTROLLER

29 - I.C engine 30 - Hydrostatic pump A4VG56DA 31 - Hydrostatic motor A6VM80HA 32 - Cooler 59 - Strainer 60 - Filter 61 - Hydraulic reservoir 62 - Clogging switch

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AL 70 e

57

PRESSURE TO BRAKING

PRESSURE TO CONTROLLER

29 - I.C engine 30 - Hydrostatic pump A4VG56DA 31 - Hydrostatic motor A6VM80HA 32 - Cooler 59 - Strainer 60 - Filter 61 - Hydraulic reservoir 62 - Clogging switch

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AL 85 t

58

PRESSURE TO BRAKING

PRESSURE TO CONTROLLER

29 - I.C engine 30 - Hydrostatic pump A4VG56DA 31 - Hydrostatic motor A6VM80HA 32 - Cooler 59 - Strainer 60 - Filter 61 - Hydraulic reservoir 62 - Clogging switch

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AL 100 t

59

PRESSURE TO BRAKING

PRESSURE TO CHAIN TENSION

529 30 31 32 60 61 62 63 -

Pump 16 ccm/U I.C engine Hydrostatic pump A4VG28DA1 Hydrostatic motor A6VM107HA1 Cooler Filter Hydraulic reservoir Clogging switch Air breather

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AS 45

60

PRESSURE TO BRAKING

PRESSURE TO CONTROLLER

529 30 31 32 60 61 62 63 -

Pump 14 ccm I.C engine Hydrostatic pump A4VG56DA Hydrostatic motor A6VM107HA Cooler Filter Hydraulic reservoir Clogging switch Air breather

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AS 70

61

PRESSURE TO BRAKING

PRESSURE TO CONTROLLER

529 30 31 32 60 61 62 63 -

Hydraulic pump I.C engine Hydrostatic pump A4VG56DA Hydrostatic motor A6VM107HA Cooler Filter Hydraulic reservoir Clogging switch Air breather

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AS 90

62

BRAKING SYSTEM

PRESSURE TO CONTROLLER

529 30 31 32 34 36 59 60 61 62 -

Pump 32 ccm I.C engine Hydrostatic pump A4VG90DA Hydrostatic motor A6VM107DA Cooler Thermostat 55° Gear box Strainer Filter Hydraulic reservoir Clogging switch

GEAR BOX CONTROL

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AS 14

63

TO BRAKING REGULATION VALVE

PRESSURE TO CONTROLLER

529 30 31 32 33 34 60 61 62 -

PRESSURE TO STEERING AND HYDRAULIC

Hydraulic pump I.C engine Hydrostatic pump A4VG125DA Hydrostatic motor A6VM200HA Cooler Thermoswitch Hydraulic cooling motor Filter Hydraulic reservoir Strainer

TO EMERGENCY ELECTRIC STEERING PUMP

HYDROSTATIC DIAGRAM MANILOADER AS 200

64

PRESSURE BRAKING RELIEF VALVE

529 30 31 32 60 61 62 63 -

Hydraulic pump I.C engine Hydrostatic pump A4VG28DA1 Hydrostatic motor A6VM107HA1 Cooler Filter Hydraulic reservoir Clogging switch Air breather

PRESSURE TO STEERING AND HYDRAULIC

HYDROSTATIC DIAGRAM MANILOADER AF 60

65

66

PUMP A 4 VG / DA

PUMP A 4 VG 40 DA (BT 420/425) Serial 2

PUMP A 4 VG 56 DA (MSI 40/50)

PUMP A 4 VG 71 DA (MA 460/470) (MT 1645 H)

PUMP A 4 VG 90 DA (MSI 20/25/30) (MSI 20/25/30 D)

67

PUMP A 4 VG / DA

Like the A 4 V series, this pump is fitted with : • a tachometric control device, • a plate restoring force control device, but also : a DR control known as a "flow cut-off valve" with pressure hold.

MAIN DIFFERENCES IN RELATION TO THE A 4 V SERIES : - Less space required - 50 mm shorter.

- Booster pump built into the connection plate.

- Larger control cylinder.

- Larger drive shaft to receive greater torque.

- Straight piston pump.

- Plate angle : 18°.

- Greater speed.

- Three ports on pump housing : X1 - X2, housing pressure.

- On the 40 and 56 series, the HP and booster relief valves cannot be adjusted externally. The HP relief valves are fitted with a by-pass system which allows the machine to be drawn by a tractor.

- From size 71, external adjustment of the relief valves is possible.

MOST IMPORTANT From size 71, a locking screw for the plate oscillation bearings is fitted to the side of the pump fixing flange. Do not mistake this for the pressure connection plug.

68

SECTIONAL VIEW OF PUMP A 4 VG DA

69

MOTOR A 6 VM / DA SERIAL 60

Series 6 variable displacement motor - for open and closed circuits - design : axial tapered pistons with sealing rings and bent axis. Size : 28 to 200 - nominal pressure : 400 bar - peak pressure : 450 bar.

Adapted to mobile and stationary applications. Its wide control range allows this motor to meet high speed and torque requirements.

Its displacement is continuously variable in the ratio Vg max / Vg min = 4.85.

The output speed is proportional to the flow absorbed and inversely proportional to the displacement. The output torque varies according to the difference in pressure between the high and low pressure outlets, and according to the displacement.

A 6 VM

Special features - Wide control range for hydrostatic transmission systems.

- Various displacement control devices.

- Reduced cost due to the elimination of the gearbox or the use of smaller pumps.

- Compact, robust tapered bearings.

- High specific output.

- Good start-up characteristics.

A 6 VM motors are fitted with a scavenging needle built into the control plate for better circuit cooling.

The role of this needle is to draw oil from the LP branch. This oil is directed to the motor housing via the kingpin (bearing lubrication), and then drained through the cooler to the reservoir at the same time as the leak oil. The booster pump delivery therefore compensates the oil drawn off the circuit with cooler oil.

The switching pressure of this needle is 3 bar (Dp between the two HP circuits). This is lower than the start-up pressure of the unloaded hydraulic motor. Sealed in central position.

SCAVENGING RATES Size

28

55

80

107

160

200

Scavenging rate ...............................

(L/mn)

2,5

3,0

3,9

4,9

5,8

6,7

ADVANTAGES OF THE SCAVENGING NEEDLE a) Increased bearing life. b) Reduced oil temperature in motor housing.

70

MOTOR 6 VM / DA SERIAL 60

SCAVENGING NEEDLE BUILT INTO THE CONTROL PLATE

This system provides a good exchange of cooling oil and improved bearing lubrication.

HYDRAULIC DIAGRAM OF THE MOTOR A 6 VM / DA SERIAL 60

Scavenging needle

71

MOTOR A 6 VM / DA SERIAL 63

A6 VM / DA 1

A6 VM / DA 2 Fitted on MT . . H 230947

Characteristics of serial 63 in comparison with 60 : - Crankcase in a single part (suppression of the seal support cover).

- Bearing held by retaining rings "Length reduced by approximately 11 %".

- Retainer spring of the rotor (instead of Belleville washers) increased operating safety.

- Additional sweep port at the front of the bearings.

- Cylinder head O-ring joint (instead of the gasket) - Control piston in two parts, without seal, reinforced section, quicker tilting time, less hysteresis.

- Exchange valve (sweep) integrated into the lower cover.

Scavenging rates

size

28

55

80

107

160

200

250

355

500

1000

Scavenging rate (L/mn)

3,5

3,5

5

8

10

10

10

16

20

25

72

MOTOR A 6 VM / DA SERIAL 63

HYDRAULIC DIAGRAM MOTOR

A 6 VM / DA SERIAL 63

73

MOTOR A 6 VM / DA 1 SERIAL 63

CONTROL ELEMENT

1 - Housing 2 - Liner 3 - Piston 4 - Adjusting socket 5 - Spring seat 7 - Pressure spring 9 - Pressure spring 10 - Slide 12 - Union 14 - O ring joint 15 - Screw 16 - Plug 17 - Retaining ring 18 - Set screw 19 - Set screw 20 - Cylindrical pin 21 - Flanged nut 22 - Plug 23 - Plug 24 - Plug 25 - Plug

74

MOTOR A 6 VM / DA 2 SERIAL 63

CONTROL ELEMENT Motor 230947

1 - Housing 2 - Liner 3 - Piston 4 - Adjusting socket 5 - Spring seat 7 - Spring 9 - Spring 10 - Control piston 11 - Control piston 13 - Spring (2)

21 - Nut

16 - Plug (2)

22 - Plug

17 - Retaining ring

26 - O ring joint

18 - Screw

29 - Solenoid

19 - Screw

30 - Screw M 8 x 50

20 - Cylindrical pin

31 - Screw M 8 x 90 75

MOTOR A 6 VM / DA SERIAL 63

SWEEP AND BOOST VALVE

1 - Housing 2 - Sweep slide valve 3 - Neck : pin 4 - Valve slide 5 - Plug 6 - Plug 7 - Washer 8 - Pressure spring 9 - Pressure spring 10 - Nozzle 11 - Nozzle 15 - Screw 16 - O ring joint 17 - O ring joint 18 - O ring joint 19 - Retaining ring 20 - Plug 24 - Adjusting washer 30 - Calibrated orifice 76

MOTOR A 2 FE

The A2FE fixed displacement plug-in motor is built according to the bent axis design with tapered axial pistons.

The mounting flange located towards the rear allows the motor to be “plugged in” to the mechanical gearbox to give a short, compact unit.

Compared with the integrated kit designs, the plug-in motor offers the following advantages : • Complete unit, ready assembled and tested.

• Easy to fit, simply plug into the mechanical gearbox.

• No installation tolerances to consider.

• Interchangeable with the A6VE variable displacement plug-in motor.

77

78

80

82

84

86

88

90

92

Mechanical zero

JET : DIA.0,8

94

H.P. Relief Valve

End of Control Screw

Booster Pressure Relief Valve

Booster Pressure Connection

Start of Control Screw

To TH7

H P Relief Valve

DR Valve

PUMP A 4 VG 40 - 56 FRONT 3/4 VIEW

Partition if External Filtration

DR Valve

95

Booster Pump Suction

Suction Vacuum Pressure Connection (18 x 150)

Fe FA possibility of Filtration on Booster Return (18 x 150)

Plug (8 x 100) Possibility of HP measurement

Booster Pressure (18 x 150) Higher than working pressure

Port for Supply to Attachment or Booster Pressure Connection (18 x 150)

PUMP A 4 VG 40 - 56 REAR 3/4 VIEW

OPERATION OF PUMP A 4 VG..DA

PILOT CIRCUIT The pilot circuit is drawn from the booster circuit via the control cartridge.

On leaving the control cartridge, the control flow passes through a 1.8 to 2 mm dia. jet to feed the PS outlet at the same time as the DR valve.

The jet is located behind a plug in the pump connection plate near to the MB pressure connection port. Its role is to prevent saturation through the TH 7 valves and the DR valve. If the jet is blocked, there is no pilot pressure to the circuit.

The pilot flow through the hydraulic hoses is directed towards two TH 7 (accelerator * and one brake) valves, then towards the front/rear drive solenoid valve. (* some machines are not fitted with this second TH 7)

• ROLE OF THE TH 7 VALVE ON THE ACCELERATOR The machine is fitted with an IC engine acceleration system coupled with the control lever of the hydraulic valve bank used for lifting, so as to obtain a quicker lifting movement automatically when the operator pulls the lever.

At this moment, the TH 7 reduces the pilot pressure either to prevent the machine from moving if it is idling at a standstill in forward or rear drive, or to retain the initial travel speed if the machine is moving.

• ROLE OF THE TH 7 VALVE ON THE BRAKE This second valve is activated by the brake pedal on the clearance stroke to cut off the pilot pressure when the brakes are activated. This provides hydrostatic braking before the brake discs come into action.

This TH 7 valve also allows the operator to reduce or keep the same travel speed when approaching the loading site if he wishes to increase the IC engine to a much higher speed with the accelerator in order to achieve high lifting speed (increased delivery from main pump).

• FORWARD DRIVE /NEUTRAL /REVERSE DRIVE SOLENOID VALVE Its function is to direct the pilot flow from one side or another of the control cylinder of the pump in order to pilot the pump towards the forward or rear drive. Contrary to the A 4 V series, the pumps in the A 4 VG series are not equipped with a pilot jet at X1 and X2 but the slide valve of the forward/rear drive solenoid valve is fitted with stepping slots.

The return port located in the centre of the solenoid valve is equipped with a 0.8 mm dia. time delay jet acting on the forward/rear drive reversal movement.

96

Mechanical Zero

DR Valve

End of Control Screw

To Servocontrol Cylinder

97

1.8 to 2 mm dia. Jet Access Control Valve Outlet

TH7 Accelerator

TH7 Brake

Jet on Return 0.8 to 1.2 mm dia.

Solenoid Valve Supply

PILOT CIRCUIT PUMP A 4 VG 56 DA MSI 40 / 50

PILOT CIRCUIT PUMP A 4 VG 90 DA MSI 20 / 25 / 30

1 mm dia. jet on solenoid valve supply

To Servocontrol Cylinder

2 mm dia. jet access on control valve outlet

1.2 mm dia. jet on return

PS

G

TH7 Brake

TH7 Accelerator

To reducer brakes

EV Brake

98

INCHING VALVE OPERATION (TH 7 Valve on Brake Pedal)

With the foot off the inching pedal, the tappet 1 is fully in and the oil passes unhindered between port P (pilot pressure in) and port A (pilot pressure out). The oil flows freely through the opening 3 in the slide valve 2.

The pilot pressure, injected into the control cylinder of the pump cam plate, is therefore identical to that which would be obtained without this TH 7 valve.

With the foot on the inching pedal for a slow approach, the tappet 1 is partially out; the oil passage is calibrated by the opening 3 in the slide valve 2.

The pilot outlet pressure through port A will therefore be controlled and the value of this pressure will be constant. If the pilot pressure entering through port P were to increase, as this pressure would be applied to the section S of the slide valve 2, the springs 4 and 5 would be slightly compressed and the slide valve 2 would move in the direction of the arrow F. This would reduce the oil passage through the opening 3 and in turn create a drop in pressure between port P and port A. The pilot outlet pressure through port A is therefore controlled and the value of this pressure is constant whatever the level of pilot pressure entering through the port P. This means that the pressure injected into the control cylinder of the pump cam plate will be constant, and therefore the angle of the cam plate will also be constant. This allows the truck to approach slowly and at a constant speed selected according to the pressure exerted on the inching pedal.

With the inching pedal pressed to the limit of travel before the truck brake control comes into force, the tappet 1 is fully out (this position with the slide valve out is retained when the pedal at the limit of travel controls the truck brakes).

With the tappet 1 in this position, there is no pilot pressure at port A, and therefore no pressure in the control cylinder of the pump cam plate.

The pump displacement is therefore nil.

NB : It is understood that the pilot pressure leaving through port A is always guided: • on the one hand towards the pump control cylinder, • and on the other towards the hydraulic motor displacement control unit.

99

CONTROL CARTRIDGE OPERATION

The pilot pressure is drawn via the control cartridge slide valve into the booster circuit. At maximum IC engine speed, the pilot pressure is a few bars lower than the booster pressure.

On idling (850 rpm), the booster flow which passes through the calibrated opening in the control cartridge slide valve is insufficient to create a drop in pressure capable of displacing the slide valve 1 against the force of the spring 2. The pilot pressure is therefore nil.

When the operator accelerates in order to move forward (to approximately 1050 rpm), the booster flow increases ; the drop in pressure before the calibrated opening is now sufficient to move the slide valve to the left, against the spring, thus revealing the pilot opening.

When the pilot pressure reaches approximately 6 to 7 bar, the servocontrol cylinder begins to move, tilting the plate of the variable capacity pump. The pump begins to discharge (start of control). The greater the engine speed, the more the booster flow increases thus leading to a rise in the pilot pressure and therefore increased influence on the pump and greater machine speed.

To halt this process, the operator stops accelerating, the booster flow drops, the pressure drop is reduced and the spring 2 pushes back the slide valve 1 thus closing the booster passage to the pilot conduit. The residual pilot pressure is discharged towards the housing.

100

CONTROL CARTRIDGE OPERATION

Variable capacity pump

Servocontrol cylinder

FWD/N/RR drive solenoid valve

Booster pressure relief valve

Item 2

Item 1

Control Cartridge

Accelerator Start of control adjusting screw

Booster Pump

101

DR VALVE

1) FUNCTION To cut off flow while maintaining pressure. This corresponds to a return of the pump displacement to the “O” before the HP valve calibration is reached.

This valve anticipates HP relief valve activation on acceleration and deceleration (rapid rise in pressure).

The peak pressure is reduced by the HP relief valves which also protect the circuit against ultra-rapid fluctuations. The calibration range for cutting off the flow while maintaining pressure covers the whole working pressure range. The corresponding calibration values should however be 20 to 30 bar lower than those of the HP relief valves.

- Reduced transmission noise.

- Wider control range.

Composition of the DR Valve 1) 2)

HP circuit sensor flow selector.

A slide valve which connects the pilot circuit to the tank in order to release the pump from the pilot control while maintaining the 400 bar level (control starts at 6 to 7 bar, control ends at 20 bar with maximum flow).

The DR valve allows the flow to be reduced while retaining maximum torque.

2) OPERATION The HP MA or MB pushes the HP circuit selector upwards or downwards thus closing the opposite low pressure port (in a HP direction of A to B, the HP traverses the centre of the selector through a small channel).

In all cases, the HP then pushes the needle 4 which in turn raises the control slide valve 3 which creates a partial connection between the control opening and the return thus reducing the pilot pressure.

The effect of this is to reduce the pump displacement, thus reducing the flow while maintaining the 400 bar HP (flow reduction for a maximum torque).

This action of removing the pilot control from the pump acts in the same way as the restoring forces generated by the HP and the adjustment of the control plate.

102

SECTIONAL VIEW OF THE DR VALVE

Locknut

Collar

Seal

Spring

14

9

Adjusting screw

8

1

End cap

10

2

Bronze slide valve

7

3

DR control slide valve

Pilot Collar

8

4

Needle

MB

5

HP selector

MA

6

Seat

103

DR VALVE

Adjusting Screw Pilot Needle

Hole in Collar for Leaks

Bronze Slide Valve

HP Selector Control Slide Valve Seat

IMPORTANT In the event of a considerable drop in the IC engine speed, check that the pilot needle has not become stuck in the slide valve.

104

105

HP VALVE WITH HAULAGE BY-PASS A 4VG 40 - 56 DA •

•

PRESSURE RELIEF VALVE ADJUSTMENT : -

Remove the complete pressure relief valve.

-

Loosen check screw 2 with a 3 mm hexagonal key.

-

Tighten screw 3 to increase the pressure.

-

Loosen to reduce the pressure (1 turn = approximately 44 bar).

RELEASING THE HP RELIEF VALVES FOR HAULAGE : -

Measure the distance “x”.

-

Loosen the locknut.

-

Fully screw the screw 1 in order to bring it into contact with the seat 3. Then tighten this screw 1 by a complete turn so as to loosen the seat 3.

-

Carry out the above operations in reverse to reset the HP relief valves to x.

REMARKS ❖ Haulage should be carried out at a very low speed and over a short distance only.

3

2

106

1

HP VALVE WITH HAULAGE BY-PASS A 4VG 71 - 180 DA

PRESSURE RELIEF VALVE ADJUSTMENT : • Remove the lead seal A. • Take off the cap B. • Loosen the locknut D. • Adjust the screw E to increase the pressure.

• Refit the cap having installed a new lead seal.

RELEASING THE HP RELIEF VALVES FOR HAULAGE : • Adjust the two HP relief valves.

• Withdraw the caps B slightly without removing the lead seals A. • Loosen the nuts C by a maximum of two turns.

• Once the haulage operation is over: • Tighten the nuts C. • Refit the caps B.

REMARKS : Haulage should be carried out at a very low speed and over a short distance only.

B

E

A

C

107

D

PUMP A4VG - DA PRESSURE MEASURING POINTS

For the kits of pressure port hoses and couplings, please refer to the catalogue "pressure gauge box" Ref. 547037 PUMP A 4 VG 40 - 56 DA Case pressure * Pilot Pressure Fwd. & Rev.*

Tee P/N 165711

High pressure HP * Boost pressure *

* : Ports = (12 x 150) Ref. 477484 PUMP A 4 VG 71 - 90 DA Pilot pressure connection (16x150) Ref. : 477 485

HP pressure connection (12x150) Ref. : 477 484

Housing pressure connection Branch piece Ref. : 173 568 + connection Ref. : 58 181 108

Booster pressure connection Branch piece Ref. : 165 711 + connection Ref. : 58 181

PRESSURE MEASURING POINTS MOTOR A 6 VM

MOTOR A 6 VM Serial 60 High pressure (14 x 150) PN. 58189

Pilot pressure (14 x 150)

A6VM DA

Changeover pressure (12 x 150) PN. : 477484 MOTOR A 6 VM Serial 63 High pressure (14 x 150)

Pilot pressure (14 x 150)

Changeover pressure (14x150)

109

110

TRANSMISSION ADJUSTMENT POINTS

PUMP A 4 VG D.R.Valve

Swashplate zero position HP Valve

Control Valve Start of regulation Boost Valve

Eccentric for valve plate adjustement

HP Valve

MOTOR A 6 VM Serial 60

Serial 63

Minimum displacement stop. (Do not readjust)

Regulation screw

Minimum displacement stop. (Do not readjust)

A6VM DA

Maximum displacement stop.

(Do not readjust) 111

Regulation screw

TRANSMISSION A 4 VG - A 6 VM

CHECKS BEFORE PRESSURE TESTING •

Check the transmission oil level.

•

Check there are no leaks at hoses or unions.

•

Check the electrical connections at the solenoid.

•

Make sure the circuit is filled with oil. In some cases the filter should be filled with oil prior installation.

•

Confirm correct connection of pilot hoses : - Port x 1 on pump to X1 on motor, - Port x 2 on pump to X2 on motor.

•

In all cases, the pilot hose be opposite the HP hose (e.g. If the HP for forward drive is on the right of the motor the forward pilot hose must be on the left).

•

Install the pressure gauges for boost, pilot, HP and housing checks.

PREPARATION • For safety purposes support the front wheels on blocks (disconnect 4 wd shaft if applicable).

• Crank the engine a few times with the fuel shut off solenoid disconnected, to ensure the circuit is charged with oil.

• The boost pressure during cranking should be around 15 bar. "Never run the transmission without boost pressure".

• Reconnect the fuel shut off solenoid.

• Start the engine and run for a few minutes at idle. The boost pressure should be between 22 and 23 bar. A flickering gauge indicates cavitation in the system.

With the drive selector in neutral the pressure in the two HP circuits should be the same as the boost pressure.

• Bypass the inching valve(s) using flexible hose.

• When the oil temperature is 50 to 60 C check the engine speed : - Idle speed, - Maximum speed - Maximum speed under load.

(See specifications).

112

TRANSMISSION INSPECTION AND ADJUSTMENTS

1. CHECK/ADJUST BOOST PRESSURE

- The pumps A 4 VG 71-180 are equipped with an adjustable boost valve.

- The pumps A 4 VG 40-56 are equipped with a boost valve that is adjustable by means of shims (6).

A 1 mm thick shim will give approximately 4 bar of pressure adjustment.

Booster valve

Shims

Pump A4VG 40.56

113

TRANSMISSION INSPECTION AND ADJUSTMENTS

2. ADJUSTMENT OF SWASHPLATE "O" POSITION

- Install two 100 bar gauges at the HP test points.

- Ensure the parking brake is released, the truck supported on blocks (wheels free to turn).

- Engine running at idle.

- Drive selector in neutral position.

- Unscrew the locknut of the "O" adjuster (19 mm ring spanner). Screw in very slowly the screw (6 mm allen key) until movement is seen on the pressure gauge.

- Make a mark relative to the allen key position, slowly turn the screw in the opposite direction until movement is seen on the other pressure gauge, mark the position of the allen key. Turn the adjuster back so that the allen key is exactly central between the two marks. Lock the locknut.

• CKECKING ADJUSTMENT Remove the low pressure gauges from the HP circuit and install two 600 bar gauges : 1) Check the start of regulation in forward and reverse drive using a tachometer.

Select forward drive, increase the engine speed slowly until the wheel begin to turn - record the engine speed.

Repeat the same in reverse drive.

Compare the two readings ; they should be identical 2) Check the pilot and HP readings.

Select forward drive, apply foot brake, accelerate progressively to maximum speed.

Record the forward HP and forward pilot pressure.

Repeat the same operation in reverse. The valves should be the same.

114

TRANSMISSION INSPECTION AND ADJUSTMENTS

3. A. CHECK AND ADJUST START OF REGULATION

Control valve Start of regulation

START OF REGULATION : • Check the engine speed at idle depending on machine type. It should be 750 to 850 rpm.

• Select forward drive, gradually increase the engine speed until the wheels start to move - check the engine speed.

It should be between 1050 and 1100 rpm. If not adjust the screw on the end of the regulation valve.

- Screw in to delay the start of regulation.

- Screw out to advance the start of regulation.

• Adjustment of the start of regulation outside its specified limits will change the performance curve of the pump.

• Confirming the adjusment is correct is done as described in step 2 point 2.

For certain machines fitted with TH7 valves on the accelerator, please refer to specific pages and to the Service memo book.

115

TRANSMISSION INSPECTION AND ADJUSTMENTS

3 B. CHECK AND ADJUST END OF REGULATION

End of regulation CHECK : -

The truck is supported on blocks, inching valve by passed, brakes applied (foot and park).

Drive reverser in forward drive.

Select forward drive.

Engine at low idle - check rpm.

Gradually increase the engine speed until the forward HP reading is 400 bar. At this point check engine speed and compare with specifications. (See Service sheet)

END OF REGULATION : - The adjustment of the pump end of regulation (e.g. MSI40 = 400 bar at 1600 rpm) is obtained using an eccentric screw which restricts the pump flow creating back pressure against the swash plate.

This adjustment can only be set using a test bench.

IMPORTANT The slot in the eccentric screw should point towards the boost pump (opposite to A4V pump where slot pointed to drive shaft). The adjustment must not go beyond 90 to the left or right - Do not exceed or damage may occur.

116

TRANSMISSION INSPECTION AND ADJUSTMENTS

4. CHECK AND ADJUST HP VALVES • The HP valves are checked with the truck supported on blocks with the brakes applied • It is also necessary to by-pass the inching (TH7) valve(s) with a flexible hose.

• Also, if fitted, by-pass the parking brake drive isolation system.

• Overset the DR valve (1) to check the pressure of the HP valves.

Screw the adjuster in 1 turn. The HP valves pressure should be 440 bar *.

(During this test the engine speed should drop 570 600 rpm).

After the HP valves have been checked the DR valve should be re-set to 420 bar **. * (410 bar for MSI 40/50) **(380 bar for MSI 40/50)

CALIBRATION OF HP RELIEF VALVES :

CALIBRATION OF HP RELIEF VALVE :

A 4 VG 40 - 56 DA series pump

A 4 VG 71 - 180 DA series pump

• Remove the complete relief valve.

• Tighten screw 3 to increase the pressure.

• Loosen to reduce.

1 turn = approximately 44 bar.

• Remove the lead seal A. • Remove the cap B. • Loosen the locknut D. • Turn screw E to increase the pressure.

• Refit the cap having installed a new lead seal.

B

E

A C

117

D

TRANSMISSION INSPECTION AND ADJUSTMENTS

Procedure for the adjustment of the control system on the EP electric distributor on A10VG First stage : Check and adjust if necessary the mechanical zero on the servo-piston.

Procedure : Connect two 600 bar pressure gauges on the HP pressure outlets.

Run the engine on idle Reverse to neutral Loosen the counter nut for mechanical zero adjustment and tighten screw using an hexagonal wrench.

Mark the wrench position when the pressure starts rising in one HP line. Then loosen wrench to increase pressure in the opposite HP line. Mark wrench position and centre it between the two marks.

Second stage : On A10 VG EP pumps, the electric distributor is fitted with an eccentric for the adjustment of the neutral position on the slide valve.

Adjustment of the neutral position on the slide valve

118

TRANSMISSION INSPECTION AND ADJUSTMENTS

To carry out this adjustment, it is necessary to connect two pressure gauges (40 bars) on pilot.

Then use "eccentric" in order to balance the housing pressure on bed pressure gauges.

Warning, the adjustment is made within one half a screw turn span.

Eccentric

119

TRANSMISSION INSPECTION AND ADJUSTMENTS

5.

ADJUSTING MOTOR A 6VM DISPLACEMENT CHANGEOVER A) CHECK MINIMUM DISPLACEMENT (MAX. SPEED) : •

The check is made driving the truck on level ground with the engine a full speed in forward drive.

HIGH PRESSURE

REGULATION PRESSURE

A 6 VM DA Serial 60

HIGH PRESSURE

REGULATION PRESSURE

A 6 VM DA Serial 63

CHANGEOVER PRESSURE

CHANGEOVER PRESSURE

• Connect two 600 bar pressure gauges as shown above. At maximum drive speed the two gauges should read the same. This signifies that both sides of the Servo piston are subject to the same pressure and the motor is at its minimum displacement.

B) CHECK START OF REGULATION : • With the wheels raised from the ground and the truck supported on blocks gradually apply the brake pedal to raise the pressure in the HP circuits (inching valve by-passed)..

• Watch the two gauges. When the HP gauge shows 200/250 bar the changeover pressure will drop then the HP will continue to rise until it reaches the setting of the DR valve.

(Changeover pressure : See specification for different trucks).

• The changeover point can be adjusted by the screw.

120

TRANSMISSION INSPECTION AND ADJUSTMENTS

C) MAXIMUM DISPLACEMENT : (MAX. TRACTIVE FORCE) • To make this adjustment, the machine should be chocked (brakes locked).

The check is made at maximum IC engine speed in forward drive.

• The switching pressure (large section side of control cylinder) must be around zero bars.

• Adjust the control screw as required (tighten to increase the switching pressure, loosen to reduce).

• A check on the tractive force (using a hook) should then be carried out (refer to “Hand book” for values).

121

ADJUSTING THE TH 7 VALVE ON THE ACCELERATOR MSI 40/50 ADJUSTING THE MACHINE TRAVEL STARTING POINT / 1050 RPM +50 -0

To make this adjustment, firstly check by by-passing the pilot circuit (TH7 valve on accelerator - TH7 valve on brake) that the start of control point of the pump has been set to 1000 rpm.

• Reconnect the pilot circuit.

• Place the machine on chocks with the handbrake off.

• Electric reverser in forward drive.

• Increase the IC engine speed gently and check that the wheels begin to turn at 1050 rpm. If required, adjust the TH7 valve by turning screw 91.

• Loosen to delay the start of control.

• Tighten to advance the start of control.

122

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20 MSI 25 MSI 30 NB : The pressure levels and values are given at a transmission hydraulic oil temperature of approximately 50°C. 1) - Mount a 60 bar pressure gauge on to the TH7 braking valve.

2) - Mount a revolution counter on to the engine.

3) - Check the engine idling speed of 750 ± 25 rpm.

FIG. 1 : - Check the height of the inching-brake pedal 05 (dimension A = 70 mm from the bottom of the pedal to the top of the pedal support).

- Adjust screw 35.

- Tighten the locknut 17.

FIG. 1

123

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20 MSI 25 MSI 30 FIG. 2 : - Adjust the contactor push rod 37. Dimension B = 18 mm (inching pedal released).

- Adjust screw 03 to draw in the push rod to obtain dimension B. - Tighten the locknut 02.

FIG. 3 : - Adjust the braking boss 06. Dimension C = approximately 13 mm (in relation to the TH7 body 16).

- Fine down the adjustment to obtain a pressure reading on the gauge of 14 bar (engine idling speed of 750 ± 25 rpm).

- Tighten the locknut 17.

FIG. 2

FIG. 3

124

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20 MSI 25 MSI 30 FIG. 4 : - Press the inching pedal 05 as far as the electric contactor 37 cut-off point (dimension D approximately 19.8 mm).

- Adjust the screw 03 on the boss 06 to obtain a pressure gauge reading of 8 bar + 1.

- Tighten the locknut 02.

FIG. 5 : -

Press the inching pedal to obtain a pressure gauge reading of 3 bars.

Adjust the screw 03 (low stop).

Tighten the locknut 02.

Place the reverser in the forward drive position.

Press the push rod of the TH7 valve 16 (Fig. 3) with a screwdriver, the machine should advance.

FIG. 4

FIG. 5

125

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20 MSI 25 MSI 30 FIG. 6 : - Press the accelerator pedal 01 until an engine speed of 1000 rpm is reached.

- Adjust the screw 03 to obtain the start of travel of the machine.

- Move the reverser lever to neutral.

FIG. 7 : - Place a 0.5 to 1 mm thick shim between the screw head and the push rod of the TH7.

- Press the accelerator pedal 01 to draw in the push rod of the TH7 valve 16 completely. The engine speed should be 2600 rpm.

- Adjust the screw 03 on the support 11.

FIG. 6

FIG. 7

126

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20 MSI 25 MSI 30 17 Fig.3

14 Fig.3 17 Fig.1 35 Fig.1

16 Fig.3

16 Fig.6

36 Fig.1

03 Fig.7 02 Fig.7

11 Fig.7

02 Fig.4

03 Fig.4

02 Fig.5 02 Fig.2

09 Fig.5

06 Fig.3 / Fig.4

03 Fig.2

03 Fig.6 05

02 Fig.6

01 Fig.6 / Fig.7

127

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20D MSI 25D MSI 30D NOTE : - The machine is unloaded and on level ground.

- The pressure levels and values are given at a transmission hydraulic oil temperature of approximately 50°C. 1) - Mount a 60 bar pressure gauge on to the TH7 braking valve.

2) - Mount a revolution counter on to the engine.

3) - Make sure that the push rod of the braking TH7 is fully bottomed and the accelerator TH7 push rod is completely extended, make sure that the screw Pt. 49 (Fig. 5), lower stop of the brake pedal is tightened.

4) - Check the engine idle speed at 900 ± 50 / 0 r.p.m. (unladen).

0

FIG. 1 : - Check the height of the inching-brake pedal 05 (dimension A = 70 mm from the bottom of the pedal to the top of the pedal support).

- Adjust screw 35.

- Tighten the locknut 17.

FIG. 1

128

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20D MSI 25D MSI 30D FIG. 2 : - Adjust the contactor push rod 37 dimension B = 18 mm (inching pedal released).

- Adjust screw 03 to draw in the push rod to obtain dimension B. - Tighten the locknut 02.

FIG. 3 : - Adjust the braking boss 06 dimension C = approximately 13 mm (in relation to the TH7 body 16) - Fine down the adjustment to obtain a pressure reading on the gauge of 25-30 bar (engine idling speed of 900 ± 50 rpm).

0

- Tighten the locknut 17.

FIG. 2

FIG. 3

129

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20D MSI 25D MSI 30D FIG. 4 : - Press the brake pedal 05 as far as the electric contactor 37 cut-off point (dimension D approximately 19,8 mm).

- Adjust the screw 03 on the boss 06 to obtain a pressure gauge reading of 13 +2 bar.

0 - Tighten the locknut 02.

FIG. 5 : - Place the reverser in the neutral drive position.

- Press the brake pedal 05 to obtain a pressure gauge reading of 4 bars.

- Adjust the screw 49 (low stop).

- Tighten the locknut 02.

- Checking the working order of the regulation start of the hydrostatic pump.

- Place the reverser in the forward drive position.

- Press the push rod of the TH7 valve 16 (FIG.3) with a screwdriver, the machine should advance.

FIG. 4

FIG. 5

130

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20D MSI 25D MSI 30D FIG. 6 : - Press the accelerator pedal 01 until an engine speed of 1000 + 100 0 rpm is reached.

- Adjust the screw 03 to obtain the start of travel of the machine.

- Move the reverser lever to neutral.

FIG. 7 : - Place a 0,5 to 1 mm thick shim between the screw head and the push rod of the TH7.

- Press the accelerator pedal 01 to draw in the push rod of the TH7 valve 16 completely the engine speed should be 2240 + 10 0 rpm max. unladen..

- Adjust the screw 50 on theTH7 valve 16.

Checking the engine speed during lifting.

- Engine speed with cross levers 1750 r.p.m. min. unladen.

- Engine speed with line levers 2000 r.p.m. min. unladen.

FIG. 6

FIG. 7

131

ADJUSTING THE PEDALS AND TH7 VALVES ON MSI 20D MSI 25D MSI 30D

35 14

17 36 17 16 16

11 1

2 3 5

2 49

2 3

2 6

132

133

134

135

136

137

138

Variable displacement motor A6VM Serial 63 Axial piston unit Bent axis design, variable displacement Mode of operation Motor Size ≅ Displacement Vg (cm3)

Control and regulating device Adjustment hydraulic, pilot pressure

Pilot pressure increase ∆ p = 10 bar Pilot pressure increase ∆ p = 25 bar

with constant pressure control

Hydraulic two position control

Electrical control with proportional solenoïd

Control voltage 12 V Control voltage 24 V

with constant pressure control

Electrical two position control with switching solenoïd

Control voltage 12 V Control voltage 24 V Automatic control, high pressure related

Model without pressure increase Model with pressure increase ∆ p = 100 bar

Hydraulic control, speed related pST/pHD = 5/100 hydraulic valve for travel direction el.valve for travel direction (12V) + el.Qmax switch (12V) el.valve for travel direction (24V) + el.Qmax switch (24V)

pST/pHD = 8/100 hydraulic valve for travel direction el.valve for travel direction (12V) + el.Qmax switch (12V) el.valve for travel direction (24V) + el.Qmax switch (24V)

139

140

Direction of rotation Facing shaft end Right-hand rotation

Index

Series

DA cartridge, set to a fixed value and Ports for TH 7 Controller

Automotive control

Size Max. displacement cm3

Closed circuit operation

Axial pistons Tilting plate Variable displacement Nominal pressure 400 bar Peak pressure 450 bar

Rotation

Index

Series

DA Cartridge

Control Device

Size

Operation

Pistons

A4V

G 56

DA1D

7 /

3 1

R P

Z

C

02

F02

Valves

Filtration

Direct action HP relief valves (set to fixed value) Range from 250 - 420 bar

Filtration on pipe Backing pump (Booster pump) suction

Seals

Shaft End

Mounting Flange

Connecting Ports

Perbunan

Shaft end Splined DIN 5480 (Standard for single pump)

Mounting Flange SAE - 2 holes

Working pipes connecting ports A/B SAE (Metric thread and fixture) Lateral (opposite)

Baking Pump, PTO Backing pump and Power take-off SAE B C N 7/8" - 13 T 16/32 DP SAE B - 2 holes

3 S

IDENTIFICATION OF PUMP A4VG ON MSI 40 - 50 - REF. 193132

141

Min. displacement setting Example 0320 = 32 cm3

Direction of rotation Facing shaft end Rotation in both directions

Index

Series

Automotive Control

Max. displacement cm3

Motor operation

Axial piston unit bent axis, variable displacement

M

Min. disp. setting

Direction of rotation

Index

Series

Control device

Size

Operation

Pistons

A6V 107 DA

/

6 0 W 0320

-

P

Z

B 02

Valves

Start of control

With built-in scavenging valve 6

Start of control at max. speed Standard for DA adjustments

Seals

Shaft End

Perbunan seals (VITON shaft seal)

Shaft end Splined DIN 5480 Adaptation

Mounting Flange ISO 4 holes

Connecting Ports Pipe connecting ports SAE A ; B ports (Opposite lateral)

B

Mounting Flange

6

IDENTIFICATION OF MOTOR A6VM ON MSI 40 - 50 - REF. 193133

IDENTIFICATION OF MOTOR A2FE ON MSI 20 - 25 - 30

A2F

E

28 / 61 W -

N

Pressure medium Mineral oil or HFD fluid with no simplified code

Axial piston machine Constant displacement bent axis design (pressure range - see page 3)

A2F

Type of operation Motor operation - plug-in motor

E

Sizes Displacement Vg (cm3))

28 32 45 56 63 80 90 107 125 160 180

Series 61

Direction of rotation Facing drive shaft - both directions

W

Seals Perbunan

P

Viton

N

Shaft end

28 32 45 56 63 80 90 107 125 160 180

DIN 5480 splined shaft

Standard A

1

1

1

1

1

1

1

1

1

1

1

A

(see space requirements)

Adaptation Z

1

-

1

1

1

1

1

1

1

1

1

Z

Mounting flange Special two-hole flange

L

Adapter plate with 3/4" ports

Built-in scavenging needle

Special two-hole T version 1 = available

- = not available

142

A

L

306-S

143

: : :

: : :

IC ENGINE SPEED IN RPM:

TYPE OF MACHINE SERIAL NO HOURS RUN

PUMP TYPE SERIAL NO MOTOR TYPE SERIAL NO

: : : :

BLOCKED INCHING VALVE ADJUSTMENT

BLOCKED DR VALVE ADJUSTEMENT

MAX

MAX

FWD

REV

MAX

End of regulation

REV

FWD

End of regulation

FWD

MAX

REV

(DR. VALVE OVERSET)

BLOCKED END OF REGULATION CHECK

MAX

FWD

MAX

Start of regulation

MAX

Start of regulation

MAX

IDLE

ENGINE SPEED

BLOCKED CHECK HP VALVE

REV

FWD

NEUTRAL

BOOST VALVE ADJUSTEMENT

AT MAX SPEED CONTROL CARTRIDGE ADJUSTMENT

DRIVE LEVER POSITION

STATE OF MACHINE / CONTROLS BOOST PRESSURE

PILOTE PRESSURE FWD REV

HYDROSTATIC PUMP FWD

REV

HIGH PRESSURE

CASE PRESSURE SUCTION VACUUM

HIGH PRESSURE

CONTROL PISTON PRESSURE

DRAWBAR PULL : ..................................Kg

TRAVEL SPEED (MAX) : ....................Km / H

OIL TEMPERATURE : ............................°C

OIL TYPE:

FWD drive blocked max speed

FWD drive at point of displacement change over

Max FWD drive speed

MACHINE CONDITION+ DRIVE LEVER POSITION

HYDROSTATIC MOTOR

1 idle :........... 2 max speed :........... 3 max with hydraulics blocked : .......... 4 start of regulation :........... 5 end of regulation 400 b : .......... 6 max fwd drive blocked............

DATE OF CHECK NAME OF DEALER NAME OF ENGINEER

MANITOU - HYDROSTATIC TRANSMISSION CHECK SHEET - A4VG--DA / A6VM--DA

144

PUMP HYDROSTATIC DISASSEMBLY A4 VG 40-56 (Serial 3) 75-3-10 EN

24 / 06 / 1998

REPAIR PUMP A 4 VG 40 - 56 Serial 3

3

REPAIR INSTRUCTIONS CONTENTS

- Seal Kits and Sub-Assemblies ..............................................................................................................................

5

- Sub-Assemblies .....................................................................................................................................................

6

- Cover - Main Shaft ................................................................................................................................................

7

- Booster Pump .........................................................................................................................................................

8

- Control Piston Cover Seals ..................................................................................................................................

9-10

- Valve Seal ...............................................................................................................................................................

11

- Changing the DA Valve Seal ...............................................................................................................................

12-13

- Removing the Solenoid Valve ..............................................................................................................................

14

- Disassembling the Pump .....................................................................................................................................

15-16

- Disassembling the Turning Gear Assembly.......................................................................................................

17

- Disassembling the Control Piston .......................................................................................................................

18

- Checks .....................................................................................................................................................................

19

- Inspection of Turning Gear Parts.........................................................................................................................

20-21

- Refitting the Barrel ................................................................................................................................................

22

- Fitting the Turning Gear ......................................................................................................................................

23-25

- Tightening Torques................................................................................................................................................

26

4

REPAIR INSTRUCTIONS Seal Kits and Sub-Assemblies

1

Face Seal Kit.

2

Outer Seal Kit.

3

Housing.

4

Complete Turning Gear.

5

Control Piston.

5

REPAIR INSTRUCTIONS Sub-Assemblies

6

Connection plate.

7

EP Solenoid Valve.

8

DA Solenoid Valve.

9

Booster Pump.

10

Control Cartridge.

Non utilisé sur Manitou

6

REPAIR INSTRUCTIONS Main Shaft Cover

11 12

Protect the splined shaft.

13

Remove the circlip with two screwdrivers.

Extract the seal plate.

14

Check : Groove (1) - Bore (2) - Shaft (3) - "O" ring (4).

15

Using the special tool, position the seal.

Refitting : opposite to removal procedure.

7

REPAIR INSTRUCTIONS Booster Pump

Fitting : Chamfer on cover side.

17

Identify the position of the cover.

18

Exert pressure beneath cover to remove.

19

Inspect the booster pump and component wear.

The pump should be replaced as a complete unit.

8

16

REPAIR INSTRUCTIONS Control Piston Cover Seals

20 21

Remove the retaining screws.

Rotate the cover ty tapping lightly with a mallet.

22

Check : "O" ring (1) - Groove (2) - Housing (3).

23

Remove the locking nut.

Identify the cover position in relation to the adjusting screw.

9

REPAIR INSTRUCTIONS Control Piston Cover Seals

24

Turn the mechanical zero adjusting screw and remove the cover.

25

Check : Seal (1) - Groove (2) - Housing (3).

26

Protect the threads, push off the small "O" ring.

Refit in the opposite manner.

27

Caution : The zero point may only be adjusted on a bench or on the machine.

28

10

Refer to the mechanical zero adjustment instructions.

REPAIR INSTRUCTIONS V

Valve Seals

HP

BOOSTER VALVE

Shims + Spring collar

SHIMS 1 mm = 3 bar

29 30

Protect the threads before fitting new seals to avoid damaging them.

31

Remove the valve with the spring.

32

Protect the threads before fitting the new "O" ring (risk of damage).

11

REPAIR INSTRUCTIONS Changing the Valve Seal

PILOT NEEDLE

BRONZE SLIDE VALVE

HP SELECTOR

DR CONTROL SLIDE VALVE

SEAT

33 34

Before fitting the sealing nut, check distance X.

35

Caution : After refitting the valve, check the adjustment.

12 10

REPAIR INSTRUCTIONS Changing the DA Valve Seal

36

37

Remove the valve.

38

Do not damage the inside edge of the nozzle.

39

Protect the threads before changing the seal.

13

REPAIR INSTRUCTION Removing the Solenoid Valve

MANITOU VERSION NO JET

SOLENOID VALVE

on X1 and X2

0.8 to 1.2 mm JET ON RETURN

40

41

Remove the side retaining screw, followed by the four other screws.

42

Remove the solenoid valve.

43

Check : Contact surfaces (1), Seal (2), "O" ring (3).

14

REPAIR INSTRUCTIONS Disassembling the Pump

44

45

Identify the position of the booster pump and the connection plate.

Remove the booster pump.

46

Mark the position of the eccentric screw.

47

Caution : Remove the connection plate. If necessary, use screwdrivers.

Take care not to damage the contact surface.

15

REPAIR INSTRUCTIONS Disassembling the Pump

48

Remove the control plate and note the position of the slots.

49

Check : "O" ring and Bore (1), Housing (2) and the two seals on Pilot port (3).

16

50

Lift off the turning gear assembly.

51

Remove the solenoid valve.

52

Remove the control piston(1).

REPAIR INSTRUCTIONS Disassembling the Turning Gear Assembly

53 54

Remove the retaining circlip and the shaft seal.

55

Remove the barrel and retainer plate assembly.

56

Remove the tilting plate and the half bearings.

17

REPAIR INSTRUCTIONS Disassembling the Control Piston

57

58

Compress the springs using the special tool.

59

Remove the circlips.

Remove the collars.

NB : The springs are under pressure.

18

REPAIR INSTRUCTIONS Checks

60

Replace all the bearings.

61

Check : Splines (1), Smooth surfaces (2) and Seal surface.

62

Check that the pin (1) is not bent.

Check the bearing stop groove.

63

Check that the control piston ring is not worn or scored.

64

Check that the piston (1) is not marked.

19

REPAIR INSTRUCTIONS Inspection of Turning Gear Parts

65

Check the condition of tilting plate surface.

66

Check the control piston drive finger for wear.

67

Check the condition of the ball joint (1) and check the sliding surface for wear.

68

Check that the shoe surfaces have no signs of impact or metal deposits and that there is no axial play.

The pistons and barrel must be replaced as a unit.

69

Check : The bore of the sleeves (1) and the condition of the splines.

20

REPAIR INSTRUCTIONS Inspection of Turning Gear Parts

70

Check the condition of the control plate and the barrel (there should be no scratches or marks).

Replace as a unit only.

71

Check that the ring (1) is not worn.

72

Check the surface condition of the bearing sections (1).

73

Check the surface condition of the bearing cup (1).

21

REPAIR INSTRUCTIONS Refitting the Barrel

74

Refit the control piston and cover assembly.

75

Refit the shaft bearing preheated to 80° and the retainer ring.

76

Preheat the cradle for the oscillating bearings to 80° and fit it to the shaft-mounted bearing.

77

Fit new oscillating bearing with grease.

Fit the tilting plate with bearing stop needle.

78

22

Note the correct position for the 5 Belleville washers (1) and the shims (2).

REPAIR INSTRUCTIONS Fitting the Turning Gear

79

Fit the pistons into the barrel with the retainer plate.

80

Lubricate the shoes and the sliding surfaces (1) and (2).

81

Grease and fit the control finger on to the shaft of the tilting plate.

82

Mount the turning gear assembly, making sure that the control finger is engaged.

83

Refit the control plate making sure that it is the correct way round.

Information : - Hole for DA : control open ; - No DA : valve closed.

23

REPAIR INSTRUCTIONS Fitting the Turning Gear

Rotation D.

84

Caution : Turning to the right, pin visible.

NB : the grooves are machined according to the direction of rotation.

Rotation G.

85

Caution : Turning to the left, pin visible.

NB : the grooves are machined according to the direction of rotation.

86

Lubricate the rotating surfaces.

Grease the "O" ring and its housing.

Refit the eccentric by pressing the barrel.

24

87

Refit the connection plate in the correct position (refer to marks made during disassembly see illustration 45).

88

Tighten the connection plate at alternate points to the recommended torque.

REPAIR INSTRUCTIONS Fitting the Turning Gear

89

Refit the booster pump, referring to the marks made during disassembly (see illustration 45).

90

Refit the solenoid valve.

91

Refit the face seal and circlip.

25

INSTRUCTIONS DE REPARATION

26

REPAIR INSTRUCTIONS Notes

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27

DISASSEMBLY REPAIR PUMP A4 VG 40-56 (Serie 3.2) 75-3-11 EN

22 / 06 / 1998

REPAIR PUMP A 4 VG 40 - 56 Serie 3.2

3

REPAIR INSTRUCTIONS CONTENTS

- General Repair Instructions .................................................................................................................................

5

- Seal kits and sub assembly groups .....................................................................................................................

6

- Sub assemblies groups .........................................................................................................................................

7

- Sealing of the drive shaft ......................................................................................................................................

8

- Sealing of the boost pump ...................................................................................................................................

9

- Sealing of the control piston cover .....................................................................................................................

10 à 11

- Sealing of the valves .............................................................................................................................................

12

- Sealing of the pressure cut-off valve ..................................................................................................................

13

- Sealing of the control valve ..................................................................................................................................

14

- Removing of the control module ........................................................................................................................

15

- Pump disassembly ................................................................................................................................................

17 à 18

- Removal of the rotary group ................................................................................................................................

19

- Disassembly of the positioning piston ...............................................................................................................

20

- Inspection notes .....................................................................................................................................................

21

- Inspection of rotary group parts .........................................................................................................................

22 à 23

- Installation of rotary group .................................................................................................................................

24 à 27

- Assembly of the Pump .........................................................................................................................................

28 à 29

- Tightening torques ................................................................................................................................................

30

4

REPAIR INSTRUCTIONS General repair Instructions

Attention !

Observe the following notices when carrying out repair work at hydraulic aggregates !

Close all ports of the hydraulic aggregates.

Replace all seals.

Use only original MANITOU spare parts.

Check all seal and sliding surfaces for wear.

Attention : Rework of sealing area f. ex. with abrasive paper can damage surface.

Fill up hydraulic aggregates with medium before startup.

5

REPAIR INSTRUCTIONS Seal kits and sub assembly groups

Seal kit for drive shaft.

External seal kit.

Housing.

Complete rotary group.

Positioning piston.

6

REPAIR INSTRUCTIONS Sub assemblies

Port block.

Control moduls DA.

Boost pump.

Control valve.

7

REPAIR INSTRUCTIONS Sealing of the drive shaft

Protecting the drive shaft.

Remove retaining ring.

Screw in sheet metal screw into the holes fitted with rubber.

Pull out shaft seal with pliers.

Press-in shaft seal with bush to stop.

8

REPAIR INSTRUCTIONS Sealing of the boost pump

Note ! * Mount chamfered side facing cover.

Mark position, remove fixing screws.

Pry-off cover.

Inspect the parts of the boost pump ad wear parts.

Boost pump can only be interchanged completely.

9

REPAIR INSTRUCTIONS Sealing of the control piston cover

Loosen mounting screws.

Rotate cover and release by tapping gently with hammer.

Check !

O-ring (1), groove (2), housing (3).

Remove locknut whilst holding setting screw.

Mark cover. Must be fixed, loosen counter nut.

10

REPAIR INSTRUCTIONS Sealing of the control piston cover

Pull cover off using zero position adjustment screw.

Check !

O-ring (1), groove (2), housing (3).

Cover threads, push on small O-ring.

Assemble in reversed order.

Attention !

Adjustment of the correct zero position to be carried out after installation into the machine or on the test bench.

Reset mechanical zero position. To do this, connect X1 to X2 (> size 6).

11

REPAIR INSTRUCTIONS Sealing of the valves

Valve P HP

with bypass-function

Valve P SP

Cover threads before fitting new O-rings.

(Damage protection).

Remove valve poppet with spring. * with bypass-function

Cover threads before fitting new O-rings.

(Damage protection).

12

REPAIR INSTRUCTIONS Sealing of the pressure cut-off valve

Change of the sealing nut.

Note setting measure (*).

Attention !

After assembly check "valve setting".

13

REPAIR INSTRUCTIONS Sealing of the control valve

Remove control valve.

Do not damage throttle diameter.

Before installing the new O-ring, tape the threads.

14

REPAIR INSTRUCTIONS Removing of the control module

Remove fixing screws.

Pry-off the control module.

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

15

16

REPAIR INSTRUCTIONS Pump disassembly

Locking screw / pin

Timing adjustment screw

Mark position of the boost pump and the port plate.

Remove the boost pump.

Mark the position of the indexing screw (1).

Set the indexing screw to disassembly position (2).

Release port plate fitting.

Take off port plate. If necessary, use screwdriver.

Attention ! Sealing surface.

17

REPAIR INSTRUCTIONS Pump disassembly

Lift off control plate.

Note position.

Check !

O-ring and groove (1), housing (2), Quad-ring and groove (3).

Press the cylinder to the bottom (1).

Remove fiming indexing screw (2).

Lift out rotary group (3).

Remove 1. cylinder 2. swash plate 3. joint pin

18

REPAIR INSTRUCTIONS Removal of the rotary group

Remove retaining ring, radial seal ring.

Remove drive shaft with slight hammer strokes.

Remove bearing cups.

19

REPAIR INSTRUCTIONS Disassembly of the positioning piston

Remove control module.

Pull out control piston (1).

Mount fixture and tension spring.

Remove receiving ring.

Take out rings.

Remove retaining ring.

Note ! Parts are spring loaded.

20

REPAIR INSTRUCTIONS Inspection notes

Replace all bearings.

Check !

1. splines for damage or fretting.

2. running surfaces.

3 groove cut by shaft seal.

Check that the control piston guide bush (1) is free of grooves and has not worn out.

Check !

Control piston (1) is not scored.

21

REPAIR INSTRUCTIONS Inspection of rotary group parts

Check !

Sliding surface free of grooves.

Check !

Make sure sliding ring/swivel pin are free of play.

Check !

Check that return device is free of grooves (1) no wear in slipper pad area (2).

Check !

Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (otherwise : pistons must be replaced in sets).

Check !

Cylinder bores (1), splines (2).

22

REPAIR INSTRUCTIONS Inspection of rotary group parts

Check !

Cylinder gilding surface (1), free of scratches, no traces of wear and no embedded foreign particles. No scratches on the valve plate (2) (Replace ONLY in sets).

Check !

DU-bearing bush (1) is not worn out.

Information : Boring for DA-control open.

Without DA-control closed.

Check !

Bearing surfaces (1).

23

REPAIR INSTRUCTIONS Installation of the rotary group

Insert bearing cup set.

Insert positioning piston into the housing.

Instruction : Oil positioning piston before assembly.

Assemble bearing, wire, gliding stone and articulating pin.

Assistance : Devices e.g. - Clamp / rubber rings / grease

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in the housing.

Remove auxiliary device.

24

REPAIR INSTRUCTIONS Installation of the rotary group

Assemble articulating pin.

Assemble device for fixation of the swivel cradle.

Assemble drive shaft with bearings and radial seal rings !

Disc 1, 2

25

REPAIR INSTRUCTIONS Installation of the rotary group

Assemble piston with retaining plate.

Note : Oil piston and piston pad.

Assemble cylinder completely.

Remove assembly device.

26

REPAIR INSTRUCTIONS Installation of the rotary group

Control plate clockwise rotation - indexed in the direction of rotation.

Note !

Noise grooves are machined - in based on direction of rotation.

Control plate counter clockwise rotation - indexed in the direction of rotation.

Note !

Noise grooves are machined - in based on direction of rotation.

Oil the running surfaces of the cylinder barrel and the DU-bearing. Grease the O-rings and insert in grooves.

Basic setting - indexing screw A4VG... 40 * = 24 +_ 0,75 mm.

A4VG... 56 * = 21 +_ 0,75 mm.

Press the cylinder to the bottom (1).

Screw in the indexing screw (2).

Groove in mounting position.

27

REPAIR INSTRUCTIONS Assembly of the pump

Insert the control plate - clockwise rotation.

Insert the control plate - Counter - clockwise rotation.

Place in correct position.

Note : HW, HD, EP - Put control plate with greas to the port block.

Tighten screws (Cross-corner).

Turn the indexing screw to marking.

Assemble boost pump.

28

REPAIR INSTRUCTIONS Assembly of the pump

Mount control module.

29

REPAIR INSTRUCTIONS

30

REPAIR INSTRUCTIONS Safety regulations

General advice • 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.

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

Before starting • Observe the operating instructions before starting.

• Check the machine for obvious faults.

• Do not operate the machine with defective instruments, warning lights or control elements.

• All safety devices must be in a secure position.

• Do not carry with you movable objects or secure them to the machine.

• Keep oily and inflammable material away from the machine.

• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.

• Be careful when entering the driver's cabin, use stairs and handles.

• Adjust your seat before starting.

31

REPAIR INSTRUCTIONS Safety regulations Start • When starting all operating levers must be in "neutral position".

• Only start the machine from the driver's seat.

• Check the indicating instruments after start to assure that all functions are in order.

• Do not leave the machine unobserved when the motor is running.

• When starting with battery connection cables connect plus with plus and minus with minus.

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

Attention • Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms !

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

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 machine.

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 functions 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 !

32

HYDROSTATIC PUMP DISASSEMBLY A 4 VG 71 - 180 75-3-15 EN

REPAIRS PUMP A 4 VG 71 - 180 3 Series

REPAIR INSTRUCTIONS CONTENTS

- General Instructions...............................................................................................................................................

3

- Seal Kits and Sub-Assemblies ..............................................................................................................................

4

- Sealing the Control System...................................................................................................................................

5-6

- Sealing the Drive Shaft ..........................................................................................................................................

7-8

- Sealing the Booster Pump .....................................................................................................................................

9

- Sealing the Control Piston ....................................................................................................................................

10-11

- Sealing the Booster Valve......................................................................................................................................

12

- Sealing the HP Valves ...........................................................................................................................................

13

- Sealing the DR Valve .............................................................................................................................................

14

- Sealing the Solenoid Valve ...................................................................................................................................

15

- Solenoid Valve Inspection ....................................................................................................................................

16

- Sealing the Control Valve .....................................................................................................................................

17

- Removing the Turning Gear.................................................................................................................................

18-21

- Removing the Control Piston ...............................................................................................................................

22-23

- Removing the Turning Gear Pistons ...................................................................................................................

24

- Checking Instructions............................................................................................................................................

25-26

- Refitting the Turning Assembly...........................................................................................................................

27

- Turning Assembly..................................................................................................................................................

28-29

- Turning Gear Assembly ........................................................................................................................................

30

- Refitting the Pump.................................................................................................................................................

31

- Tightening Torques................................................................................................................................................

32

2

REPAIR INSTRUCTIONS General Instructions

1

Caution : Read the following instructions before carrying out any repairs on a hydrostatic assembly.

2

Block all ports.

3

Replace all seals.

4

Check visually for signs of wear and the surface conditions.

The use of abrasive paper may damage the surfaces.

5

Fill the oil sumps.

3

REPAIR INSTRUCTIONS Seal Kits and Sub-Assemblies

4

6

Drive shaft seal kit.

7

Outer seal kit.

8

Turning Gear.

9

Control Piston.

10

Connection plate.

REPAIR INSTRUCTIONS Sealing the Control System

11

Solenoid Valve Unit.

12

Booster Pump.

13

Control Valve.

14

HP Valve.

5

REPAIR INSTRUCTIONS Sealing the Control System

6

15

Booster Valve (LP).

16

DR Valve.

REPAIR INSTRUCTIONS Sealing the Drive Shaft

Caution : the spring is under pressure.

18

Protect the shaft splines.

19

Special tool for removing the face seal.

20

Using this tool, exert pressure on the shaft end.

17

Remove the circlip.

7

REPAIR INSTRUCTIONS Sealing the Drive Shaft

21

Using a screwdriver, exert pressure on the seal and remove the tool.

22

Extract the circlip.

23

Check : the groove (1), the orifice (2), the shaft (3) and the seal (4).

24

Refit the face seal and the circlip using the special tool.

25

Caution : Press in the drive shaft until the bearing is level with the housing.

Position the face seal and the circlip.

8

REPAIR INSTRUCTIONS Sealing the Booster Pump

Caution : the chamfered face should be fitted to the cover side.

27

26

Mark the cover position (1).

Remove the screws.

28

Remove the cover.

29

Check : the condition of the “O” ring (1), the seal groove (2) and the condition of the contact area.

9

REPAIR INSTRUCTIONS Sealing the Control Piston

Caution : identify the mechanical zero.

10

31

Identify the cover.

32

Turn the cover and extract it using a mallet.

30

REPAIR INSTRUCTIONS Sealing the Control Piston

33

Make a mark on the cover.

Loosen the locknut while holding the centre screw in position.

34

Unscrew the retaining screws.

35

Unscrew the cover.

36

Check : the seal (1), the groove (2) and the housing (3).

11

REPAIR INSTRUCTIONS Sealing the Booster Pump

37 38

Remove the complete valve.

Do not touch the adjusting screw.

Check calibration after refitting.

12

REPAIR INSTRUCTIONS Sealing the HP Valve

39 40

Remove the valve.

Check the “O” ring and its housing.

Replace the nut.

Before replacing, check the distance *.

Check calibration after refitting.

13

REPAIR INSTRUCTIONS Sealing the DR Valve

41 42

Remove the valve.

Check the “O” ring and its housing.

Replace the nut.

Before disassembling, check distance *.

Check calibration after refitting.

14

REPAIR INSTRUCTIONS Sealing the Solenoid Valve

EP

NG 71...125

NG 180

Caution : identify the hydraulic 0.

43 15

REPAIR INSTRUCTIONS Solenoid Valve Inspection

Check the condition of the “O” rings.

Check the condition of the metallic-asbestos gasket.

44

45 16

REPAIR INSTRUCTIONS Sealing the Control Valve

46 47

Check the condition of the gauged port (Nozzle).

48

Protect the threads and fit a new “O” ring.

17

REPAIR INSTRUCTIONS Removing the Turning Gear

49

18

50

Remove the solenoid valve.

51

Identify and remove the booster pump.

REPAIR INSTRUCTIONS Removing the Turning Gear

52

Identify the position of the eccentric.

Measure distance *.

Remove the eccentric.

53

Identify the connection plate position and remove the screws.

54

Remove the connection plate and the control plate.

55

Check the condition of the control plate pin and bore.

56

Remove the rotating assembly.

19

REPAIR INSTRUCTIONS Removing the Turning Gear

57

Protect the shaft splines.

Remove the circlip.

Remove the face seal cover.

58

Remove the drive shaft with a mallet.

59

Make a mark on the cover.

Remove the screws.

20

60

Remove the cover.

61

Remove the oscillating cradle.

REPAIR INSTRUCTIONS Removing the Turning Gear

62

Remove : - the cradle, - the stop needle, - the half-bearings, - and the bearing cups.

63

Remove the shaft bearing stop screw.

21

REPAIR INSTRUCTIONS Removing the Control Piston

64 65

Make a mark on the cover.

Measure adjustment from point O *.

Remove locknut.

66

22

Remove the cover.

REPAIR INSTRUCTIONS Removing the Control Piston

67

Identify the cover position.

Extract the screws.

Remove the cover.

68

Remove the piston.

69 70

Using a special tool, compress the spring and remove the circlip.

71

Remove the seats.

Remove the circlip.

Caution: the parts are slightly under pressure.

23

REPAIR INSTRUCTIONS Removing the Turning Gear Pistons

72

Remove the piston assembly and the retainer plate.

Remove the sphere and the Belleville washers.

24

74

Remove the circlip.

75

Identify the washers (1) and (2) (different diameters).

73

REPAIR INSTRUCTIONS Checking Instructions

Lager Bearing

Lagerschalen Bearing cup

1

76

Check : - the bearings (1) - the bearing cups (2).

2

77

Check the surface condition of the bearing cup cradle.

78

Check the surface condition of the cradle on the shoe side.

79

Check : - the half-sphere (1), - the retainer plate (2).

80

Check : - the splines, - the bearing surfaces, - the seal contact areas.

25

REPAIR INSTRUCTIONS Checking Instructions

81

Check : - the friction surface (shoes) (1), - axial play (2).

82

Check : - the bore (1), - the grooves (2).

83

Check : - the surface condition of the control plate contact area on the barrel (1), - the surface condition of the control plate (2).

84

Check : - the condition of the control piston, - the control finger groove, - the control finger shaft.

26

REPAIR INSTRUCTIONS Refitting the Turning Assembly

85

Refit the various circlips correctly.

86

Lubricate the piston and reposition it in the housing.

87

Refit the cover.

88

Refit the half-bearings and needles with grease.

89

Refit the cradle.

Make sure that the piston control finger is correctly inserted into its housing.

27

REPAIR INSTRUCTIONS Turning Assembly

90

Position the needles in their housings.

91

Fit the shaft bearing locking screw.

92

Cradle supporting tool.

93

Position the tool.

94

Refit the cover leaving a slight clearance.

Refit the screws without tightening.

28

REPAIR INSTRUCTIONS Turning Assembly

95

Refit the splined shaft.

96

Refit the face seal and the circlip.

97

Refit the rotating unit.

98

Refit the barrel.

Make sure that washers 1 and 2 are fitted in the correct position.

99

Direction for fitting the Belleville washers.

29

REPAIR INSTRUCTIONS Turning Gear Assembly

100

Refit the pistons and the retainer plate in the barrel.

Lubricate before fitting.

101

Refit the barrel assembly on to the shaft.

102

Left-hand rotation.

103

Grease the control plate before assembly and fit the connection plate.

Tighten the connection plate at alternate points to compress the springs.

104

30

Graisser la glace avant montage, et poser la culasse.

Serrage de la culasse en quinconce pour compresser les ressorts.

REPAIR INSTRUCTIONS Refitting the Pump

105

Refit the control plate eccentric, making sure that its position and distance * are correct (see illustration n° 52).

106

Remove the special tool.

Tighten the piston cover screws.

Adjust the 0 point.

107

Refit the cover.

108

Refit the booster pump.

Pay attention to direction of rotation (see marks).

109

Refit the solenoid valve.

31

PUMP DISASSEMBLY A4 VG 71-180 (Série 3.2) 75-3-16 EN

10 / 01 / 2001

REPAIR PUMP A 4 VG 71 - 180 Série 3.2

3

REPAIR INSTRUCTIONS CONTENTS

- General repair instructions ..................................................................................................................................

5

- Seal kits and sub assembly groups .....................................................................................................................

6

- Sub assemblies groups .........................................................................................................................................

7à8

- Sealing of the drive shaft ......................................................................................................................................

9

- Sealing of the boost pump ...................................................................................................................................

10

- Sealing of the control piston cover .....................................................................................................................

11

- Sealing of the control piston cover ....................................................................................................................

12

- Sealing of the boost pressure valve ....................................................................................................................

13

- Sealing of the pressure relief valve HD .............................................................................................................

14

- Sealing of the pressure cut-off valve ..................................................................................................................

15

- Sealing of the control device.................................................................................................................................

16

- Control device DA ................................................................................................................................................

18

- Sealing of the regulator valve...............................................................................................................................

19

- Pump disassembly .................................................................................................................................................

20 à 22

- Disassembly of the positioning piston ...............................................................................................................

23 à 24

- Dismantling of the cylinder ..................................................................................................................................

25

- Inspection notes......................................................................................................................................................

26 à 27

- Positioning piston, rotary group assembly ........................................................................................................

28

- Installation of rotary group ..................................................................................................................................

29 à 30

-Assembly of the pump ...........................................................................................................................................

31 à 33

4

REPAIR INSTRUCTIONS General repair instructions

Attention !

Observe the following notices when carrying out repair work at hydraulic aggregates !

Close all ports of the hydraulic aggregates.

Replace all seals.

Use only original MANITOU spare parts.

Check all seal and sliding surfaces for swear.

Attention : Rework of sealing area f. ex. with abrasive paper can damage surface.

Fill up hydraulic aggregates with medium before start-up.

5

REPAIR INSTRUCTIONS Seal kits and sub assembly groups

Seal kit for drive shaft.

External seal kit.

Complete rotary group.

Positioning piston.

Valve plate.

6

REPAIR INSTRUCTIONS Sub-assemblies

Control device DA Note : Size 71 control device as size 40 - 56 with flat seal.

Boost pump.

Control valve.

High pressure valve.

7

REPAIR INSTRUCTIONS Sub-assemblies

Low pressure valve.

Pressure cut-off.

8

REPAIR INSTRUCTIONS Sealing of the drive shaft

Protecting the drive shaft.

Remove retaining ring.

Screw in sheet metal screw into the holes fitted with rubber.

Pull out shaft seal with pliers.

Press-in shaft seal with bush to stop.

Assemble retaining ring.

9

REPAIR INSTRUCTIONS Sealing of the boost pump

Note ! * mount chamfered side facing cover.

Mark position, remove fixing screws.

Pry-off cover.

Check : O-ring, groove, gliding surface, connection plate.

10

REPAIR INSTRUCTIONS Sealing of the control piston cover

Attention !

Check correct mechanical 0-position.

Mark position.

Rotate cover and release by tapping gently with hammer.

11

REPAIR INSTRUCTIONS Sealing of the control piston cover Mark cover. Must be fixed, loosen counter nut, hold adjustment screw.

Remove cover.

Lift off by turning the setting screw.

Check !

O-ring (1), groove (2), housing (3).

12

REPAIR INSTRUCTIONS Sealing of the boost pressure valve

Remove valve completely.

Note : Do not change adjustment screw.

Attention !

Check valve setting after installation.

13

REPAIR INSTRUCTIONS Sealing of the pressure relief valve HD

Remove valve completely.

Control : O-ring, housing.

Replacement of the tightening nut, record measure (*).

Attention !

After assembly check "valve setting".

14

REPAIR INSTRUCTIONS Sealing of the pressure cut-off

Unscrew setting cartridge completely.

Control : 0-ring, housing.

Replacement of the tightening nut, record measure (*).

Attention !

After assembly check "valve setting".

15

REPAIR INSTRUCTIONS Sealing of the control device

DA

Size 71 - 125

Size 180

Remove control device.

Note : Size 71 : Sealing of control device as size 40 - 56 with flat seal.

Attention !

Check correct hydraulic 0-position.

16

REPAIR INSTRUCTIONS Control front/rear electrovanne

Check : 0-rings

Outlet jet

17

REPAIR INSTRUCTIONS Sealing of the regulator valve

Inspect orifice.

No damage.

Cover threads.

Insert O-ring.

19

INSTRUCTIONS DE REPARATION Démontage de la pompe

Locking screw / pin

Timing adjustment screw

Remove control device.

Remove auxiliary pump.

Note : Mark assembly position previously.

20

REPAIR INSTRUCTIONS Pump disassembly

Mark the position of the indexing screw (1).

Record setting measure.

Set the indexing screw to disassembly position (2).

Mark position of the connection plate.

Loosen connection plate fixation.

Lift off port plate and control plate.

1. Press the cylinder to the bottom.

2. Remove fixing indexing screw.

Push off hydraulic section of rotary group.

21

REPAIR INSTRUCTIONS Pump disassembly

Remove retaining ring and radial seal ring.

Remove drive shaft with slide hammer strokes.

Remove swash plate / bearing cups.

Remove joint pin

22

REPAIR INSTRUCTIONS Dismantling of the control

Mark position of the cover, note measure of "zero position".

Loosen nut.

Remove cover.

23

REPAIR INSTRUCTIONS Dismantling of the control

Mark position of the cover.

Loosen locking screw, remove cover.

Remove positioning ring.

Fit tool device and preload spring.

Remove take-off ring.

Remove rings.

Remove safety ring.

Attention : parts are under spring load.

24

REPAIR INSTRUCTIONS Dismantling of the cylinder

Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.

Remove safety ring.

Disc 1, 2

25

REPAIR INSTRUCTIONS Inspection notes

Check !

Cage set (1) Bearing cup set (2).

Check !

Bearing surfaces (1)

Check !

Sliding surface free from scoring.

Check !

Check that return device is free of scoring.

Check !

1. Splines for damage or fretting.

2. Running surfaces.

3. Groove cut by shaft seal.

26

REPAIR INSTRUCTIONS Inspection notes

Check !

Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (otherwise : pistons must be replaced in sets).

Check !

Cylinder bores (1), splines (2).

Check !

Cylinder surface (1) free of scoring.

Control plate (2) without scoring.

Check !

Positioning piston -cradle linkage Gliding stone (1), groove at the positioning piston (2), Positioning piston.

27

REPAIR INSTRUCTIONS Positioning piston, rotary group assembly

Assemble positioning piston.

Instruction : Observe correct fit of the divided rings.

Insert positioning piston into the housing.

Instruction : Remarque : Oil positioning piston before assembly.

Insert bearing cup set.

Assemble bearing, wire, gliding stone and articulating pin.

Assistance : Devices e.g - clamp / rubber rings / grease

28

REPAIR NSTRUCTIONS Installation of the rotary group

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in the housing.

Remove auuxiliary device.

Assemble articulating pins.

Assemble device for fixation of the swivel cradle.

Assemble drive shaft with bearings and radial seal rings.

29

REPAIR INSTRUCTIONS Installation of the rotary group

Disc 1, 2

Assemble piston with retaining plate.

Note : Oil piston and piston pad.

Assemble cylinder completely.

Remove assembly device.

30

REPAIR INSTRUCTIONS Assembly of the pump

Control plate clockwise rotation - indexed in the direction of rotation.

Note !

Noise grooves are machined - in based on direction of rotation.

Control plate counter clockwise rotation - indexed in the direction of rotation.

Note !

Noise grooves are machined - in based on direction of rotation.

Basic setting - indexing screw A4VG... 71 * = 28 +- 0,75 mm.

A4VG... 125 * = 20 +- 0,75 mm.

A4VG... 90 * = 29 +- 0,75 mm.

A4VG... 180 * = 22 +- 0,75 mm.

Insert the control plate - clockwise rotation.

Press the cylinder to the bottom (1) Screw in the indexing screw (2).

Groove in mounting position.

31

REPAIR INSTRUCTIONS Assembly of the pump

Insert the control plate - counter - clockwise rotation.

Assemble connection plate.

Attention ! Spring preloaded !

Insert control plate into housing, guidance with two locking screws crossing over - Finish assembly !

Locking screw - Observe adjusting measure.

1. Assemble cover.

2. Adjust zero position according to measure.

32

REPAIR INSTRUCTIONS Assembly of the pump

Attention !

Adjustments of the correct zero position to be carried out after installation into the machine or on the bench test.

Assemble auxiliary pump.

Note : Take care of direction of rotation.

Assemble control device.

33

REPAIR INSTRUCTIONS

34

REPAIR INSTRUCTIONS

General advice • 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.

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

Before starting • Observe the operating instructions before starting.

• Check the machine for obvious faults.

• Do not operate the machine with defective instruments, warning lights or control elements.

• All safety devices must be in a secure position.

• Do not carry with you movable objects or secure them to the machine.

• Keep oily and inflammable material away from the machine.

• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.

• Be careful when entering the driver's cabin, use stairs and handles.

• Adjust your seat before starting.

35

REPAIR INSTRUCTIONS Notes Start • When starting all operating levers must be in "neutral position".

• Only start the machine from the driver's seat.

• Check the indicating instruments after start to assure that all functions are in order.

• Do not leave the machine unobserved when the motor is running.

• When starting with battery connection cables connect plus with plus and minus with minus.

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

Attention • Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms !

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

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 machine.

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 functions 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 !

36

PUMP DISASSEMBLY A 10 VG 28-45 (Série 3.2) 75-3-5 EN

REPAIRING A10VG PUMP

1

REPAIR INSTRUCTIONS TABLE OF CONTENTS - Cross section view ...................................................................................................................................

3 to 4

- General repair instructions .......................................................................................................................

5

- Packets of gaskets and sub-assemblies .................................................................................................

6 to 8

- Drive shaft seal.........................................................................................................................................

9

- Booster pump seal ...................................................................................................................................

10 to 12

- Displacement control cylinder cover seal .................................................................................................

13

- Valve seals ...............................................................................................................................................

14

- Flow cancellation valve seal.....................................................................................................................

15

- Adjustment valve seals.............................................................................................................................

16

- Removing the control mechanism ............................................................................................................

17

- Control devices.........................................................................................................................................

18

- Disassembling the pump ..........................................................................................................................

19 to 21

- Removing the rotor...................................................................................................................................

22

- Disassembling the displacement control cylinder.....................................................................................

23 to 24

- Recommendations for checking parts ......................................................................................................

25 to 27

- Assembling the cover/Turcon-Glyd ring ...................................................................................................

28

- Reassembling the pump...........................................................................................................................

29 to 31

- Fitting the rotor .........................................................................................................................................

32 to 34

- Tightening torque .....................................................................................................................................

36

- Safety measures ......................................................................................................................................

37

2

Cross section view

Repair instructions A10VG

HW

with flow cancellation and pressure maintained

without flow cancellation

HDD

EPD

3

Cross section view

DA

4

Repair instructions A10VG

General repair instructions

Repair instructions A10VG

Warning !

Whenever carrying out repairs on a hydraulic component please remember the following recommendations !

Seal all openings on the hydraulic component.

Replace all gaskets.

Use genuine HYDROMATIK spare parts only.

Check all seal and slide faces for wear.

Warning : touching up seal faces, e.g. with emery paper, can cause damage to their surfaces.

Before starting up, fill the component casing with oil from the circuit.

5

Repair instructions A10VG

Packets of gaskets and sub-assemblies

1

2

3

4

5

6

Packet of gaskets for drive shaft.

Packet of external gaskets.

Complete rotor (pump part mechanism).

Displacement control cylinder.

1. Standard cylinder head.

2. Cylinder head with flow cancellation.

3. Cylinder head for DA governing, with flow cancellation.

Packets of gaskets and sub-assemblies

Repair instructions A10VG

6

7

HW control device

HW control device with zero position indicator.

8

HD control device

9

EP control device

10

DA control device

7

Packets of gaskets and sub-assemblies

Repair instructions A10VG

10

11

8

Booster pump with wear plate.

1. HP Valve 2. HP valve with by-pass 3. PB valve

12

With flow cancellation and pressure maintained.

13

1. DA cartridge, adjustable by lever.

2. DA cartridge, set to a fixed value.

3. Sequence valve.

Drive shaft seal

Repair instructions A10VG

14

15

Protect the drive shaft.

Remove the stop collar.

16

Screw sheet metal screws in the rubber filled holes.

Extract the shaft gasket with pincers

17

Use a spacer to position the shaft gasket till it butts up.

9

Booster pump seal

Repair instructions A10VG

Warning ! * assemble the chamfered «face» on the cover side.

18 19

20

21

10

Remove the mounting screws.

Pull the cover clear

Mark the position.

Booster pump seal

Repair instructions A10VG

22

23

Remove the O ring seal.

Pull the booster pump clear.

24

1. Wear plate.

2. Mounting pin.

25

1. Kantsil seal.

2. Decompression groove.

3. Mounting pin.

26

Put the wear plate in place.

Make sure to follow the direction of rotation !

11

Booster pump seal

Repair instructions A10VG

27

Put the wear plate in place.

Rightward rotation, shaft end towards you.

Take care with the mounting pin.

coté aspiration

28

Put the wear plate in place.

Rightward rotation, shaft end towards you.

Take care with the mounting pin.

coté aspiration

rotation gauche

29

rotation droite

12

30

Mount the booster pump.

31

Mount the O ring seal and the cover.

Displacement control cylinder cover seal

Repair instructions A10VG

Warning !

Make sure that the mechanical zero setting is correct !

19 20

21

22

Remove the lock nut while holding the positioning screw.

Mark the cover. Keeping the dimension, loosen the lock nut.

Pull the cover free of the positioning screw.

Check ! the O ring seals (1), their housings (2), the body and the cover (3).

Warning !

Optimization of the mechanical zero setting must be carried out once the pump is mounted on the vehicle or on a test bench.

13

Valve seals

Repair instructions A10VG

High pressure valve (P HP)

with by-pass

Booster valve (P SP)

23 24

25 bague d’appui

Protect the screw threads before fitting the new O ring seal.

Disassemble the valve flap and the pressure setting spring. * with by-pass function.

joint torique

26

14

Protect the screw threads before fitting the new O ring seal.

Flow cancellation valve seal

Repair instructions A10VG

27 28

Change the seal nut, observing the adjustment value (*)

Warning !

Check the valve pressure setting after reassembling.

15

Adjustment valve seals

Repair instructions A10VG

29 30

31

32

16

Disassemble the adjustment valve.

Do not damage the nozzle diameter.

Check this diameter.

Protect the screw threads before fitting the new O ring seal.

Removing the control mechanism

Repair instructions A10VG

HW with neutral position switch

33 34

35

36

* Remove the mounting screws

Pull the control mechanism clear

Check : the seal face (1), the flat seal (2), the O ring seals (3).

17

Control devices

Repair instructions A10VG

calibre 28 HW control device

calibre 45 37

HD - EP control device EP

38

DA control device

39

18

Disassembling the pump

Repair instructions A10VG

flow cancellation

40

off-centring screw

41

19

Disassembling the pump

Repair instructions A10VG

46

47

20

Mark the position of the booster pump and the cylinder head.

Disassemble the booster pump.

Variant with DA regulation : Mark the position of the off-centring screw (1).

Place the off-centring screw in disassemble position (2).

46

Unscrew the cylinder head mountings. Lift and remove the cylinder head.

47

Pull clear the port plate.

Note its position.

48

Check !

The O ring seal and its housing (1).

The O ring seal and its housing (2).

The port plate mounting pin (3) In DA, no mounting pin The closing of outlet T (4).

Disassembling the pump

Repair instructions A10VG

49

Variant with DA regulation : Press the cylinder barrel downwards (1).

Remove the off-centring screw (2).

Lift and remove the rotor (3).

Disassemble : 1. the cylinder barrel.

2. the plate.

3. the knuckle pin.

50

52

Remove the stop collar and the shaft seal.

21

Removing the rotor

22

Repair instructions A10VG

53

Extract the drive shaft with light hammer strokes (rubber mallet).

54

Remove the cradles.

56

Pre-stress the spring with a tool.

57

Remove the stop collar.

Remove the spring and the pressure holding pins.

Disassembling the displacement control cylinder (Housing with liner)

Repair instructions A10VG

58

Disassemble the control device.

59

Remove the displacement control cylinder (1).

Break down the displacement control cylinder.

60 23

Disassembling the displacement control cylinder (Housing with Turcon-Glyd ring)

Repair instructions A10VG

58

59

Disassemble the control device.

Remove the displacement control cylinder (1).

Break down the displacement control cylinder.

(Housing with Turcon-Glyd ring seal).

60 24

Recommendations for checking parts

Repair instructions A10VG

61

62

Replace all bearings.

Check !

1. the spline : damaged by wear, presence of adjusting rust?

2. areas receiving the bearings.

3. for the presence of scratches due to the shaft seal.

63

Displacement control cylinder liner (1) free of scratches and wear.

64

Check ! for the absence of scratches on the displacement control cylinder (1) .

25

Recommendations for checking parts

Repair instructions A10VG

65

66

Check ! for the absence of clearance in the link between the slide piece and the journal.

67

Check ! for the absence of scratches on the return device (1), the absence of traces of binding (2) in the pad area.

68

Check ! for the absence of scratches on the contact face (1), the absence of metal deposits, the absence of axial clearance (2), (the pistons to be changed a full set at a time only).

69

26

Check ! for the absence of scratches on the contact face.

Check ! the bore of the cylinder barrel (1), the splines (2).

Recommendations for checking parts

Repair instructions A10VG

70

71

Check ! for the absence of scratches or traces of binding on the cylinder barrel sliding face (1), for the absence of deposits, the absence of scratches on the port plate (only change these parts with a whole new set).

Check ! for the absence of damage to the port plate contact face.

72

Remark : For DA regulation, this hole is open (only for A10VG 45).

73

Check ! the surfaces of the bearings (1).

74

Absence of scratches or traces of binding.

27

Assembling the cover/Turcon-Glyd ring

Repair instructions A10VG

75

76

28

Insert the seal in the mounting pliers.

77

With the pliers and its tooling, form the seal into a bean shape. Proceed with care when shaping Turcon seals so as to avoid damaging the edges of the seal.

78

Place the O ring seal in the groove.

Bring the Turcon seal into the housing and place it in its housing. Release the pressure exerted on the seal, then remove the pliers and tool. Check that the seal is properly in position, smoothing it with the finger if necessary.

79

Calibrate the seal with a test mandrel (displacement control cylinder) to an angle of 10° to 15°.

Reassembling the pump

Repair instructions A10VG

75

Put the cradles in place.

76

Place the displacement control cylinder in the housing.

Remark : Grease the front cylinder before putting it in place.

Fit the bearing, the wire, the slide piece and the knuckle pin.

Tooling : for example, clamp, rubber ring, grease.

77 78

Fit the complete plate in the housing.

Make sure the cradles are properly in place in the housing.

Disassemble the tooling.

29

Reassembling the pump

Repair instructions A10VG

Check the position of the bearings in their guides.

Incline the plate and the displacement control cylinder, this should be easy to do. Place them in a central position using a measuring instrument (dial gauge or depth gauge).

Check points 1 and 2 : they should have the same dimensions.

80

30

Put the knuckle pin in place.

Reassembling the pump

Repair instructions A10VG

Put the tooling in place.

Hold the plate in position with a threaded pin.

Do not force it.

Tooling for A4V «plate»

Section no. 3

Section no. 4

Section no. 5

Mark 1 2 3 4 5 6 7 8 9

Description square threaded pin wedge wedge wedge M12 x 25 DIN 912 cheese head screw M14 x 25 DIN 912 cheese head screw M16 x 30 DIN 912 cheese head screw M20 x 35 DIN 912 cheese head screw

quantity 2 2 2 2 2 2 2 2 2

31

Fitting the rotor

Repair instructions A10VG

82

New assembly position !

Fit the shaft together with bearings and shaft seal.

80

Put the assembling unit in place.

83

New assembly position !

Fit the shaft together with bearings and shaft seal.

84 85

32

Fit the pistons and the return device.

Remark : Grease the pistons and pads.

Fitting the rotor

Repair instructions A10VG

86

87

Disassemble the assembling unit.

Fit the cylinder barrel and the pistons, and also the return device.

Assembly hint : Hold the pistons with an O ring seal.

86

On variant with off-centring screw : Press the cylinder barrel downwards -Screw the off-centring screw to the mark x. * Notch in assembly position.

87

Calibre 28 = 31 + 0.75 mm Calibre 45 = 32 + 0.75 mm

33

Fitting the rotor

Repair instructions A10VG

88

89

90

91

Fit the port plate mounting pin.

DA adjustment : the pump has an off-centring screw but no mounting pin.

Port plate for righthand rotation. * mounting pin.

Port plate for lefthand rotation with * mounting pin.

Port plate for righthand rotation with off-centring screw.

Do not exceed the maximum thread depth.

34

Reassembling the pump

Repair instructions A10VG

92

93

Grease the surfaces of the cylinder barrel, take new O ring seals grease them and then put them in place.

Position them correctly.

Remark : HW, HD, EP adjustments : place the grease port plate on the cylinder head.

DA Adjustment : place the port plate on the cylinder barrel.

94

Tighten the cross head screw.

Position the off-centring screw on the marking.

95

Assemble the booster pump.

96

Assemble the control unit with its seal.

35

Tightening torque

Repair instructions A10VG

Tightening torque for the VSTI caps (metric fine thread)

Tightening torque for the headless screw (ISO metric coarse thread)

Ø of thread

Resistance Ø of

Tightening torque values opposite are only valid for the

thread

headless screw with ISO metric

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

coarse thread and head support dimensions as per DIN 912, DIN 931 and DIN 933

Also, these values are only valid for slightly greased or ungreased, untreated surfaces, and when using

exclusively

torque

wrenches or wrenches with stress limitation.

8,8

10,9

12,9

Tightening torque (Nm) 1,1 2,9 6 10 25 49 86 135 210 290 410 550 710 1050 1450

1,6 4,1 8,5 14 96 69 120 190 295 405 580 780 1000 1500 2000

1,9 4,9 10 17 41 83 145 230 355 485 690 930 1200 1800 2400

M8x1 M 10 x 1 M 12 x 1,5 M 14 x 1,5 M 16 x 1,5 M 18 x 1,5 M 20 x 1,5 M 22 x 1,5 M 26 x 1,5 M 27 x 2 M 30 x 1,5 M 33 x 2 M 42 x 2 M 48 x 2

description VSTI 8 x 1 VSTI 10 x 1 VSTI 12 x 1,5 VSTI 14 x 1,5 VSTI 16 x 1,5 VSTI 18 x 1,5 VSTI 20 x 1,5 VSTI 22 x 1,5 VSTI 26 x 1,5 VSTI 27 x 2 VSTI 30 x 1,5 VSTI 33 x 2 VSTI 42 x 2 VSTI 48 x 2

Tightening torque (Nm) - ED/SA - ED - ED - ED - ED/SA - ED/SA - ED/SA - ED - ED/SA - ED - ED/SA - ED/SA - ED/SA - ED

=5 = 10 = 20 = 30 = 30 = 40 = 50 = 60 = 70 = 90 = 100 = 120 = 200 = 300

Tightening torque for the cross-recessed button head screw as per DIN 7985 (ISO metric coarse thread)

Tightening torque for the seal-lock collar nuts (ISO metric coarse thread) resistance

resistance Ø of Tightening

torque

values

opposite are only valid for resistance class 8.8 seal-lock collar nuts with ISO metric coarse thread.

36

thread M6 M8 M10 M12 M14 M16

8,8

10,9

12,9 Ø of

tightening torque (Nm) 10 22 40 69 110 170

Tightening

torque

values

opposite are only valid for resistance class 8.8 crossrecessed button head screws as per DIN 7985 with ISO metric coarse thread.

thread M3 M4 M5 M6 M8 M10

8,8

10,9

12,9

tightening torque (Nm) 1,1 2,9 6 10 25 49

Safety measures

Repair instructions A10VG

The hydraulic plant

1. The hydraulic power plant is under high pressure !

High pressure fluids (fuel, hydraulic oil) coming out under high pressure can pass through the skin and cause very serious injury. If this occurs, call a doctor immediately, as there is a risk of serious infection !

2. Whilst searching for leaks take appropriate measures to protect against the risk of injury !

3. Before carrying out work on the hydraulic power plant it is imperative to turn off the pressure and to lower the vehicle tooling !

4. During work on the hydraulic power plant it is imperative to switch off the engine and prevent the vehicle from moving (parking brake, wedge) !

5. When connecting the cylinders and hydraulic motors, the hydraulic hoses must be connected in compliance with the instructions !

6. If the connections are made the wrong way round, the functions are also reversed (e.g. lift/lower) ˆrisk of accidents !

7. Inspect the hydraulic hoses regularly and change them if they are damaged or worn !

The replacement hoses must meet the appliance maker's technical specifications !

Take away and recycle the oil, fuels and filters in line with standard practice !

37

HYDROSTATIC MOTOR DISASSEMBLY A 6 VM Serie 60 75-3-20 EN

REPAIRS PUMP A 6 VM 60 Series

2

G

A6VM DA

T

X1

X2

B

A

T1

3

REPAIR INSTRUCTIONS Seal Kits and Sub-Assemblies

4

D1

Drive shaft seal kit.

D2

Complete seal kit.

REPAIR INSTRUCTIONS Sub-Assemblies/Replacing the Sealing Nut

B5

DA Control (automotive control).

B6

Connection plate with positioning cylinder.

We recommend replacing the connection plate complete with the required pretested control unit.

B7

Rotor.

5

REPAIR INSTRUCTIONS Sub-Assemblies/Replacing the Sealing Nut

B10

Non-return valve (1).

Cartridge for non-return valve (2).

1 2

B11

Tilting time limit.

Throttle : 1 fixed, 2 single-action, 3 double-action, 4 double-action - adjustable.

1

Replace the sealing nut.

Firstly measure and record the adjustment height.

2

6

When tightening the nut, hold the adjusting screw then check the adjustment height.

REPAIR INSTRUCTIONS Sealing the Drive Shaft

1

3

Protect the drive shaft with adhesive tape.

4

Remove the circlip and remove the sealing flange.

5

Remove the seal carrier.

6

Check : The dust and seal lip 1, the “O” ring 2, the “O” ring groove 3, the contact surface 4, the housing 5 (“O” ring position).

2 3 5 4

7 1

Pre-assembly : Fit the shaft seal (dry) with the sleeve 1. Only fit the washer 2 if the bearing surface is deep.

2

7

REPAIR INSTRUCTIONS Sealing the Drive Shaft / Fitting the “O” Rings

8

Pre-assembly : Fill the space between the dust lip and the seal lip with grease.

9

Circlip 1, seal carrier 2, sealing flange 3, shaft seal 4, “O” ring 5.

10

“O” ring in groove. Do not fill groove 1 with grease, grease the “O” ring. Slide the “O” ring over the chamfer 2.

11

“O” ring behind the thread or groove (protect thread or groove with adhesive tape).

1

3 2 4

5

2 1

1

8

REPAIR INSTRUCTIONS Sealing the Adjusting Unit

12

Control piston cover.

Mark the housing and cover.

13

Check :

1 1

3

The bore hole in the housing 1, the “O” ring 2 and the groove 3.

2 1

14 2

Control Unit : Mark 1, do not remove the adjusting screw 2.

1 1

1

2

15

Check : The “O” ring 1, the “O” ring groove 2 and the housing 3.

3

16

For easier assembly : Fit the pin with grease.

9

REPAIR INSTRUCTIONS Sealing the Adjusting Unit

17

Complete adjusting unit.

Mark position 1 ; d not use a screwdriver - sealing surface.

1

1

2

18

1

Check : The adjusting unit sealing surface 1 and the housing sealing surface 2.

1

2

2

19

Check : The barrel contact surfaces 1 and the control plate sliding surfaces 2. Do not disassemble the barrel.

1

20

For easier assembly : Insert the control plate into the slide with grease. Pivot the rotor 2 into the housing depending on the control plate position.

21

For easier assembly : Place a new gasket on the flat surface. Do not use a liquid sealant as the thickness of the gasket is taken into account during rotor adjustment. Comply with tightening torques on page 16.

10

REPAIR INSTRUCTIONS Replacing the Adjusting Piston Seal

22

Lift the adjusting unit (N° 17-21).

23

Disassemble the adjusting piston cover and the control unit with the springs and collars (N° 12-16).

24

Remove the locking screw (fixed with Loctite 601) by heating the adjusting piston/bearing to approx. 120°C.

25

Remove the positioning pin. Carefully remove the remaining adhesive by rethreading thread 1.

26

Remove the old seals.

1 1

1

Check the condition of the positioning piston 1 and the bore hole 2.

2

11

REPAIR INSTRUCTIONS Replacing the Adjusting Piston Seal

27

For easier assembly : Fit new back-up ring 1 and lip seal 2 with the adjusting piston (lubricate). Pull the piston once again and check that the rings are correctly fitted.

1

2

1

28

Alternately push the piston rings by hand.

Insert the adjusting piston.

29

Fit pin 1 in the correct position. Beware of the drying time 2 (Loctite 601) and the tightening torque (page 16).

30

Fit the cover and the control unit with the springs and collars.

31

Complete the assembly as in steps 18 to 21.

1

2

12

REPAIR INSTRUCTIONS Replacing the Rotor

1

32

Disassemble the adjusting unit.

33

Remove the barrel 1 with the four Belleville washers 2 and the support 3.

34

Disassemble the shaft seal; take off the back-up washer and remove the circlip 2.

35

Remove the rotor.

36

Check :

3 2

1

1

That the outer seals 1 in the housing are not deformed and that the housing is in good condition.

13

REPAIR INSTRUCTIONS Replacing the Rotor

1

37

Check that the control plate sliding surfaces are not scratched or worn.

38

For easier assembly :

1

Heat the housing to approxuimately 80°C, insert the rotor and the circlip.

14

39

Complete the assembly operation as indicated in steps 5 to 9, then pull the rotor against the circlip.

40

Complete the assembly operation as indicated in steps 18 to 21.

REPAIR INSTRUCTIONS Control Units

48

DA Control unit.

49

Non-return valve.

15

REPAIR INSTRUCTIONS Tightening Torques

Strength classes Thread

8,8

10,9

12,9

Nm/ftlb M 3 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 Thread

1,6 4,0 8,3 14 34 68 118 186 289 397 569 Nm/ftlb

M 12 x 1,5

20

M 22 x 1,5

60

M 26 x 1,5

70

M 33 x 2 Thread M 12 x 1,5 M 14 x 1,5 Thread

16

1,08 2,84 5,90 9,80 24 48 84 132 206 284 402

120 Nm/ftlb 30 40 Nm/ftlb

M 8

10

M 10

25

M 12

49

M 16

86

1,9 4,8 9,8 17 40 81 142 226 348 476 677

HYDROSTATIC MOTOR DISASSEMBLY A 6 VM Serie 63 75-3-35 EN

REPAIR MOTOR A 6 VM Serial 63

3

Recommandations

Motor A 6 VM Serial 63 Repair Instructions

A

Attention !

Observe the following notices when carrying out repair work at hydraulic aggregates !

B

Close all ports of the hydraulic aggregates.

C

Replace all seals.

Use only original MANITOU spare parts.

D

Check all seal and sliding surfaces for wear.

Attention : Rework of sealing area f. ex. with abrasive paper can damage surface.

E

Fill up hydraulic aggregates with medium before start-up.

5

Seal kits and sub assembly groups

Motor A 6 VM Serial 63 Repair Instructions

1

Seal kit for drive shaft.

2

External seal kit.

3

Housing.

4

Complete rotary group.

5

Port plate with control piston.

6

Seal kits and sub assembly groups

Motor A 6 VM Serial 63 Repair Instructions

9

Cover with flushing and boost pressure valve and * Throttle pin. * Throttle pin "as to order requirement".

7

Component groups / Control components

Motor A 6 VM Serial 63 Repair Instructions

8

9

Replace seal hut

Motor A 6 VM Serial 63 Repair Instructions

10

Replace seal nut.

First measure and record setting height.

11

When tightening counterhold setting screw, then check setting height.

10

Sealing of the cover plate

Motor A 6 VM Serial 63 Repair Instructions

12 13

Protecting the drive shaft.

Remove retaining ring and shim.

14

Screw in sheet metal screw into the holes fitted with rubber.

Pull out seal with pliers.

15

Press in shaft seal ring and shim with bush to stop.

- Take note of press-in depth !

- Install mark for press-in depth of safety ring.

11

Sealing of the control parts

Motor A 6 VM Serial 63 Repair Instructions

Attention !

Spring load

16 17

Inspect Drilling in housing, O-ring, groove.

18 Do not remove adjustment screw.

Inspect O-ring, O-ring groove, housing.

19

Assembly aid Insert pin with grease.

12

13

Sealing of the control parts

Motor A 6 VM Serial 63 Repair Instructions

24 25

Example : A6VM…Control - différential piston.

Disassembly position : Remove cover Pos. 2.

Attention ! Spring load.

Dimension X : Note dimension (begin of regulation).

26

1. Check of O-ring.

27

1.

2.

3.

4.

High pressure - small control piston side Control pressure High pressure - check valve High pressure - check valve

14

Disassembly of the port plate

Motor A 6 VM Serial 63 Repair Instructions

Différential piston : Note dimension X.

For disassembly of the port plate, swivel always rotary group to zero position.

Piston rings to hang out of the cylinder boring.

Screw Qmin

Remove Qmin - screw.

Swivel rotary group to 0°.

15

16

Motor A 6 VM Serial 63 Dissassembly of the port plate

Repair Instructions

28

Port plate Mark position. Loosen screws.Removal.

29

Check O-ring.

-Stick new O-ring with some grease.

- Do not swivel rotary group.

- Piston rings to hang out from the cylinder boring.

30 - Stick control lens in sliding surface with grease.

- Assembly in reversal order.

- Mount port plate.

Rotary group vertical.

17

Remove of the positioning piston

Motor A 6 VM Serial 63 Repair Instructions

Différential piston

31 32

Loosen fixing screw.

Use only socket wrench.

18

Remove of the positioning piston

Motor A 6 VM Serial 63 Repair Instructions

33

Remove piston with piston ring.

34

Différential piston Warm up fixation screw for positioning plug via boring (screw glued - to turn out).

- Use new screw - Note tightening torque !

19

Remove rotary group

Motor A 6 VM Serial 63 Repair Instructions

36

37

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.

Remove Qmax - stop screw.

Size

38

28 55 80 107 140 160 200

: : : : : : :

M4 M5 M6 M6 M8 M8 M8

x x x x x x x

58 mm 71 mm 82 mm 92 mm 105 mm 105 mm 109 mm

Press out rotary group !

If the bearings are used again do not hit on the drive shaft.

20

Remove rotary group

Motor A 6 VM Serial 63 Repair Instructions

39

Or press-out with extraction device.

39 bis

21

Exchanging of the rotary group

Motor A 6 VM Serial 63 Repair Instructions

Complete rotary group Setting of hydraulic part necessary.

40

Rotary group 1. Mechanical part : Adjust drive shaft with bearing.

2. Hydraulic part :

Adjustment necessary.

41

Rotary group : All parts * Setting Setting value, torque see service information.

42 22

Exchanging of the rotary group

Motor A 6 VM Serial 63 Repair Instructions

43

Remove fixing screw (cylinder).

Remove cylinder.

44

Disassembly retaining plate.

Screws are glued.

Use Torx-tools.

23

Inspection notes

Motor A 6 VM Serial 63 Repair Instructions

45

Free of corrosion, erosion or fretting, no damage to splines or keyways.

46

Pistons No scoring and no pittings.

47

Center pin No scoring and no pittings.

48

Retaining plate No scoring and no evidence of wear.

49

1. Bores free of scoring, no evidence of wear.

2. Faces smooth and even, free of cracks and scoring.

24

Inspection notes

Motor A 6 VM Serial 63 Repair Instructions

50

Control housing.

Sliding surface and side guides free of scoring and no wear.

51

Visual check : Bearing areas free of scoring and no evidence of wear.

25

Rotary group assembly / see service information

Motor A 6 VM Serial 63 Repair Instructions

Rotary group : mechanical part

Adjustment dimension * and bearing torque see service information.

Press on bearing.

Do not exeed bearing torque during press-on.

Preload bearing with assembly sleeve and steady control of the torque.

26

Rotary group assembly

Motor A 6 VM Serial 63 Repair Instructions

Rotary group : mechanical part

Assemble safety ring.

Determine dimension for adjustment disc with final dimensions (crossover).

Install adjustment disc. Assemble safety ring. Drive shaft ready for assembly.

27

Rotary group assembly

Motor A 6 VM Serial 63 Repair Instructions

52 53

Insert retaining plate with pistson and center pin. Use screw with Precote-coating.

54

Make sure all parts are fitted in correctly.

55

Swivel cylinder block to max. and fix the cylinder.

28

Rotary group assembly

Motor A 6 VM Serial 63 Repair Instructions

Rotary group completely assembled ready for assembly.

Place assembly sleeve.

Warm up housing to 80°C.

29

Rotary group assembly

Motor A 6 VM Serial 63 Repair Instructions

Insert rotary group into housing to seat position.

Fix zero position of cylinder with Qmax.screw.

1. Disassemble cylinder fixing screw.

2. Insert O-ring.

30

Rotary group adjustment

Motor A 6 VM Serial 63 Repair Instructions

56

Determine cylinder swivel range to max. angle with screw.

57

* Disc.

58

Place centering disc.

59

Mount measuring device.

60

Check dimension X.

31

Assembly of the port plate

Motor A 6 VM Serial 63 Repair Instructions

1. Assemble port plate with differential piston.

Take care of assembly design !

Tighten fixing screws with torque.

2. Swivel rotary group to "starting position".

3. Set screw to dimension * 4. Assemble plug.

5. Remove assembly sleeve.

61 62

Assemble cover.

63

Assemble control components.

32

Motor assemble

Motor A 6 VM Serial 63 Repair Instructions

62

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.

Take care of press-in depth.(see fig.15)

33

MOTOR DISASSEMBLY A2F 75-3-24 EN

REPAIRING THE A2F ENGINE

1

2

SET OF SEALS / SUB-ASSEMBLIES

01

Set of external seals with assembling unit.

02

Rotor, mechanical parts, preset with set of seals and glue.

03

Rotor, hydraulic parts, preset with set of seals and glue.

04

Complete rotor, preset with set of seals and glue.

PAGES 2 4 6 8 9 11

SET OF SEALS SHAFT SEALS CYLINDER HEAD DISASSEMBLING THE ROTOR INSPECTION OF COMPONENTS ROTOR ASSEMBLY

3

SHAFT SEAL

4

1

For non-splined shafts : pull clear the key.

Cover the shaft end.

2

Remove the retaining ring.

3

Push back the locking ring.

4

VISUAL INSPECTION : 1 - shaft seal 2 - locking ring 3 - inlet shaft 4 - housing 5 - O ring seal

5

Disassemble the shaft seal.

SHAFT SEAL

6

Position the shaft seal ring correctly with the appropriate socket.

7

If the shaft is deeply grooved, insert a shim behind the seal.

8

Fit 1 new O ring seal, making sure it is correctly fitted. Grease the O ring seal and the shaft seal lips.

9

Fit the retaining ring with a centre punch.

10

Check that the retaining ring is properly in its housing.

5

CYLINDER HEAD/SEALS

6

11

Mark the position of the cylinder head on the body (see arrow).

Remove the mounting screw.

12

Swivel the cylinder head around the centring pin and remove.

13

Mark the position of the centring pin (see arrow).

14

Pump : Righthand rotation (viewing the face on the spherical surface side)

15

Pump : Lefthand rotation (viewing the face on the spherical surface side)

CYLINDER HEAD/SEALS

16

Engine : 2 rotation directions (viewing the face on the spherical surface side)

17

Visually inspect : O ring seal (1) groove (2) cylinder head (3)

18

Fit the seal after first lightly greasing it.

19

Reassemble the cylinder head in its former position (Fig. 11). Take care with the position of the face.

20

Reassemble the screw to the required torque see P.14

7

DISASSEMBLING THE ROTOR

8

21

Remove the cylinder head (page 6). Turn and remove the control plate.

22

Disassemble the locking ring (page 4).

23

Remove the shims.

24

Disassemble the rotor with a puller (Fig. 50).

25

Remove the retainer plate, the screws are held with loctite

INSPECTION OF THE COMPONENTS

26

Drive shaft 1) No corrosion or erosion. No damage at the splines.

2) No signs of wear, no scratches (fig. 7).

3) No cuts, bumps or pitting

27

1) Piston end play 2) Thrust collar

28

Pistons No marks, no pitting (Do not disassemble the articulation).

29

Centring head.

1) No marks, no pitting (Do not disassemble the articulation) 2) No marks

30

Retainer plate No marks or wear

9

INSPECTION OF THE COMPONENTS

10

31

Cylinder block /Control plate 1) Bore with no marks or wear.

2) Faces, smooth and flat, with no marks or markings 3) Min hardness 700 HV 10.

32

Housing No damage or wear on the bearing radiuses.

33

Change the piston unit.

When other components need changing, recalibration is necessary.

34

Cylinder block and control plate to be changed as a pair.

35

Insert a locating pin with retainer.

Fit the retainer plate correctly.

ROTOR ASSEMBLY

36

Use a little loctite for the screw only.

37

Use grease to fit the pads and the Belleville washer (use a screwdriver).

38

Ensure that all the parts are correctly assembled.

39

Assemble the pistons

40

Press firmly on the pistons in the cup with the cylinder block held in a central position.

11

ROTOR ASSEMBLY

41

Tip over the cylinder block to Max (Fig. 40) Fix the assembling tool, the shipping protector (Fig. 51).

42

Is it a new seal?

(Comparison with Fig. 7)

43

Heat the housing to 80° C Arrangement fig. 52

44

Assemble the preheated housing.

Use a holed plate to simplify the operation.

The assembling tool (fig. 51) protrudes from the housing when the rotor is fitted.

45

Fit the shim and assemble Fig. 7 - 10

et - ou

12

ROTOR ASSEMBLY

46

Push the rotor up against the locking ring.

Check that the locking ring does not move.

47

Remove the assembling tool.

48

Complete assembly (see Fig. 18 - 20)

49

Fit the caps to protect from dust.

Protection against (internal / external) corrosion

50

Puller for rotor.

13

TOOLING / TIGHTENING TORQUE

51

Protector / assembling tool.

52

Heating device.

53

Tightening torque Threading M6 M8 M 10 M 12 M 16

14

Torque Nm 9,8 24,0 48,0 84,0 206,0

Size SW 4 SW 6 SW 8 SW 10 SW 12

HYDROSTATIC MOTOR DISASSEMBLY A 2 FE 75-3-25 EN

09 / 06 / 2000

REPAIRS MOTOR A2FE

1

2

SEAL KIT / SUB-ASSEMBLIES

01

Outer seals.

02

Rotor, mechanical parts with seal kit.

03

Rotor, hydraulic parts with seal kit.

04

Complete rotor with seal kit.

PAGES 2 4 6 8 9 11

SEAL KIT SHAFT SEALS CONNECTION PLATE DISASSEMBLING THE ROTOR CHECKING THE COMPONENTS FITTING THE ROTOR

3

SHAFT SEALS

1

Remove the protective cover.

2

Remove the circlip.

3

Remove the front cover.

4

CHECK PARTS : - shaft seal - cover - drive shaft - housing - “O” ring

5

4

Remove the seal.

SHAFT SEALS

6

Position the shaft seal ring correctly with a suitable sleeve.

7

If the shaft is deeply grooved, insert a shim behind the seal.

8

Fit a new “O” ring; ensure that it is correctly fitted.

Grease the “O” ring and the lips of the seal.

9

Fit the circlip using a punch.

10

Check that the circlip is correctly inserted into its housing.

5

CONNECTION PLATE/SEALS

6

11

Mark the connection plate position on the body (see arrow).

Remove retaining screws.

12

Pivot the connection plate around the centering pin and remove.

13

Identify the position of the centering pin (see arrow).

14

Pump : Right-hand rotation (View of control plate, spherical side)

15

Pump : Left-hand rotation (View of control plate, spherical side)

CONNECTION PLATE/SEALS

16

Motor : both directions of rotation (View of control plate, spherical side)

17

Check visually : - the “O” ring (1) - the groove (2) - the connection plate (3).

18

Lightly grease and position the seal.

19

Refit the connection plate in its initial position (Fig. 11).

Beware of the control plate position.

20

Refit the screws to the appropriate torque (see p. 14).

7

REMOVING THE ROTOR

8

21

Remove the connection plate (page 6). Turn the check plate to remove it.

22

Remove the front plate.

23

Remove the shims.

24

Remove the turning gear with an extractor.

25

Remove the retainer plate; the screws are fixed with Loctite.

CHECKING THE COMPONENTS

26

Drive shaft 1) Free from corrosion, erosion and spline damage.

2) No traces of wear.

3) No cuts, impact marks or pitting.

27

1) Axial play on piston 2) Shoulder

28

Piston Free from marks, no pitting (do not disassemble the joint).

29

Centering head.

1) Free from marks, no pitting (do not disassemble the joint).

2) Free from marks.

30

Retainer plate Free from marks and signs of wear.

9

CHECKING THE COMPONENTS

10

31

Cylinder block/Check plate 1) No marks or signs of wear in bore hole.

2) Faces smooth and flat, free from marks.

3) Min. hardness 700 HV 10.

32

Housing Free from damage and signs of wear on bearing surfaces.

33

Change the piston assembly.

When other components require changing, recalibration is required.

34

Cylinder block and check plate to be changed as a pair.

35

Insert a centering pin with a retaining ring.

Fit the retainer plate correctly.

FITTING THE ROTOR

36

Apply a small amount of Loctite to the screws only.

37

Assemble the shoes and the Belleville washers with grease (use a screwdriver).

38

Ensure that all parts are correctly fitted.

39

Fit the pistons.

40

Press the pistons firmly into the collars with the cylinder block held centrally.

11

FITTING THE ROTOR

12

41

Rock the cylinder block to the max. position (Fig. 40)

42

Is this a new seal ?

(Compare with Fig. 7)

43

Heat the housing to 80°C.

44

Fit the preheated housing.

45

Reposition.

FITTING THE ROTOR

46

Fit the shims and assemble fig. 7-10.

47

Push the rotor against the cover plate.

Check that the cover plate does not move.

48

Complete assembly (see Fig. 18-20).

49

Fit the plugs to protect from dust.

Corrosion protection (inside/outside).

50

Rotor extractor.

13

REPAIR INSTRUCTIONS

14

REPAIR INSTRUCTIONS

General advice • 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.

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

Before starting • Observe the operating instructions before starting.

• Check the machine for obvious faults.

• Do not operate the machine with defective instruments, warning lights or control elements.

• All safety devices must be in a secure position.

• Do not carry with you movable objects or secure them to the machine.

• Keep oily and inflammable material away from the machine.

• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.

• Be careful when entering the driver's cabin, use stairs and handles.

• Adjust your seat before starting.

15

REPAIR INSTRUCTIONS Notes Start • When starting all operating levers must be in "neutral position".

• Only start the machine from the driver's seat.

• Check the indicating instruments after start to assure that all functions are in order.

• Do not leave the machine unobserved when the motor is running.

• When starting with battery connection cables connect plus with plus and minus with minus.

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

Attention • Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms !

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

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 machine.

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 functions 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 !

16