STA Rubber Tyred Roller VP 2400 REPAIR MANUAL - PDF DOWNLOAD

WORKSHOP MANUAL Rubber-Tyred Roller VP 2400 Stavostroj, a.s. Nové Město nad Metují © 9 / 2000

Assembly manual applicable to machines starting with serial number

2

0002

CONTENTS CONTENTS .......................................................................................................................................................... 3 CONTENTS INTRODUCTION ................................................................................................................................................... 6 SAFETY PRECAUTIONS AND INSTRUCTIONS ..................................................................................................... 7 A - REVIEW OF APPLICATIONS ...................................................................................................................... 14 B - ROLLER DESCRIPTION ............................................................................................................................. 15 C - ENGINE..................................................................................................................................................... 18 1. SPECIFICATIONS ................................................................................................................................................................ 18 1.1. ENGINE .......................................................................................................................................................................................... 18 1.2. MOTOR OILS AND GREASE USED .................................................................................................................................................. 19 1.3. COOLANT ....................................................................................................................................................................................... 19

2. DISASSEMBLY OF THE ENGINE .......................................................................................................................................... 21 3. INSTALLATION OF THE ENGINE .......................................................................................................................................... 25 4. RADIATOR DISASSEMBLY AND ASSEMBLY........................................................................................................................ 26 5. LOCATING ENGINE DEFECTS .............................................................................................................................................. 28 6. LOCATION OF CLARK GEARBOX DEFECTS ......................................................................................................................... 30 7. FIXTURES ........................................................................................................................................................................... 31

D - REAR AXLE............................................................................................................................................... 32 1. TECHNICAL DATA - DESCRIPTION ...................................................................................................................................... 32 1.1.

1.2.

1.3.

1.4.

DESCRIPTION ................................................................................................................................................................................. 32 TECHNICAL SPECIFICATIONS ......................................................................................................................................................... 35 TORQUE ......................................................................................................................................................................................... 35 LUBRICANTS AND GLUES .............................................................................................................................................................. 36

2. POSSIBLE DEFECTS AND REMEDIES ................................................................................................................................. 36 3. DISASSEMBLY OF AXLE ..................................................................................................................................................... 37 3.1.

3.2.

3.3.

3.4.

3.5.

PREPARATIONS .............................................................................................................................................................................. 37 AXLE DISASSEMBLY FROM THE MACHINE ..................................................................................................................................... 37 DISASSEMBLY OF DRIVESHAFT ..................................................................................................................................................... 38 DISASSEMBLY OF DRIVE HOUSING ................................................................................................................................................ 40 CLEANING AND INSPECTING PARTS .............................................................................................................................................. 42

4. AXLE ASSEMBLY ................................................................................................................................................................ 43 4.1. DRIVE HOUSING ASSEMBLY .......................................................................................................................................................... 43 4.2. GEARBOX ASSEMBLY .................................................................................................................................................................... 50 4.3. ASSEMBLING AXLE TO THE MACHINE ........................................................................................................................................... 53

5. DIFFERENTIAL LOCK .......................................................................................................................................................... 54 5.1. DESCRIPTION ................................................................................................................................................................................. 54 5.2. POSSIBLE DEFECTS AND REMEDIES ............................................................................................................................................. 56

6. FIXTURES ........................................................................................................................................................................... 57

E - FRONT AXLE............................................................................................................................................. 58 1. TECHNICAL DATA ............................................................................................................................................................... 58 1.1.

1.2.

1.3.

1.4.

VP 2400

DESCRIPTION ................................................................................................................................................................................. 58 SPECIFICATIONS ............................................................................................................................................................................ 58 TORQUE VALUES ........................................................................................................................................................................... 59 LUBRICANTS AND GLUES .............................................................................................................................................................. 59

3

CONTENTS 2. DEFECTS AND REMEDIES .................................................................................................................................................. 60 2.1. INSPECTION OF INSTALLATION OF FOUR FRONT WHEELS ............................................................................................................. 60

3. AXLE DISASSEMBLY .......................................................................................................................................................... 61 3.1.

3.2.

3.3.

3.4.

3.5.

PREPARATORY WORK ................................................................................................................................................................... 61 DISASSEMBLY OF AXLE FROM THE EQUIPMENT ............................................................................................................................ 62 DISASSEMBLY OF GUIDING PIPE OF THE FRONT AXLE ................................................................................................................... 63 DISASSEMBLY OF FORK ................................................................................................................................................................. 64 CLEANING AND INSPECTION OF PARTS ......................................................................................................................................... 66

4. INSTALLATION OF FRONT AXLE ......................................................................................................................................... 67 4.1.

4.2.

4.3.

4.4.

INSTALLATION OF GUIDING PIPE AND FORK .................................................................................................................................. 67 ASSEMBLY OF WHEEL HUBS AND SHAFT ...................................................................................................................................... 69 ASSEMBLY OF FORK AND SHAFT ASSEMBLY WITH WHEEL HUBS ................................................................................................. 71 ASSEMBLY OF AXLE TO THE MACHINE .......................................................................................................................................... 73

5. FIXTURES ........................................................................................................................................................................... 74

F - FLEXIBLE SHAFT ...................................................................................................................................... 77 1. SPECIFICATIONS ................................................................................................................................................................ 77 1.1.

1.2.

1.3.

1.4.

DESCRIPTION ................................................................................................................................................................................. 77 SPECIFICATIONS ............................................................................................................................................................................ 77 TORQUE ......................................................................................................................................................................................... 77 GREASE ......................................................................................................................................................................................... 77

2. POSSIBLE DEFECTS AND REMEDIES ................................................................................................................................. 78 3. DISASSEMBLY AND RE-ASSEMBLY ................................................................................................................................... 78 3.1. PREPARATORY WORK ................................................................................................................................................................... 78

G - STEERING................................................................................................................................................. 79 1. SPECIFICATIONS - DESCRIPTION....................................................................................................................................... 79 1.1. DESCRIPTION ................................................................................................................................................................................. 79 1.2. TECHNICAL DATA ........................................................................................................................................................................... 79 1.3. LUBRICANTS AND GLUES .............................................................................................................................................................. 82

2. POSSIBLE DEFECTS AND REMEDIES ................................................................................................................................. 83 3. DISASSEMBLY AND ASSEMBLY OF THE STEERING ASSEMBLY ........................................................................................ 84 3.1.

3.2.

3.3.

3.4.

3.5.

3.6.

PREPARATORY WORK ................................................................................................................................................................... 84 DISASSEMBLY OF STEERING HYDRAULIC GENERATOR U10 ......................................................................................................... 85 DISASSEMBLY OF POWER STEERING ............................................................................................................................................ 86 DISASSEMBLY OF LINEAR HYDRAULIC MOTOR ............................................................................................................................. 87 REMOVAL OF POWER STEERING TANK .......................................................................................................................................... 88 REMOVAL AND INSTALLATION OF THE LEVER ASSEMBLY ............................................................................................................. 89

4. ADJUSTMENT OF TOE-IN ................................................................................................................................................... 90 5. FIXTURES ........................................................................................................................................................................... 92

H - SERVICE BRAKE ....................................................................................................................................... 93 1. SPECIFICATIONS ................................................................................................................................................................ 93 1.1. DESCRIPTION ................................................................................................................................................................................. 93 1.2. SPECIFICATIONS ............................................................................................................................................................................ 96 1.3. BRAKE FLUID ................................................................................................................................................................................. 98

2. DEFECTS ............................................................................................................................................................................ 98 3. DISASSEMBLY AND INSTALLATION.................................................................................................................................. 100 3.1. PREPARATIONS ............................................................................................................................................................................ 100 3.2. DISASSEMBLY OF PEDAL BRAKE ................................................................................................................................................ 100 3.3. DISASSEMBLY OF BOOSTER ........................................................................................................................................................ 101 3.4. DISASSEMBLY OF BRAKE SYSTEM .............................................................................................................................................. 102

4

VP 2400

CONTENTS 4. BRAKE SHOES ADJUSTMENT .......................................................................................................................................... 103 5. SERVICE BRAKE VENTING ................................................................................................................................................ 104 6. MACHINING BRAKE DRUMS ............................................................................................................................................ 104

I - PARKING BRAKE .................................................................................................................................... 105 1. SPECIFICATIONS - DESCRIPTION..................................................................................................................................... 105 1.1. DESCRIPTION ............................................................................................................................................................................... 105 1.2. SPECIFICATIONS .......................................................................................................................................................................... 105

2. MAINTENANCE ................................................................................................................................................................. 106 2.1. DISASSEMBLY AND INSTALLATION OF THE DISK BRAKE ............................................................................................................. 106 2.2. REMOVAL AND INSTALLATION OF THE SPRING-LOADED CYLINDER ............................................................................................ 107

J - INFLATING THE TIRES ............................................................................................................................ 108 1. SPECIFICATIONS .............................................................................................................................................................. 108 1.1. DESCRIPTION ............................................................................................................................................................................... 108 1.2. SPECIFICATIONS .......................................................................................................................................................................... 108

2. REMOVAL AND INSTALLATION ......................................................................................................................................... 109 2.1. CONTROL VALVE .......................................................................................................................................................................... 109 2.2. ROTOR ......................................................................................................................................................................................... 109

K - WHEELS ................................................................................................................................................. 110 1. SPECIFICATIONS .............................................................................................................................................................. 110 1.1. DESCRIPTION ............................................................................................................................................................................... 110 1.2. SPECIFICATIONS .......................................................................................................................................................................... 110

2. REMOVAL OF WHEELS ..................................................................................................................................................... 110 2.1. PREPARATION FOR WORK ........................................................................................................................................................... 110 2.2. FRONT AXLE WHEELS .................................................................................................................................................................. 110 2.3. REAR AXLE WHEELS ................................................................................................................................................................... 111

3. REMOVAL AND INSTALLATION OF TIRES ......................................................................................................................... 112 4. INSTALLATION OF WHEEL TO THE MACHINE................................................................................................................... 112 5. SAFETY VALVE ADJUSTMENT .......................................................................................................................................... 112

L - ELECTRICAL WIRING .............................................................................................................................. 113 1. DESCRIPTION ................................................................................................................................................................... 113 1.1. BATTERY BREAKER ..................................................................................................................................................................... 114

2. BATTERY........................................................................................................................................................................... 116 2.1.

2.2.

2.3.

2.4.

2.5.

SPECIFICATIONS .......................................................................................................................................................................... 116 OPERATION .................................................................................................................................................................................. 116 INDICATIONS OF FULL CHARGE ................................................................................................................................................... 117 SERVICE DURING OPERATIONS ................................................................................................................................................... 117 SAFETY REGULATIONS ................................................................................................................................................................ 118

3. ALTERNATOR .................................................................................................................................................................... 119 3.1. CHECKING THE ALTERNATOR ON THE ROLLER ........................................................................................................................... 119 3.2. DETERMINING DEFECTS OF ALTERNATOR-REGULATOR .............................................................................................................. 120 3.3. VOLTAGE REGULATOR ................................................................................................................................................................. 120

4. STARTER .......................................................................................................................................................................... 121 4.1. OPERATION AND MAINTENANCE ................................................................................................................................................. 121 4.2. CHECK OF IDLING – ON THE MACHINE ........................................................................................................................................ 121 4.3. STARTER DEFECTS ...................................................................................................................................................................... 121

VP 2400

5

INTRODUCTION

INTRODUCTION The roller, series VP 2400, is designed for compacting operations of medium to large magnitudes in the construction of highways, railroads, airports, dams, industrial tracts, harbors, etc. Specifications of the machine, weight, tire sizes, turning radius, leveling of front wheels, and the first-rate engine, provide for an efficient roller with very good output, high reliability, and safety in operations. The fact that the inflation of tires can be adjusted continuously allows for compacting of all kinds of materials in a wide range of consistency, and for the optimal adaptation of the roller.

The roller is well suited for compacting asphalt mixtures, hydraulically compacted mixtures, clay soils, and soil mixtures of sand and gravel. However, it is nor suited for rockfills.

The roller operates under conditions specified in standards ČSN IEC 721-2-1 (038900): WT, WDr, MWDr - that is mild, warm and dry, hot and dry environment at temperatures of –15 °C (5 °F) to 45 °C (113 °F).

The roller is manufactured to most modern rules and standards of work safety.

There exists danger of damage or injury, should the roller be applied incorrectly, by untrained personnel, or for other than specified purposes.

The main purpose of this manual is to provide basic information for the disassembly, assembly, and service of the main construction elements of the roller. The manual consists of separate chapters in reference to the catalogue of spare parts, and contains data on assembly, adjustment, and instructions for the application of special tools and fixtures.

The manufacturer improves the product continually under application of the most recently gained experience and know-how, and for that reason, reserves the right to install modifications that have not been included in the pictures, descriptions, and/ or construction details of this manual.

This Manual is copyrighted and it is not permitted to copy and distribute it or its parts.

The text in this Manual refers to right, left, forward, or backward from the direction of forward travel.

6

VP 2400

SAFETY PRECAUTIONS AND INSTRUCTIONS

SAFETY PRECAUTIONS AND INSTRUCTIONS THESE SAFETYREGULATIONS MUST BE OBEYED BY ALL THAT MAINTAIN THE ROLLER! • The roller may be maintained only by a trained, certified, and experienced professional, or by the STA Service.

• Maintenance should always follow our Service Shop Manual. Each chapter contains special instructions for proper maintenance procedures.

• Before using the roller, become acquainted with the Driver’s Manual, and make sure that you understand the equipment of the roller completely.

• Never use the machine, unless you understand all control elements and the operation of the roller.

• Become acquainted with the site, where you work.

• Do not re-build or modify the roller, since the stability of the machine may be disturbed.

• Original parts and accessories have been designed especially for the roller • Installation and use of spare parts not supplied with the roller or not authorized by the manufacturer may have a detrimental effect on the operation and safety of the machine.

SAFETY PRECAUTIONS FOR REPAIR AND INSPECTION OF THE MACHINE • Wear work clothes and shoes.

• When handling oil, fuel, and/or coolant always wear gloves.

• Wear glasses or goggles, when handling batteries.

• Situate the roller on a flat, firm ground before you start repair. Wedge the machine.

• Secure the frame and the drum against turning against each other by a safety pin and a push rod.

• Remove the key from ignition, disconnect batteries, and let hot parts cool off.

• Attach a warning label ”The Machine is being repaired” on the steering wheel and leave it there until finished.

• Wash the roller thoroughly. If using hot steam, avoid direct stream affecting electrical components and insulation, or cover it beforehand.

• During assembly and service repair of particular assemblies, keep them clean. Protect removed parts from dirt.

• Clean removed parts and provide dust-free shop area with a necessary area for depositing parts.

• Be careful with cleaners. Do not use gasoline or other flammables!

• Dry cleaned parts and apply anti-corrosion oil – never use corroded parts!

• All tools, hoists, supports and other fixtures must be in a useable shape and condition.

• Hoists, cables, and chains should be of sufficient carrying capacity, and undamaged.

• Provide sufficient air supply, when starting the engine in closed areas.

• Before starting the roller, make sure that nobody is in the vicinity. The start of the engine must be announced by a warning sound beforehand and after every pause before the roller starts moving. Persons on the machine or its vicinity must leave after the sound. Sound, light, and hand signals should be used as specified in ČSN 27 7012 standard, Appendix no.1.

• Do not adjust while moving.

• During work on a running engine, avoid contact with hot and rotating parts of the roller. Adjustments in such cases must be done while another person is nearby, who has access to emergency switches and is in continuous contact with the service person, so that the engine could be turned off immediately when needed.

• Use only specified types of motor, transmission, and hydraulic oils, and coolant.

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7

SAFETY PRECAUTIONS AND INSTRUCTIONS SAFETY RULES FOR WORK ON HYDRAULIC LOOPS • Check, whether hydraulic loops are not under pressure, before disassembly. Hydraulic oil seeping under pressure may injure your skin and cause serious injury.

• Mark all parts, hoses, and pipes before removal.

• Do not run hydraulic generator and hydraulic motor with oil.

• Hot oil may burn the skin.

• Do not heat oil to temperatures above 160 °C - oil or its vapors may catch fire.

• For wiping and cleaning of hydraulic parts use lint-free rags.

• For assembly and installation of parts use hydraulic oil as lubricant – not grease.

• Clean thoroughly all threads, hoses, and pipes, wash them and blow with pressurized air.

• Use only new seals.

• Fill devices with hydraulic oil before installation.

• Following the replacement of a hydraulic device, flush the hydraulic loop and the tank.

• Replace the oil filter cartridge.

• Fill the hydraulic loop with clean oil of prescribed viscosity, only when the engine is off.

• Wipe off spilled oil.

• Check the tightness of joints for seeping oil before the system is pressurized.

• Finally, check all joints and connections.

• Do not adjust safety valves.

• Install all safety elements before finishing work.

WHILE RUNNING CHECK • Oil level in the hydraulic tank.

• Fill pressure of hydraulic generators and safety valves pressure.

• Test at 40 °C (104 °F).

8

VP 2400

SAFETY PRECAUTIONS AND INSTRUCTIONS SAFETY PRECAUTIONS WHEN WORKING OF THE FUEL SYSTEM Gasoline and diesel fuel mixtures are as flammable as pure gasoline -

Do not fill in closed areas

-

Wipe off spilled fuel

-

During work do not use open flame and do not smoke! Danger of fire!

SAFETY PRECAUTIONS WHEN WORKING ON ELECTRICAL WIRING • Disconnect batteries when repairing the charging circuit to avoid accidental shorts.

• When disconnecting, remove first the negative pole and then the positive.

• Do not disconnect while the engine is running.

• Connect the negative pole to chassis, and the positive pole to the alternator output B+. Otherwise, the entire semiconductor circuit would be damaged.

• When starting from an auxiliary external source, do not disconnect the source before the battery is in. Watch for the voltage of the source – 24V.

• Do not run the alternator without load. Conductor on terminal B+ should be on and terminal D+ as well.

• Do not check for voltage by touching conductor against the chassis.

• Do not produce sparks.

• Use rubber gloves and eye protection, when working with the battery.

• Protect your skin and clothing against the electrolytic and lead particles.

• Should electrolyte enter your eye, wash the eye thoroughly for a few minutes with water. Thereafter, see your doctor as soon as possible.

• After coming in contact with the electrolyte on your skin or clothing, disrobe, wash off the affected spot by soapy water or soda solution, and see your doctor.

• If you swallowed electrolyte, drink a large quantity of milk or dissolved magnesia in water, and see your doctor.

• Never add distilled water in the cells, unless followed by a charging process, in the machine or outside. Involuntary discharge would follow otherwise.

• Never fill with sulfuric acid (H 2SO4)!

• Battery shouldn’t be turned upside. The electrolyte would start seeping through aerating holes.

• Use water and lime to neutralize spilled electrolyte.

• When batteries are being charged, the emanating hydrogen mixes and air create a highly explosive mixture. Do not approach with open flame, and do not smoke.

VP 2400

9

SAFETY PRECAUTIONS AND INSTRUCTIONS WELDING ON THE MACHINE Before electrical arc welding on the machine, all components containing semiconductors must be disconnected from the ·

alternator

·

operating hours counter

·

travel and shifting electronic assemblies

·

Ground the source and the machine

·

protect the source against moisture

·

place the ground terminal as close as possible to the weld.

Attention!

• During welding, protect plastic tubes WABCO Tecalan in the air loop, and Schlemmer plastic hoses in the electrical circuit.

• The maximum permissible temperature for the WABCO tubes without pressure is 130 °C (266 °F) for 60 minutes.

• When welding a part on a machine attached to a hoist, the tying spot must be isolated or a non-conductive tie should be used, like a cable of organic material, to prevent the current from flowing through the hoist.

SEALS • Always use new seals.

• Sets of seals are available as spare parts.

TORQUE • Use torque wrench for tightening bolts to the correct torque.

• Bolts and nuts are tightened to the correct torque listed in the table.

• The correct type of bolt is visible on the head.

• Other torque values are specified in applicable chapters.

• Threaded connections in hydraulic loops are tightened according to tables.

• Specified torque values are valid for not lubricated screws.

• Use only new self-locking nuts.

10

VP 2400

SAFETY PRECAUTIONS AND INSTRUCTIONS ECOLOGICAL AND HEALTH PROVISIONS In repairing the machine, observe rules of environment and health protection, laws, notices, and regulations valid in the territory of use.

HEALTH PROVISIONS • Oil products, coolants, battery content, and lacquers with thinners are injurious to health, and may cause severe injuries when in contact with the body.

• It is therefore necessary to observe safety and health protection instructions and use personal protection when handling these products.

• Workers handling these products must obey general rules of protection and follow instructions issued by the manufacturers of such products.

• We draw your attention primarily to -

eye and skin protection when handling batteries

-

skin protection when handling oil products, lacquers, and coolants

-

washing your hands after work and before meals, application of special skin creams

-

instructions supplied with the cooling systems.

• Keep oil products, coolants, battery fills, lacquers with thinners, cleaning and preservation chemicals in original containers properly described on the outside. Do not allow their storage in unmarked bottles and other containers to avoid danger of substitution, mainly for food or drink.

• Should the skin, mucous membranes, or eyes come in contact, or should vapors be inhaled, apply first aid immediately.

In case of accidental consumption, see your doctor immediately.

ECOLOGICAL PROVISIONS • Contents of some systems and some of the parts become waste bearing risks to the environment, when discarded.

• This category includes mainly -

organic and synthetic lubricants, oils, and fuel

-

coolants

-

batteries and their contents

-

cleaning and preservation chemicals

-

all removed filters and cartridges

-

all removed hydraulic and fuel hoses, rubberized metal parts, and other parts soiled by above-mentioned chemicals.

• Such parts and chemicals must be handled in accordance with national standards for the protection of the environment and health.

• When replacing hydraulic, fuel, and cooling systems, seepage of liquids in the ground must be prevented by suitably placing catch basins underneath, and openings must be plugged.

• Apply sawdust, Vapex, etc. to places of seepage in the ground.

• Remove soiled ground to prevent continuous seepage, and transfer contaminated soil to further liquidation.

VP 2400

11

SAFETY PRECAUTIONS AND INSTRUCTIONS FIRE PREVENTION • Used flammable fluids are separated into danger classes II.

danger class - diesel fuel

IV. danger class - mineral oils - grease - anti-freeze

• The place for oil changes must be situated away from areas with danger of explosion or fire.

• Such place must be provided with information boards forbidding smoking and open flame.

• The working area must be of a size large enough to contain the contents of the largest fuel container.

• It must be equipped with a portable fire extinguisher.

• For handling oils and diesel fuel use metal barrels, cans, and/or metal pails.

• Such vessels must be properly closed in storage.

• Cans with one opening must be stored with the opening up, and protected against dripping.

• The cans must be indelibly described as to contents and fire danger class.

RELATED REGULATIONS The following standards and regulations must be complied with:

Valid regulations for work safety, and health protection regulations during operation and maintenance Valid regulation of fire prevention Valid regulations on flammable materials Valid regulations on health and environment protection related to the operation of the machine Valid regulations on handling of dangerous material and waste.

12

VP 2400

SAFETY PRECAUTIONS AND INSTRUCTIONS EQUIPMENT ACCESSORIES INCLUDE Catalogue ND VP 2400 Operation Instructions for roller series VP 2400 ND catalogue for the installed engineInstructions for the operation and maintenance of the installed engine.

GENERAL SERVICE TOOLS FOR THE MAINTENANCE AND ADJUSTMENT TO ISO 4510-1 STANDARD. SPECIAL TOOLS AND FIXTURES AS LISTED IN SPECIFIC CHAPTERS OF THE MANUAL

VP 2400

13

A - REVIEW OF APPLICATIONS

A - REVIEW OF APPLICATIONS

Fig. A/1

The serial and type numbers are important for the identification of the machine in case of warranty claim. The label with the main machine data is attached on the left side of the frame, Fig. A/1.

The label with Cummins engine and other data is attached to the injection drive and steering pump case, Fig. A/2.

Serial numbers and data of subcontracted aggregates are to be found stamped in them.

Fig. A/2

14

VP 2400

B - ROLLER DESCRIPTION

B - ROLLER DESCRIPTION The VP 2400 roller is constructed on a welded box frame. The frame contains the engine with a three-speed reversible gearbox with torque converter. The gearbox is connected by a flexible shaft to the rear axle with the differential and brakes. Steered telescopic axle without brakes is mounted in the front section of the frame. The front and rear axles are suspended so that the wheels of one axle overlap the space between the wheels of the other axle longitudinally. Steering is hydraulic by means of steering rods and levers controlled by a linear hydraulic motor, which is supplied with pressurized oil from a geared hydraulic generator over power assisted steering assembly controlled by the steering wheel. Operating brakes are hydraulic, drum-type, with pressurized hydraulic power assistance on the rear wheels. The driver’s compartment has two seats fixed to the frame, and is equipped with dual steering, travel and other controls. The driver’s compartment is protected by a cabin, or a guard railing sheltered by a roof.

ACCESSORIES: Guard railing ROPS protects the driver in case of roller upset. See data on label.

Differential lock improves the movement of the roller in difficult terrain (on inclines) with low adhesion, when driving up a loading platform, in assisting in emergency situations, etc.

Additional load - 4,5 t (9922 lb) Weight assisting plates (5 pieces) installed underneath the frame between the wheels.

Wheel covers Insulating wheels by means of covers installed on the frame when compacting asphalt surface.

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15

B - ROLLER DESCRIPTION SPECIFICATIONS ENGINE Manufacturer

CUMMINS Engine Company, Inc.

Type

4BT3.9 C-105

Number of cylinders

4

Power to ISO 3046/1, DIN 6271 kW (HP) -1

Nominal revolutions min (RPM)

78 (105) 2400

Water-cooled Engine complies with emission regulations 97/68/EC, EPA, CARB.

OPERATING WEIGHTS TO ISO 6016 - KG (LB) Roller,cabin,ROPS,wheel covers Weights under the frame Sand in the frame Steep in the frame 12440 (27425)

4500 (9920)

12440 (27425)

4500 (9920)

12440 (27425)

4500 (9920)

Total weight 16940 (37346)

4000 (8818)

20940 (46164) 7060 (15565)

24000 (52910)

ISO 6016 indicates weight including the limit of operating fluids.

Other weight data for specific types of machine listed in Specifications Manual, Chapter 1.3.1.

OVERALL DIMENSIONS

16

Total length

mm (in)

4775 (188)

Total width

mm (in)

2265 (89,2)

Axle base

mm (in)

3500 (137,8)

Wheel base

mm (in)

1580 (62,2)

Height incl. cabin

mm (in)

3040 (119,7)

Clearance

mm (in)

300 (11,8)

VP 2400

B - ROLLER DESCRIPTION DRIVING PROPERTIES: Speed in both directions in specific gears I. gear

II. gear

III. gear

Climbing with full load

km/h

0-5

MPH

0 - 3,1

km/h

0 - 11

MPH

0 - 6,8

km/h

0 - 19

MPH

0 - 11,8

%

25

Turning radius Inside track - outside Contour inside - outside

mm (in)

left

right

5350 (210,6)

5800 (228,3)

mm (in)

8150 (320,9)

8250 (324,8)

mm (in)

5350 (210,6)

5580 (219,7)

mm (in)

8350 (328,7)

8630 (339,8)

FLUID CONTENT: Motor oil in crankcase

l (gal US)

15,5 (4,1)

Oil in gearbox

l (gal US)

21,5 (5,68)

Oil in differential

l (gal US)

13,5 (3,57)

Oil in end gearbox

l (gal US)

2x5,2 (2x1,4)

Oil in hydraulic steering

l (gal US)

6,5 (1,72)

Oil in telescopic front axle

l (gal US)

6 (1,6)

Fluid in brakes

l (gal US)

0,75 (0,2)

Diesel fuel in tank

l (gal US)

250 (66)

Water in tires sprinkling tank

l (gal US)

285 (75)

Voltage

V

24

Batteries

Ah

2 x 100

ELECTRICAL WIRING

VP 2400

17

C - ENGINE

C - ENGINE 1. Specifications 2. Engine disassembly 3. Engine assembly 4. Radiator disassembly and assembly 5. Locating engine defects 6. Locating defects in CLARK gearbox 7. Fixtures

1. SPECIFICATIONS 1.1. ENGINE Manufacturer

Cummins Engine Company, Inc.

Engine model

4BT3.9 C-105

Type of engine

diesel, water-cooled

Number of cylinders

4

Bore

mm (in)

102 (4,02)

Lift

mm (in)

120 (4,72)

3

Lift volume

cm (cu in)

3922 (239,3)

Engine power to ISO 3046/1, DIN 6271

kW (HP)

78 (105)

–1

(RPM)

Nominal revolutions

1.min

Normal operation fuel consumption (depends on machine load and application)

l/h (US gal /hour)

Fuel filter make

2400 (2400) 7,3 (1,93) to12,8 (3,38) FLEETGUARD FF1280 and FF5052

Oil filter make

FLEETGUARD LF3345

Air filter make – dry filter with a rotary pre-cleaner

DONALDSON FPG 08-2503

Markings of air-filter cartridges main cartridge

P77 – 2580

safety cartridge

P77 – 5302

Injection pump */

Bosch ES4 A95D 320/3 RS2880

Alternator make */

Bosch K1 14V 23/65A

Starter make */

Delco-Remy 12V

Fuel tank volume

l (US gal)

250 (66)

Engine complies with emission regulations 97/68/EC, EPA, CARB. */ Type and markings may vary (delivery with Cummins engine). State always the serial number of the applicable engine when ordering spare parts.

18

VP 2400

C - ENGINE 1.2. MOTOR OILS AND GREASE USED Motor oil

Oil in the engine

Make

Quantity [l]

16,4

Benzina

Quantity [gal US]

4,4

M7ADS III

Mobil

ESSO

SHELL

CASTROL

SAE 15 W/40 API CE/ SGE, ACEA E1-E2, CCMC D2-D3

Grease Synthetic grease containing lithium to NLGI-2* must be used. * - NLGI (National Lubricating Grease Institute, part 2) Grease – make BENZINA P-ML-A2

MOBIL

ESSO

SHELL

CASTROL

Mobilgrease MP

Multi-Purpouse

Retinax A

Castrolease LM

Mobilgrease Special

Grease H

Alvania

Spherol

Grease No.3

Grease RBB2

Mobilplex EP-1

1.3. COOLANT For cooling the engine use coolant containing 50% of ethylene-glycol antifreeze and 50% water, see table, down to –37 °C (–35 °F) year round. Use coolant containing antifreeze even in regions where temperature doesn’t drop below 0 °C (32 °F).

The coolant doesn’t only protect the cooling system against freezing, but also increases the boiling point. The inhibitors in the antifreeze protect parts of the cooling system of the engine, and extend their life. In addition, propylene antifreeze may be used in the cooling system. The content of the ethylene glycol or propylene glycol antifreeze must be at least 40% of the coolant.

Mix the coolant by adding antifreeze to water. Use water that complies with the rules of the following table: Water parameters

min.

pH - factor at 20°C (69°F)

6,5

8,5

content of chlorides (mg/dm3 )

-

100

content of sulfates (mg/dm3)

-

100

total hardness (°dGH)

3

12

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max.

19

C - ENGINE Antifreeze must contain anti-corrosive ASTM 4985. For instance, SUNOCO ANTIFREEZE or CASTROL ANTI-FREEZE may be used.

The content of antifreeze in the coolant at different temperature levels is indicated in the following table: Ethylene-glycol antifreeze 40 %=-23 °C (-10 °F) 50 %=-37 °C (-35 °F) 60 %=-54 °C (-65 °F) 68 %=-71 °C (-90 °F) Propylene-glycol antifreeze 40 %=-21 °C (-6 °F)

• Do not use more than 50% of antifreeze in the coolant, unless absolutely necessary.

• Never use more than 68 %!

• Use antifreeze that is environment friendly.

• Antifreeze fluids are formulated on different bases.

• We do not recommend mixing them, since deterioration of their anti-corrosive properties may result.

• When mixing nitride-based antifreeze with amino based fluids, the resulting nitric amine is injurious to health.

• Check the content of antifreeze in the coolant prior to the arrival of winter, using densimeter.

50 %=-33 °C (-27 °F) 60 %=-49 °C (-56 °F) 68 %=-63 °C (-82 °F)

20

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C - ENGINE 2. DISASSEMBLY OF THE ENGINE

Fig. C/1

Perform all work prior to and during disassembly and assembly in accordance with the introductory chapter on Safety, and comply with ecological and health protection rules and regulations.

Preparatory work

1

• Place the machine horizontally on a firm surface.

• Wedge front wheels on both sides.

• Turn the battery breaker off – brakes are automatically applied.

2

• Place a sign on the steering wheel “MACHINE BEING REPAIRED”.

Remove the protective frame ROPS

• Remove cover plates 1 behind the seat in front of the fuel tank, Fig. C/1.

• Install lifting loops on ROPS frame, hook up by hoist of at

Fig. C/2

least 450-kg carrying capacity.

• Unfold lid 2.

• Unscrew nuts 1 on the right and left side that attach ROPS 1

to the frame of the machine, Fig. C/2.

• Insert bolts so that they be outside the holes in the machine frame.

• Lift the frame out of the machine.

2

Remove the cabin

Attention – disconnect electrical wiring between the cabin and the machine, Fig. C/3.

Fig. C/3

!

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21

C - ENGINE Fig. C/5

Disassembly within the frame

• Disconnect hoses from the compressor.

• Drain on the right side of the machine, Fig. C/4 -

coolant 1

-

motor oil 2

-

gearbox oil 3

24

• By pulling ring 24, drain pressurized air from the air-tank using the drainage valve, Fig. C/5.

• On rollers with cabin, remove floor covering and floor plates.

• Remove engine hood.

• Remove engine suction basket bracket from the frame, Fig. C/6.

• Remove propeller shaft from the gearbox, Fig. C/7.

Fig. C/6

Fig. C/4

Fig. C/7

3

22

2

1

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C - ENGINE • Remove steering hydraulic generator – do not disconnect

Fig. C/9

hoses, Fig. C/8.

• Disconnect from the box in the frame floor, Fig. C/9.

-

coolant drain hose from the engine block 1

-

engine oil drain hose 2

-

Gearbox oil drain hose 3

1

• Disconnect heater hoses • Disconnect electrical wiring from : -

Gear shifting

-

temperature sensor

-

starter and breaker

-

pressure oil switch

-

alternator

-

chassis

-

pressure switch

• Remove exhaust piping.

• Remove air suction with the filter.

2 3

Fig. C/10

• Remove gas pedal cable with the bowden.

• Disconnect hose from fuel input and overflow pipe from the fuel pump.

• Remove attachment of platform to the frame, and slide platform towards the seats.

• Using fixture no. 1 remove bolts 51and nuts 68 attachment of the front beam assembly 1 to the frame, Fig. C/10.

• Remove nuts 30, attachment of the gearbox to the frame,

51

51

68

68

Fig. C/11.

Fig. C/8

Fig. C/11

30 30

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23

C - ENGINE • Attach engine to lift hooks, place a rope underneath the

• Disassembly of the engine.

gearbox, hook up using fixture no. 2, lift slowly, remove from frame, and place on support no. 3. Remove the suction basket and radiators.

-

Loosen tightening screw of the alternator, remove belt, then the alternator, the starter, and the fan.

• Place the engine together with the gearbox on a suitable

-

Remove brackets, supports and springs from the engine.

wooden frame, and secure against tipping over.

• Remove gearbox.

-

Unscrew brackets off the gearbox,

-

disconnect radiator hoses,

-

hook up the gearbox on the hoist using fixture no. 4, Fig. C/12,

-

remove lid, Fig. C/13,

-

turn the propeller shaft with the flywheel by the belt Fig. C/14, and remove eight screw connecting the engine to the gearbox.

-

For reassembly of brackets to the gearbox use torque 300 Nm (221 lb ft).

Let specialized service disassemble or repair the engine from that point on.

Fig. C/13

Fig. C/12

24

¹. 4

9

¹. 4

Fig. C/14

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C - ENGINE 3. INSTALLATION OF THE ENGINE

• Install safety frame ROPS. -

Insert attachment bolts into holes of frame ROPS so that the threads of the bolts don’t show on the front side of the holes.

-

Place ROPS in the frame using the hoist.

-

Insert bolt in the frame, secure with nuts 1, and tighten with torque of 700 Nm (516 ft lb), see Fig. C/2.

-

Install cover plates behind the seats.

-

Remove lifting hooks and insert screws instead.

• Place the engine on a suitable support and prevent it from tipping over.

• Attach gearbox to the engine, level horizontally using fixture no. 4.

• Place the assembly of the engine and the gearbox on fixture no. 3, attach radiator with the suction basket to the engine.

• Connect radiator hoses.

• Hook up the engine on the hoist using fixture no 2 and install in the machine frame.

• Thereafter install the steering hydraulic generator, connect all electrical wiring, draining assembly on the engine and the gearbox.

• Connect control cable to the injection pump, and fuel lines.

• Connect propeller shaft to the gearbox, hose to the compressor output

• Assemble intake and exhaust manifolds.

• Install dashboard, hood, and cabin.

• Fill up the engine and gearbox with appropriate fluids.

• Install cabin, connect wires, Fig. C/3.

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25

C - ENGINE 4. RADIATOR DISASSEMBLY AND ASSEMBLY • Remove front cover, hood, and grill.

• Disconnect radiator hoses and remove expansion tank.

• Remove suction basket bracket, Fig. C/15, and screws at the bottom of the basket Fig. C/16.

Fig. C/15

26

Fig. C/16

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C - ENGINE • Remove air collector and move it towards the engine, Fig. C/17.

• Remove two screws at the bottom of the radiator, Fig. C/18, and two screws attaching the radiators to the frame.

• Lift the radiators using hoist.

• Assemble in reverse order, center the air collector to the cooling fan.

Fig. C/18

Fig. C/17

% VP 2400

27

C - ENGINE 5. LOCATING ENGINE DEFECTS Defect

Cause

Possible remedy

Engine doesn't start, starter

No fuel

Add fuel, and bleed air

Leaks, air locks in fuel lines

Check and repair leaks. pump fuel manually,

is turning

bleed air from lines Fuel strainer, filters and lines plugged

1. clean filter and lines 2. Replace filters

Fuel strainer, filters and lines plugged with paraffin in winter time

1. clean filter and lines 2. replace filters 3. replace fuel

Engine doesn't start, starter not turning at all or slowly

Too heavy oil used in winter time

Use suitable oil for actual temperature

Incorrect wiring, indicators don't light up

Connect wiring by breaker

Travel control not in neutral - neutral indicator not on

Shift lever to neutral

Loose or oxidized terminals on starter, ground cable, battery faulty

1. Tighten terminals, clean, grease 2. Check starter cables 3. Check ground cable 4. Check batteries for electrolyte level and density

Starter

Check connections and pinion movement (solenoid)

Engine overheats

28

Starting relays

Check leads and switches

Engine electrical stopping

Check leads and operation

Insufficient level of coolant

Stop the engine immediately, add fluid, find leaks, repair

Radiator plugged

Remove dirt

Belt loose or broken

Repair, replace belt

Thermostat incorrect

Check function of thermostat, replace

The cooling loop contains too much dirt

Clean cooling loop

Faulty injectors

Service inspection

Incorrect amount of fuel set in injector pump

Service set-up

Ambient temperature too high

Limit working period and let engine cool off

Incorrectly adjusted start of injection

Service inspection

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C - ENGINE

Závada

Pravděpodobná příčina

Odstranění (určení) závady

Engine incorrectly

Oil level too low

Add oil

lubricated lubrication

Oil leaks in the oil loop

indicator on

Engine runs irregular and low power

Engine smokes too much

High use of oil

Low power

Stop the engine immediately, check oil lines and filter for leaks. Repair.

Motor oil of incorrect viscosity for the momentary ambient temperature

Replace oil with recommended viscosity

Engine overheated

Let engine cool off, investigate

Air locks in fuel lines

Bleed, repair leaks

Defective injectors

Service inspection

Incorrectly set valves

Service inspection

Broken injector tube

Service inspection

Incorrectly adjusted injection pump

Service inspection

Increased vacuum in intake manifold

Check vacuum switch, replace gaskets

Oil level too high

Decrease to mark on dip stick

Defective compression due to burnt or broken rings, or

Let service check rings and cylinders, adjust

incorrect set-up of valves

valves

Leaks in oil loop

Repair leaks

Rings leaky, or engine worn out

Service inspection

Excessively soiled fuel filters

Replace filters

Incorrect valve gaps

Adjust valves

Plugged holes in injectors, injectors not set to correct

Service inspection

pressure Injection pump incorrectly adjusted. Fuel advance injection incorrect. Cylinders have defective

Service inspection

compression. Turbo fans not working properly Additional information on engine defects are in Engine Manual supplied with the machine.

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29

C - ENGINE 6. LOCATION OF CLARK GEARBOX DEFECTS Defect

Cause

Remedy

Low pressure of clutch

Low level of oil

Add oil to prescribed level

Gate in the control valve of the clutch is stuck

Clean valve and housing

in open position Filling pump is not functioning

Replace pump

Broken or worn gasket rings of the propeller

Replace gaskets of clutch or piston

shaft

Insufficient power of changer

Overheating

Converter is noisy

Exhaust valve of piston stuck open

Clean thoroughly exhaust valve

Low oil level

Add oil to prescribed level

Plugged intake sieve

Clean intake sieve

Faulty filling pump

-Replace pump - service

Low engine rpm

Adjust engine, check rpm regulator

See "Overheating" and check same

Repair as in "Overheating"

Worn gasket rings

Disassemble and replace gaskets - Service

Worn filling pump

-Replace pump - Service

Low oil level

Add oil to prescribed level

Filling pump worn out

-Replace pump - Service

Damaged bearings

-Disassemble and find damaged bearing Service

Shifting control to "R" or "F" doesn't move the machine

When driving not all gears are shifted

30

Faulty safety electronics and shifting

Call Service

Bad contacts in electrical circuit of control

Call Service

Bad contacts on valve solenoids

Call Service

Faulty safety electronics and shifting

Call Service

Bad contacts in electrical circuit of gearbox controls

Call Service

Bad contacts on valve solenoids

Call Service

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C - ENGINE 7. FIXTURES no. 1. Assembly (92-655-058) - extension no. 2 Handling (92-645-207) - adjustable hook-up chain GUNEBO no. 3 Assembly (64-298-461) – support for engine with gearbox assembly

no. 4 Handling (64-373-0140) - hook, turning spanner

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31

D - REAR AXLE

D - REAR AXLE 1. Technical data - description 1.1.

Description

1.2.

Specifications

1.3.

Tightening torque

1.4.

Lubricants and glues

2. Defects and remedies 3. Disassembly of axle 3.1.

Preparatory work

3.2.

Disassembly of axle from the machine

3.3.

Disassembly of gearbox

3.4.

Disassembly of drive housing

3.5.

Cleaning and checking parts

4. Assembly of axle 4.1.

Assembly of drive housing

4.2.

Assembly of gearbox

4.3.

Assembly of axle to the machine

5. Differential lock 5.1.

Description

5.2.

Defects and remedies

6. Fixtures

1. TECHNICAL DATA - DESCRIPTION 1.1. DESCRIPTION The assembly is fixed to the machine frame and consists of two vertical cabinets connected by the bridging axle and sealing boots.

Torque from the gearbox is transferred by means of an elbow shaft to the transmission and the differential. The main purpose of the transmission is the transfer of power to the two sides as a function of load on both outputs. The input torque is transferred over the bevel gearing of the OERLIKON SPIRO MATIC type, by means of a classical bevel differential to the halfaxles and then to the gears in the columnar housings. The drive-wheel hubs and the brake drums are positioned on the grooved output shaft.

To facilitate disassembly and assembly the entire breakdown of the rear axle drive assembly is shown on Fig. D/1 and D/2 specifying individual parts. It makes up for speedy and easy identification of parts for their eventual replacement. One should observe the tightness of all screws and nuts, particularly the specified torque.

32

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D - REAR AXLE Fig. D/1

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33

D - REAR AXLE Fig. D/2

34

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D - REAR AXLE 1.2. TECHNICAL SPECIFICATIONS Type of gears of the rear axle: Gears

bevel gearing OERLIKON-SPIROMATIC with the classical bevel differential

Half-axles with pinions

evolute grooved profile

Down-gear

gears wit teeth fully meshed.

Max. transferred power

78 kW

Max. input revolutions

2500 min.-1

Max. input torque Mk

3800 Nm

Døev. differential ratio.

6,875

Lead of helix of the pinion

left

Weight of the axle

1320 kg

1.3. TORQUE Bolted joint

Position

Thread

Nm (lb. ft)

Cover 17+housing 1, 2

Bolt 42

M8

18 (13)

Cover 14+housing 1, 2

Bolt 43

M8

18 (13)

Cover 13+housing 1, 2

Bolt 44

M12

45 (33)

Brake 10+Cover 12

Bolt 45

M12

45 (33)

Shaft 4+wheel 6

Bolt 46

M14x1,5

160 (118)

Cover 12+housing 1, 2

Bolt 47

M16

170 (125)

Cover 12+cover 13

Bolt 47

M16

170 (125)

Gearbox 12+axle bridge 1

Bolt 30, 29

M14

118 (87)

Sealing boot 2, 3+axle bridge 1

Bolt 27

M12

69 (51)

Sealing boot 2, 3+ housing 1, 2

Bolt 28

M12

69 (51)

Housings1, 2+frame

Bolt 50

M20x1,5

320 (236)

Disc wheel+brake drum

Disc nut 51

M20x1,5

330÷350 (243÷258)

Carrier+gearbox pinion

Nut

Other bolt joints

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500 (369)

see appendix no. 1

35

D - REAR AXLE 1.4. LUBRICANTS AND GLUES Oil fills Place

Kind

Quantity l (gal US)

Gearbox

Transmission oil SAE 80W/90; API GL 5

13,5 l (5,77)

Housing of down-gears (2x)

Transmission oil SAE 80W/90; API GL 5

2x5,2 (2x1,4)

Grease Synthetic grease with contents of lithium according to NLGI 2*, see table BENZINA

MOBIL

ESSO

SHELL

CASTROL

Mobilgrease MP

Multi-Purpouse

Retinax A

Castrolease LM

Mobilgrease Special

Grease H

Alvania

Spherol

Grease No.3

Grease RBB2

P-ML-A2

Mobilplex EP-1 * - NLGI 2 - National Lubricating Grease Institute; part 2

Sealing glue for touching areas of axle components

LOCTITE 574

Glue for cementing, fixing (sealing) bolt joints

LOCTITE 577

2. POSSIBLE DEFECTS AND REMEDIES DEFECT

CAUSE

REMEDY

Noisy axle drive

mechanical damage to components

replace

grooves in flange 8 pushed out

replace

play in conical bearings

adjust

dirt in oil

replace

defective seals 32, 33

replace

Oil leaks in housing

36

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D - REAR AXLE 3. DISASSEMBLY OF AXLE

Fig. D/3

Perform preparations, disassembly and assembly according to the introductory chapter ”Safety precautions and instructions”, keep ecological and health precautions.

3.1. PREPARATIONS • Place the machine horizontally on a firm surface.

• Secure front wheels on both sides with wooden blocks.

• Switch off batteries – the machine is automatically locked.

• Place notice “MACHINE OUT OF ORDER” on the steering wheel.

3.2. AXLE DISASSEMBLY FROM THE MACHINE • Loosen nuts on wheels 51.

Fig. D/4

• Attach suitable ties in the hooks, lift the rear of the machine so that the wheels don’t touch the ground. Support the frame suitably with hardwood blocks, Fig. D/3.

• Disassemble tire inflation, brake hoses, air intake to the control of differential lock, brush holders, sprinkling, wheels, connecting shaft, parking brake, and wiring. Place hooks in the rear section. Remove screws connecting the rear section with the frame Fig. D/4. Place the rear end to a suitable work place for further work. Secure brake drums with two nuts 51.

• Hook up the rear axle to the hoist. Remove bolts 50 and nuts 52, Fig. D/5.

• Place the axle on fixture no. 1 vertically see Fig. D/46.

• Remove drain plug 26 and control plug, possibly also filling plug 25 s. Drain oil into a suitable container, Fig. D/2.

• Hook up the rear axle to the hoist.

• Remove plugs 25 from right and left housing, Fig. D/1.

Drain oil into a suitable container.

Fig. D/5

• Thereafter reinsert all plugs – do not tighten.

50

52

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37

D - REAR AXLE • Remove right and left sealing boot 3, 2. Remove sealing

3.3. DISASSEMBLY OF DRIVESHAF T

ring 17, and O-ring 18, Fig. D/2.

• Rear axle to be placed horizontaly.

• Turn axle bridge with the differential up.

• Remove all bolts 28 connecting left and right 2, 3 sealing

• Install compressed air input 1 for switching on the lock

boot with the left housing 1 and the right housing 2, Fig. D/2.

• Screw two press-out bolts M12 into M12 holes, and by gradual tightening separate axle bridge from sealing boots and half-axles including pinions 7 from the left and right housings, Fig. D/2. Remove disassembled components to a suitable place for further work, using lift. Drive housings 1, 2 to be placed horizontally on a suitable support with flange 13 down.

Fig. D/6.

• Check locking switch by turning brake drums. This is applicable to machines with such a lock.

• Insert handling fixture no. 2 into the two opposite holes of the input flange, attach to lift Fig. D/6.

• Watch for leaking oil during disassembly.

• Remove the assembled half-axle 6, 5. From the center of the axle remove pinions 7 with the inner snap ring 23 using proper spanner (or press out), remove washer 8 and snap ring 19. Remove inner ring of the bearing 23, Fig. D/2.

Note – should the half-axles and pinions be used later again, it is advisable to mark them so that they could be installed in their original positions.

Fig. D/6

¹. 2

1

38

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D - REAR AXLE • Unscrew bolts 29, 30. Thread three press-out bolts M 16 and by gradual tightening remove gearbox from the center bridge opening 1, Fig. D/7.

• Remove differential hub and place it using fixture no. 2 and a hoist to a suitable place for further work.

Note – watch for leaking oil residuals from the axle during disassembly.

Fig. D/7

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39

D - REAR AXLE 3.4. DISASSEMBLY OF DRIVE HOUSING

Fig. D/10

• Remove two nuts 51 from brake drum 11. Remove brake

34

drum from flange bolts, if necessary use press-out bolts in the holes of the drum. Remove safety washers 35, Fig. D/8.

• Remove nut 34 using fixture no. 3 Fig. D/9.

• Remove washer 35, unscrew the other nut 34 and spacer

35

16, Fig. D/10.

• Slide flange 8 from the grooved shaft 4 using proper

34

spanner, Fig. D/11. Heat flange to 320°.

• Unscrew bolts 47 and remove brake assembly 10, Fig. D/12.

Fig. D/11

Fig. D/8

4 51

35 51 8

11

Fig. D/12

Fig. D/9

10

¹. 3

47 34

40

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D - REAR AXLE • Insert press-out bolts M 16 into 2 holes M 16, and by their

Fig. D/14

gradual tightening remove cover 12, Fig. D/13.

• Remove sealing ring 33 from the cover, washers 20, 21, ring 19, and O-ring 32, Fig. D/14.

• Turn the housing using hoist by 180 degrees (cover 13 up), from the opposite side do 1-5. Watch for leaking residual oil.

• Remove bolts 44, 45. Insert two press-out bolts M 16 into holes M 16 and by gradual tightening remove cover 13 Fig. D/15. Insert hooks into holes M16 after press-out bolts have been removed, and using a suitable handling device place it on the working bench. While replacing bearing 29, press out or knock out the outer ring of the bearing from cover 13 using a bronze rod.

• On the shaft 4 anscrew fixture no. 4, hook and remove assembly using hoist from the housing, Fig. D/16.

• Unscrew bolts 46 and press out gear 6 and inside rings of bearing 29. For replacement of the other bearing 29, knock out from the housing assembly using a bronze rod the outer ring. Remove cover 17 with seal 18, Fig. D/1.

Fig. D/15

44 13

45

Fig. D/16

Fig. D/13

¹. 4

12

4

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41

D - REAR AXLE • Remove safety rings 39, by knocking with a bronze rod,

3.5. CLEANING AND INSPECTING PARTS

remove pins 7, O-rings 31, Fig. D/17.

• Slide both idler gears 5 from the housing. One through the rectangular opening in the housing, the other through the large opening for the cover 13.

• Remove entire bearing 28 including rings 37 and spacer 23, Fig. D/17.

• Unscrew bolts 43. Screw in holes M8 press-out screws M8 and by gradual tightening remove cover of bearing 14.

Remove bearing 27 Fig. D/1.

• Should the main components (gears, pinions, splined shaft, and flange) be used further, mark the parts suitably to be able to install them in original positions later.

Cleaning For perfect cleaning of parts use suitable dissolving fluid bath. The bearings must be dipped in several times and the cones or cylinders must be forcefully turned. Completely clean bearings should be dried by forced air. Keep on turning the bearings in hand to speed up drying.

Inspection of individual parts

• Check visually all cones, rollers, cages, and rings of bearings for pitting, breaks, or fissures. If any damage should appear, it is necessary to replace the bearing. It is not recommended to replace only the internal or external rings of cone bearings.

• After checking submerge the bearing in oil and wrap in paper thereafter to keep it clean until usage.

• If no method of flaw detection can be applied, it is necessary to inspect the teeth, polished surfaces, fissures, and overall wear. Small dents may be removed by polishing.

In case of more severe damage (fissures, tears in the cemented surface, etc.) it is necessary to replace the unit.

• On shafts, check for eccentricity, straightness of grooves and play in grooves in the matching section (half-axle, carriers, etc.)

• The visual control includes the appearance of dents or frays on meshing surfaces and openings for the bearings.

Further, it is necessary to check carefully for tears and deformations. The hub and housing of the differential must be checked for fundamental deviations in geometry, like axial alignment, eccentricity, etc.

• If the check reveals tears in the brake drum, any deep damage and wear (grooves, etc.) that cannot be reworked on the lathe to the maximum value of 402,5 millimeters (15,8 in), the drum must be replaced.

• If the least damage is discovered, the part must be replaced.

Fig. D/17

42

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D - REAR AXLE 4. AXLE ASSEMBLY

Fig. D/18

4.1. DRIVE HOUSING ASSEMBLY • Housing 1, 2 to be cleaned of mechanical dirt, blown out by compressed air, and placed horizontally on a firm surface (support), Fig. D/18.

• Screw two plugs 33 in the holes of the housing, Fig. D/19.

• Place safety rings 37 and bearing 28 into holes of idler gear 5. Turn the wheel and insert ring 23 and the other bearing 28 from the opposite side into the opening, Fig. D/17.

• Turn the housing by 90 degrees with the large opening down.

• Press outer ring of bearing 29 in the large hub, Fig. D/20.

Fig. D/19

33 33

Fig. D/20

29

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43

D - REAR AXLE • Press sealing ring 33 in cover 12, Fig. D/21.

Fig. D/22

• Apply LOCTITE 574 on faces of cover 12 and the hub. In steps, place cover 12 Fig. D/21. The brake assembly 10 on the hub and fasten with bolts 47, Fig. D/22. Apply LOCTITE 577 on threads.

10

• Turn housing by 90 degrees, Fig. D/18.

• Slide idler gear assembly into the housing, one the rectangular opening Fig. D/23, the other through the opening for cover 13, Fig. D/24.

47

• Turn the housing by 90 degrees, the large opening up.

Fig. D/23

10

Fig. D/21

Fig. D/24

33

12

10

44

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D - REAR AXLE • Center holes in bearings 28 and idler gears 5 against

Fig. D/26

openings in the housing Fig. D/25.

• Slide O-rings 31 and snap ring 38 on the pins of inserted wheels 7, and press in pins 7, Fig. D/26.

• Heat gear 6 to 150 °C - 180 °C (302-356 °F) and set on

31

38

grooved shaft 8. After cooling off, bolt the assembly together using bolts 46 and correct torque – see table.

Heat inner rings of bearings 29 to 100 °C (212 °F) and set on shaft from both sides 8, Fig. D/27.

7

• On the shaft 4 anscrew fixture no. 4, and set the entire assembly using hoist in the inner ring of bearing 29 in the cover 12, Fig. D/28.

7

Fig. D/27

8

29 6

Fig. D/25

Fig. D/28

¹. 4

4

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45

D - REAR AXLE • Smear the touching surface of cover 13 and the opening in the housing with LOCTITE. Screw cable hook (screw M 12) in force-off openings in cover 13 and fit in place – selected position ”a” as in Fig. D/29. Fix screws 44, 45 by LOCTITE.

• Press in the inner ring of the other bearing 29 in cover 13, Fig. D/30.

Finding the rate of prestress: -

measure “X” - size of step on 2 as in Fig. D/31.

-

measure “Y” - distance of inner bearing ring 29 from cover face 13 as in Fig. D/32.

Calculate rate of prestress of bearings “P”: P=Y–x

• Following the installation of cover 13 adjust prestress of bearings 29 by inserting washers 20, 21. The prestress of bearings is given by 0,4 ÷ 0,6 mm (0,016 - 0,024 in).

Fig. D/29

Finding the gauge of washers ”Z” Z = P + 0,4

Fig. D/31

13 a X

Fig. D/30

12

Fig. D/32

29

13

13

Y 29

46

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D - REAR AXLE • Smear touching areas of both covers 12 and 13 with

Fig. D/34

LOCTITE. Prepare and insert limiting washers 20 and 21 as calculated for prestress in the opening of cover 13 Fig. D/33. Place cover 12 to cover 13. Set brake assembly 10 on cover 12 and tighten bolts 47. Smear thread with LOCTITE, Fig. D/34.

• Place sealing O-ring 32 and chrome plated ring 19 on shaft 4 Fig. D/35.

• Insert bolts 49 in hubs 8. Slide fixture no.5 on the shank of bolts. Apply nuts 51 and fix bolt to the hub flange using fixture. Preheat hub in an electric oven to 200 – 250 °C (392-482 °F). In turn, close the heads of bolts on two sides by welding, Fig. D/36.

47 10

In Czech Republic use electrode. OK 67.45 – made by ESAB Žamberk.

Marking of electrodes to the following standards ČSN EN 1600 (05 51 00)

OK 67.45

DIN 8556

E 18 8 Mn B 20+

AWS A/SFA 5.4 – 92

E 307 – 15

EN 1600 (European standard)

E 18 8 Mn B 42

Fig. D/35

19

Fig. D/33

Fig. D/36

8 20

21 49

13 12 VP 2400

¹. 5 47

D - REAR AXLE • Heat flange 8 to 200÷250 °C (392÷482 °F) and slide on

Fig. D/38

grooved shaft 4, Fig. D/37.

• Slide spacing ring 18 on shaft 4, use nut 34 and tighten.

Fig. D/38.

34

• Secure with washer 35. Slide on the other washer 35, screw and tighten the other nut 34, and secure using tab washer 35, Fig. D/39.

• Fix brake drum 11 on bolts in flange, and tighten with 2

16

nuts 51, Fig. D/40.

Fig. D/39

34 35

34

Fig. D/37

Fig. D/40

8 51

11

51

48

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D - REAR AXLE Brake adjustment on both housings:

• Turn brake drum with adjustment hole downwards to the adjustment wheel 2, Fig. D/41.

• Turn adjustment wheel 2 until brake shoes touch brake drum – the brake drum cannot be turned.

• Turn adjustment wheel back until brake shoes become loose – the brake drum can be turned freely, without audible friction of the drum on the shoes.

Fig. D/41

2

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49

D - REAR AXLE • Heat inner rings of bearing 23 to 100 °C (212 °F), slide

4.2. GEARBOX ASSEMBLY

them on half-axle 5, 6 from the side of longer grooves, slide washers 8 (limit axial free-play) and set snap ring 19.

Slide pinions 7 on the grooves of half-axle 5, 6, heat to 100 °C, Fig. D/43.

• Place the axle bridge 1 on a flat surface with the large opening up. Place O-ring 18 on the left and right sealing boot 2, 3, apply LOCTITE on touching faces of axle bridge 1 and sealing boot flanges. Place sealing boot in openings in the bridge and apply screws 27, Fig. D/42. Press sealing ring in openings of the left and right sealing boots 2 and 3.

•

On the lock fork 1, slide claw coupling 2 Fig. D/44.

• Attach pressurized air hose 1 for closing claw coupling, Fig. D/45. This is applicable to differential lock.

• Apply LOCTITE on the contacts of the large opening in the axle bridge and 1a of gearbox, attach padding 9.

Note: Bolts 27 on sealing boots 2 and 3 shouldn’t be tightened fully as yet. This will be done after the bolts 50 and 52 have been applied to connect the axle to the frame, Fig. D/1.

Fig. D/42

Fig. D/44

2

1

Fig. D/43

Fig. D/45

23

8 19

1

7 5,6 50

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D - REAR AXLE • Hook up gearbox 12 using fixture no. 2, on hoist in the

• Press bearings 27 in lids 14, Fig. D/48. Apply LOCTITE to

opening of the axle bridge Fig. D/46. Watch for the centering pin 34!

seating faces of covers 14 and openings in the housings 1, 2. Hit the cover lightly with a round bronze rod in the opening in the housing, and screw.

• Insert bolts on the circumference, and tighten with torque per Table.

• Slide assembled half-axles 5 and 6 with outer rings of bearings 23 on sealing boots 2 and 3.

Note: For disassembly, two force-off openings are provided on lid 14.

• Screw plug in the drain with sealing ring and dip stick.

• Place both housings with padding next to each other on a flat and firm surface to assemble the gearbox. Hook on the gearbox 3 and lift between the drive housings, Fig D/47. Equalize the axis of the sealing boot of the gearbox and the openings in housings 1 and 2. Slide the gearbox to the housing and bolt together. Support the gearbox suitably underneath the axle bridge 3. Hook up the second housing and lift, equalize the axis of the housing against the gearbox, slide and connect with bolts.

ATTENTION! When attaching the gearbox to housings 1 and 2, turn the pinion gear 7 against gaps in the idler gear 5.

Fig. D/47

1

2

3

¹. 1

Fig. D/48

Fig. D/46

¹. 2

27

12 14

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51

D - REAR AXLE • Attach fixture no.1 to the lower part of housings Fig. D/49.

Place the entire rear axle vertically, with the bridge up, using a hoist.

• Pour oil in housings 1 and 2, as per table.

• Pour oil in the gearbox per table.

• Apply LOCTITE to the rectangular opening in housings 1 and 2, cover 17, place padding 18 on its rim, and screw on the cover.

• Attach breather 24 on the cover 14 and the left sealing boot 2.

Attention!

In case of a new gearbox, pour 0.2 liter of oil (12 cu. in.) through the opening in the pinion body, Fig. D/50.

Fig. D/49

Fig. D/50

52

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D - REAR AXLE 4.3. ASSEMBLING AXLE TO THE MACHINE • Respect the rules of work safety.

• Hook rear axle on he lift, attach plates to machined areas of the frame and bolt to the frame with 16 screws 50 with washers 59, 57 and nut 52. Tighten with torque as in table, Fig. D/51.

• Tighten bolts 27 with torque of table, connecting the left sealing boot 2 to axle bridge 1 Fig. D/42.

Fig. D/51

50 52

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53

D - REAR AXLE 5. DIFFERENTIAL LOCK

• The differential is provided with a lock, represented by a pair of gear clutches 1 and 2.

5.1. DESCRIPTION

• The control of the differential lock (3) is pneumatic, closing is signaled by a light on the dashboard.

• The assembly of the rear axle drive and the differential lock is identical to the rear axle drive, except for details shown on Fig. D/52.

Fig. D/52

54

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D - REAR AXLE • The exploded view of the complete assembly of the diffe-

21.

Bolt M12x1,5-35

1

rential lock is shown on Fig. D/53 together with the specification of each component for speedy and easy orientation during required replacement.

22.

Nut M12x1,5

1

23.

Nut M12

1

24.

Washer 10

4

Pieces

25.

Pin 10x25

1

Retaining ring 18

2

Position

Name

1.

Holder of the lock cylinder

1

26.

2.

Cap cylinder

1

27.

Retaining ring 10

2

3.

Cylinder lid

1

28.

Packing 25x36

1

4.

Shaft of the gear-shift fork

1

29.

Ring 14x2

1

Ring 70x2

1

5.

Piston

1

30.

6.

Differential lock lever

1

31.

Thrust washer

1

7.

Lever fork

1

32.

Ring

2

8.

Lever pin

1

9.

Spring plate

1

10.

Spring

1

11.

Washer

1

12.

Carrying prism

2

17.

Push-button switch

1

18.

Packing K O 75

1

19.

Plug

2

20.

Bolt M10-90

4

Disassembly and assembly of the differential lock as such are not described, since the procedures are obvious from Fig. D/53.

Fig. D/53

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55

D - REAR AXLE 5.2. POSSIBLE DEFECTS AND REMEDIES

DEFECT

CAUSE

REMEDY

The sliding part of the drive doesn’t engage with the fixed part of the differential lock

deformed grooves in the sliding part of locks 1 or 2

replace

defective packing 18

replace

56

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D - REAR AXLE 6. FIXTURES

No. 4

Handling (64-373-0466) - hook M70x2

No. 5

Welding (54-373-0478) - bushing

No. 1. Assembly (64-363-0114) - for support of housing 1 and 2 vertically

No. 2

Handling (64-374-0111) - hook for flange diferecial

No. 3

Assembly (64-373-0481) - wrench for nut KM 14

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57

E - FRONT AXLE

E - FRONT AXLE 1. Technical data 1.1.

Description

1.2.

Specifications

1.3.

Torque values

1.4.

Lubricants and glues

2. Defects and remedies 2.1.

Inspection of installation of four front wheels

3. Axle disassembly 3.1.

Preparatory work

3.2.

Disassembly of axle from the equipment

3.3.

Disassembly of guiding pipe of the front axle

3.4.

Disassembly of fork

3.5.

Cleaning and inspection of parts

4. Installation of front axle 4.1.

Installation of guiding pipe and fork

4.2.

Assembly of wheel hubs and shaft

4.3.

Assembly of fork and shaft assembly with wheel hubs

4.4.

Assembly of axle to the machine

5. Fixtures

1. TECHNICAL DATA 1.1. DESCRIPTION The front axle assembly is fixed to the housing frame of the machine. It consists of two movable arms with a hydraulic cylinder.

For easier disassembly and assembly refer to Fig. E/1, E/2 to see the entire exploded view of the front axle with specifications of each part for easier orientation when replacements are necessary.

Watch particularly for proper tightening of all screws and nuts and refer to table of applicable torque.

1.2. SPECIFICATIONS axial (vertical) lift

mm (in)

200 (7,84)

pitch diameter of disc bolts on wheels

mm (in)

275 ± 0,2 (10,83) ± (0,008)

weight of front axle including tires

kg (lb)

1156 (2549)

58

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E - FRONT AXLE 1.3. TORQUE VALUES Connection

Position

Thread

Nm (lb ft)

Flange 9+shaft 8

KM nut 38

M60x2

500 (369)

Scraper 32+shaft 8

Bolt 64

M10

25 (18,5)

Pin16+shaft 8

Bolt 31

M12

45 (33)

Pin 16+washer 23

Bolt 65

M12

45 (33)

Cover 10+guiding pipe 2

Bolt 62

M10

25 (18,5)

Cover 12+Guiding pipe 2

Bolt 61

M10

25 (18,5)

Cover 11+guiding pipe 2

Bolt 63

M10

25 (18,5)

Disc nut 73

M20x1,5

330 ÷ 350 (243÷258)

Disc wheel+flange 9 other connections

see appendix no.1

1.4. LUBRICANTS AND GLUES Oil fill: For hydraulic cylinders of the front axle equalization system, the hydraulic oil of series ISO 6743/4 HM or HV with kinetic viscosity of 46 mm2/s at 40 °C (104 °F) /ISO VG 46/ is to be used.

This corresponds to DIN 51524 part 2 HLP, or DIN 51524 part 3 HVLP, eventually CETOP RP 91 H. Type of oil

Quantity l (gal US)

H M or HV 46

6 (1,6)

Lubricating grease Synthetic grease containing lithium. of consistence to NLGL – 2* - see table.

BENZINA

MOBIL

ESSO

SHELL

CASTROL

P-ML-A2

Mobilgrease MP

Multi-Purpouse

Retinax A

Castrolease LM

Mobilgrease Special

Grease H

Alvania

Spherol

Grease No.3

Grease RBB2

Mobilplex EP-1 * - NLGI 2 - National Lubricating Grease Institute; part 2

Glue for fixing bolts and nuts

LOCTITE 577 Aldurit

Sealing compound for touching faces of parts

VP 2400

Epple 39

59

E - FRONT AXLE 2. DEFECTS AND REMEDIES Defect Oil leak Axle noisy

Cause

Remedy

defective seal

replace

damaged chrome on the fork

replace (or repair)

mechanical damage to part

replace

free play in conical bearings

adjust see. 2.1

Free play in steering (mounting of conical pins of the steering rod) conical holes pressed out

2.1. INSPECTION OF INSTALLATION OF FOUR FRONT WHEELS

repair bushing

Fig. E/1

• Free play of conical bearings must be checked.

Eventually, any noticeable must be adjusted immediately. First inspection after 100 Mh and then every 500 Mh. Instructions for set-up:

• Remove complete wheel with disc, by loosening nuts 73, washers 39, outer nut 38. Tighten n. 13 up the inner nut using proper wrench with extension. While doing this, position bearings 37 and 41 by tapping the hub of the wheel Fig. E/2.

• The front wheel bearings are properly adjusted, when there is no free play in conical bearings, and the wheels may be turned easily without resistance.

60

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E - FRONT AXLE 3. AXLE DISASSEMBLY Preparatory work, disassembly and assembly must be done in line with the Safety Precautions and Instructions chapter.

Observe ecological and health regulations.

3.1. PREPARATORY WORK • Place the machine horizontally on a firm and flat surface.

• Place wooden block under rear wheels on both sides.

• Switch off batteries – the machine’s brake has been set automatically.

• Place the sign ”THE EQUIPMENT IS OUT OF ORDER” on he steering wheel.

Fig. E/2

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61

E - FRONT AXLE 3.2. DISASSEMBLY OF AXLE FROM THE EQUIPMENT

Fig. E/4

• Remove nuts 73, Fig. E/2.

33

• Insert proper ties in the lifting hooks, hoist the front end high enough so that the front wheels are off the ground, see Fig. E/3.

• Remove cover off the frame above the front wheels.

• Remove connecting pipe 33 and the connectors, plug up the hole, Fig. E/4.

• Further, remove tires inflation attachment, brush holders, wheels, sprinkling equipment, steering (connecting rod), and electrical cables.

• Unscrew plug 52, attach hook No.1, Fig. E/5.

Fig. E/5

52

Fig. E/3

Fig. E/6

72

62

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E - FRONT AXLE • Remove nuts 72 Fig. E/6 and, bolts 66, Fig. E/7.

• If it isn’t possible to remove the axle from the frame, pressout bolts must be used in the holes of guiding pipe 2 flange.

• Slide the axle from the frame forward, disconnect the hoist and remove ropes from frame holes. Hook up again and deposit on fixture No.2. Unscrew hook. Turn the guiding pipe 2 through opening for the connecting pipe, and drain oil into a suitable container.

3.3. DISASSEMBLY OF GUIDING PIPE OF THE FRONT AXLE • Remove cover 11 on the face of the guiding pipe 2. Knock out gently cover 11 and remove by prying it out. Remove O-ring, and cover 12 on the top face of fork 1, Fig. E/8.

• Using hoist remove guiding pipe 2.

Note: Watch for leaking residual oil. Protect the chromeplated part of fork 1 by a suitable cover (by a split rubber hose, for instance) against damage, after the removal of the guiding pipe.

• Remove cover 10 on the bottom face of the guiding pipe 2. Remove washer 18, scraper ring 45 from the cover 11, packing 44 from ring 18, and two O-rings 46 and 47 Remove bolt 60 (fixing the top bushing) Fig. E/1.

• Remove bushing 26 with a spanner, Fig. E/9.

Fig. E/7

66

Fig. E/9

Fig. E/8

2

11

26

12

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63

E - FRONT AXLE 3.4. DISASSEMBLY OF FORK

Fig. E/10

• Remove shim 23. Remove extension 24 with nipple 84,

23

Fig. E/10.

• Attach hook No. 3 in the center hole of the shaft (thread M16x1,5). Attach to hoist, Fig. E/11.

• Remove bolts from the yokes of the fork 1. By a gentle knock loosen the yokes Slide bushings off pins 4, Fig. E/12.

24

• Place on bench.

84

• Remove hook No.3.

• Release lock washer 39 (MB 12), gradually remove nuts 38.

Fig. E/11

¹. 3

8

Fig. E/12

4

64

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E - FRONT AXLE • Remove hub, or a suitable lever (screwdriver) by the lower

Fig. E/13

edge of the hub 9 with spanner, Fig. E/13.

• Remove washer 28 and sealing ring 42 from the hub, in

9

case of replacing bearings, also the front bearing 41 and the outer ring of the rear bearing 37. Unscrew nipple 82 Fig E/14.

Note: Should the bearing be replaced, the complete bearing must be replaced.

• Turn the fork and remove hub 9 from the opposite side.

• Remove pins 16 from shaft 8. Using spanner attached to the face of the pin 16 by two screws M12, remove pins from shaft 8. Should bearings 37 be replaced from shaft 8 remove inner rings of bearing 37 Fig. E/2.

Fig. E/14

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65

E - FRONT AXLE 3.5. CLEANING AND INSPECTION OF PARTS

CHECKING EACH PART Bearings

Cleaning of parts For complete cleaning use adequate solvent fluid bath. The bearings must be taken out of the bath repeatedly, and the cones or rollers must be turned under pressure. Perfectly clean bearings to be dried out with dry compressed air, while turning the bearings by hand to accelerate the process.

Check visually all cones, cages, and rings for pitting, breaks in material, or dents. Should there be any damage present, the bearing has to be replaced. It is not allowed to replace only the inner or outer rings of conical bearings.

Following the inspection dip the bearing in oil and wrap in paper to keep it clean until future use.

Shafts Check for eccentricity, straight grooves, and general wear.

Castings, bushings Visual control includes checking for dents, flares on functional surfaces and holes for the bearings. Further, check carefully for the appearance of fissures and deformations.

Piston rod (fork 1), guiding pipe 2 Check for eccentricity, straightness, dents on functional surfaces, and chrome on the fork. In case of non-repairable damage, replace the part. Small dents may be removed by filing.

Rubber seals, O-rings, packing Should there be any damage observed, replace.

66

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E - FRONT AXLE 4. INSTALLATION OF FRONT AXLE

Fig. E/15

4.1. INSTALLATION OF GUIDING PIPE AND FORK • Set the guiding pipe in fixture no.2 or on a bench. Press

¹. 2

bushing 26 into the guiding pipe 2, Fig. E/15 using fixture no. 4 E/16.

NOTE ! Save bushings by the usable surface, only one half of the pieces is affected, Fig. E/15 Fix the inner bushing by bolt 60, Fig. E/16.

2

• Turn the guiding pipe 2 with bushings in fixture no. 2 to

26

vertical, secure and clean the inside by air.

• Grind taper on the fork with a whetstone.

• Press ring 18 with O-rings 46, sealing set ”Merkel” 44, and scraper ring into cover 10, Fig. E/17.

Fig. E/16

60

¹. 2

¹. 4

Fig. E/17

10

18

44

45 46 VP 2400

67

E - FRONT AXLE • Install cover 10 with seals on fork 1 into holes for bolts in

Fig. E/18

cover 10, attach fixture no. 5, slide into guiding pipe 2 using hoist and fixture no. 6 inserted in hooks of fork 1, Fig. E/18 until cover 10 sits on the face of the guiding pipe 2. Pack cover 10 with EPPLE glue.

¹.15

10 1

• Attach cover 10 to guiding pipe 2. Slide fork 1 out and remove fixture no. 5.

• Tilt the assembled guiding pipe with the fork horizontally

2

• Screw in the opening for the oil pipeline the plug against dust entry.

• Screw cover 12 to the face of the fork. Screw cover 11 to the guiding pipe including ring 47 and apply glue EPPLE Fig. E/19.

• Screw hook no.1 in the cover 11. Remove the guiding pipe with the fork from the fixture and place on the workbench.

Fig. E/19

11 12

68

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E - FRONT AXLE 4.2. ASSEMBLY OF WHEEL HUBS AND SHAF T

Fig. E/21

• Insert bolts 67 in hubs 9. Slide fixture no.7 on the shank of the bolt. Screw nuts 73 and tighten bolt to the hub flange using fixture. Preheat hub in the electric oven to 200 - 250° C. Weld in turn the bolt heads from both sides, Fig. E/20.

Used electrode to ČSN EN 1600 (05 51 00) - made by ESAB Žamberk OK 67.45 – valid for the Czech Republic.

8

The corresponding electrodes according to DIN 8556

16

E 18 8 Mn B 20+

AWS A/SFA 5.4 – 92

E 307 – 15

EN 1600 (European standard)

E 18 8 Mn B 42

• Clamp shaft 8 in a vice (protect ground surface), or in fixture no. 8, install brush holders 32.

• Press pins 16 to shaft 8, screw, fix bolts with ALDURIT and degrease threads, Fig. E/21.

• Press outer rings of the conical bearing 41 into hub 9

Fig. E/22

using fixture no.9, ring 29, and sealing ring 42 using fixture no.10. Turn hub 9 and repeat the preceding operation. Screw on nipple 82. Fig. E/22.

• Place shaft 8 on the workbench in fixture no.8, preheat inner bearing ring 37 (to a maximum of 100 °C), and press on the shaft – hit with fixture no. 11 to end. Place hub 9 on shaft 8, fill space between bearings with grease, and press in the inner ring of the second bearing 41 using fixture no. 11 Fig. E/23.

Fig. E/20

Fig. E/23

9

¹. 7 VP 2400

67 69

E - FRONT AXLE • Place tapered plate no. 12 on sealing ring 42, insert shim

Fig. E/24

28, Fig. E/24.

• Screw on first nut 38 using fixture no. 13, use torque according to table. Knock off the bearing using fixture no.14, retighten the nut with torque, test pre-stress of bearings by turning hub 9 (it may not turn freely). Insert two safety washers 39 and the second nut 38, tighten Fig. E/25. Secure nuts with washers.

28 ¹.12

• Screw hook no.3 in the center hole of shaft 8 Fig. E/26, and place the assembly on the workbench with the hub down.

• Heat inner ring of bearing 37 (to a maximum of 100 °C) and place on the shaft – press to dead stop using fixture no.11 Fig. E/23.

• Place hub 9 on shaft 8, fill in the space between the bearings with grease, and press in the inner ring of bearing 41 Fig. E/22.

• Press tapered plate no. 12 on the sealing ring 42, insert shim 28, Fig. E/24.

• Install nuts 38 and washers 39 with limited pre-stress of bearings 37 and 41 as per preceding operation.

Fig. E/25

38

38 39

Fig. E/26

¹. 3

8

70

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E - FRONT AXLE 4.3. ASSEMBLY OF FORK AND SHAFT ASSEMBLY WITH WHEEL HUBS

Fig. E/27

1

• Remove yokes 1A from the fork, remove bushings 1B and

1B

smear with grease, Fig. E/27.

• Insert bushings on pins 18, Fig. E/28.

1A

1B

• Assemble axle axis (pos. 8+9), hang by hook no.3, Fig. E/26 on hoist.

• Insert shaft axle on forks into yokes, Fig. E/29.

1A

Fig. E/28

Fig. E/29

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71

E - FRONT AXLE • Assemble yokes, Fig. E/30.

Fig. E/30

• Screw on extensions 24 and nipple 84. Insert shim 23, Fig. E/31.

• Weld end stops pos. 10 on both sides using fixture no.15.

Set the fixture on hub bolts 9 and support the other end (end stop) against piston rod of fork 1 (protect the surface of the piston rod against damage), Fig. E/32. The end stop limits the spacing between the tire and the piston rod to 13 mm when the axle is off vertical.

Fig. E/31

23

24 84

Fig. E/32

¹.15

9

10

1 72

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E - FRONT AXLE 4.4. ASSEMBLY OF AXLE TO THE MACHINE • Hoist the axle to the frame of the machine, hook up a cable, and attach to hook no.1. Lift the axle to the frame and attach. Remove the hook.

• Connect both guiding pipes with pipe 33 Fig. E/3.

• Fill both guiding pipes with oil, see table in 1.3. Screw on plug 52. Following wheel alignment (see chapter ”G”), install complete wheels to flanges. Further install tire inflation assembly, sprinkler, and electrical cables.

VP 2400

73

E - FRONT AXLE 5. FIXTURES

No.4 Installation (64-373-469) - for pressing bushings 26 into guiding pipe 2

No.1 Hook (92-644-0195) for removal of axle from the machine and thread M 24x1,5 in cover 11

No.5 Installation (64-374-0008) – for installation of cover 10 into holes for screws

No.2 Assembly support (64 373-0470) for placing guiding pipe 2

No.6 Handling (65-374-0009) – for installation of fork 1 to guiding pipe 2

No.3 Hook (65-374-0010) for removal of assembly shaft 8 + hub 9, thread M16x1,5

74

No.7 Welding (54-373-0478) – bushing for placing bolts

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E - FRONT AXLE No.8 Installation (64-373-0473) – support for shaft 8

No.11 Pressing (92-631-0006) - ∅ 70/63-200 pipe inner rings of bearings 37,41

No.9 Pressing (92-631-0006) – ∅ 110/91-130 pipe inner rings of bearings 37, 41

No.12 Installation (64-374-0004) – tapered plate for sealing ring 42 to install ring 28

No.10 Pressing (92-631-0117) - ∅ 120x100x13 pressing tool for sealing ring 42, 43

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75

E - FRONT AXLE No.13 Installation (64-373-092) – extension for nut KM 12 pos.38

No.14 Pipe (92-631-0006) – Pipe ∅ 81/89-140 for knocking off bearings 37,41

No.15 Welding (64-373-0471) – for placing end stops on the fork 1

76

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F - FLEXIBLE SHAFT

F - FLEXIBLE SHAFT 1. Specifications - description 1.1.

Description

1.2.

Specifications

1.3.

Tightening torque

1.4.

Lubricants and glues

2. Possible defects and remedies 3. Disassembly and re-assembly 3.1.

Preparatory work

1. SPECIFICATIONS 1.1. DESCRIPTION The flexible shaft serves the purpose of transmitting torque to the gearbox to drive the rear axle (differential).

It consists of two separate parts inserted in each other, and moving in the groves of the axial axis.

1.2. SPECIFICATIONS Max. transmitted torque

Nm (lb ft)

4500 (3320)

Revolutions

1.min–1 (RpM)

2200

Weight of the shaft

kg (lb)

25 (55)

1.3. TORQUE Tightening torque values are listed in appended table.

1.4. GREASE Synthetic grease with Lithium added of prescribed consistence NLGI -2* , see table.

BENZINA P-ML-A2

MOBIL

ESSO

SHELL

CASTROL

Mobilgrease MP

Multi-Purpouse

Retinax A

Castrolease LM

Mobilgrease Special

Grease H

Alvania

Spherol

Grease No.3

Grease RBB2

Mobilplex EP-1 * - NLGI 2 - National Lubricating Grease Institute; part 2

VP 2400

77

F - FLEXIBLE SHAFT 2. POSSIBLE DEFECTS AND REMEDIES DEFECT

CAUSE

REMEDY

Shaft is vibrating

Mechanical damage of the bearing

Replace shaft

3. DISASSEMBLY AND RE-ASSEMBLY Do all preparatory work, disassembly, and re-assembly with Chapter on safety in mind. Comply with environmental and health regulations.

3.1. PREPARATORY WORK • Place the roller horizontally on a firm surface.

• Wedge front wheels on both sides.

• Switch off battery breaker – the machine brakes automatically.

• Place notice ”ROLLER IS BEEING REPAIRED” on the steering wheel.

• Remove rubber mat and insulation off the floor.

• Remove two floor covers.

• Hold the flexible shaft by suitable ties (ropes) in the hoist, or support it.

• Remove bolts on the gearbox side and on the rear axle drive side, Fig. F/1, F/2. Remove the shaft and place it outside.

• Install new shaft in reverse sequence – use new safety nuts.

Fig. F/1

78

Fig. F/2

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G - STEERING

G - STEERING 1. Specifications - description 1.1.

Description

1.2.

Technical data

1.3.

Lubricants and glues

2. Possible defects and remedies 3. Disassembly and re-assembly 3.1.

Preparatory work

3.2.

Geared steering hydraulic generator

3.3.

Power steering

3.4.

Disassembly of linear hydraulic motor

3.5.

Removal of power steering tank

3.6.

Removal and installation of the lever assembly

4. Adjustment of toe-in 5. Fixtures

1. SPECIFICATIONS - DESCRIPTION 1.1. DESCRIPTION The roller is steered mechanically and hydraulically. The geared hydraulic generator uses hydraulic oil from the oil tank with filter, and pushes it to the steering assembly. By turning the steering wheel, the fluid stream is separated in the power steering assembly, and enters through hoses into the linear hydraulic motor.

The front axle is steered by the linear motion of the hydraulic motor piston, the steering lever, and rods. The surplus fluid is returned to the oil tank. The roller uses dual steering consisting of dual elements in the steering loop, that is, doubled up power steering assembly and steering wheels.

1.2. TECHNICAL DATA Safety pressure in power steering

MPa (PSI)

12 (1740)

Geared hydraulic generator

2-Q10R.54600-00

Unidirectional, left-turning hydraulic generator (when looking to the driveshaft) changes mechanical energy to pressure. A pair of tooth gears is mounted in the hydraulic generator on sliding bearings, with an automatic equalization of axial free play.

The pin of the driving wheel is connected to the mechanical drive.

Seals are of rubber and plastics. It is connected to the CLARK gearbox through a flange.

Volume

cm3 /ot (cu.in/rev)

10 (0,61)

Nominal pressure

MPa (PSI)

20 (2900)

VP 2400

79

G - STEERING Power steering LAGC 200LSD 102 The power steering assembly contains various valves like safety, reversing, limiting, shock, and suction valves.

In the neutral position of the steering wheel -

the connection between the pump and the tank is open

-

and no force acts on the wheel

Shocks on the wheel during travel are compensated by the unidirectional reversible valve and the shock-absorbing valve.

The motion of the wheel is transferred through the column with a cone for the wheel and a groove leading to the power steering assembly.

Nominal pressure

MPa (PSI) 3

16 (2320)

Maximum input fluid volume

-1

dm .min (gal US/min)

50 (13,2)

Through-flow volume

cm3/ot (cu in/rev)

200 (12)

Weight of power steering assembly

kg (lb)

5,9 (13)

Maximum bending moment

Nm (lb ft)

200 (147)

Maximum axial force

A

1000

Maximum turning moment on the wheel

Nm (lb ft)

160 (118)

Load on the steering column

Inspection

• Check smooth operation of steering • Check after each 500 hours of operation: -

the tightness of steering assembly connections and hoses, sealing faces of the lid and screws on the lid, contacts on the column

-

safety locking screws on the lid

-

steering, while running without power steering, when the source of pressure has failed

Note: Intrusion into power steering is not allowed. If defective, call service!

Operation in emergency mode is not allowed for extended periods.

80

VP 2400

G - STEERING Linear hydraulic motor hv 80/40/200 Hydraulic linear cylinder transforms pressure to mechanical work in the cylinder with a linear motion.

Linear hydraulic motor consists of a cylinder and a piston, see Fig. G/12. Piston rings and collars provide sealing of surface inside the cylinder. The motor doesn’t require any special maintenance or operation, only lubrication of pins at periods specified in the lubrication schedule.

When replacing seals, cleanliness of all parts is important. Observe ecological rules, should there be leaks of oil, described in chapter ”Safety Regulations”, section on repairs.

Technical data

Type

HV 80/40/200

Nominal pressure

MPa (PSI)

16 (2320)

Max. operational pressure (max. time 0,1 s) MPa (PSI)

20 (2900)

Piston speed: Minimal Maximal

m.s-1 (feet/sec) -1

m.s

(feet/sec)

0,01 (0,033) 0,5 (1,64)

Pushing force

N (lb)

75600 (16994)

Pulling force

N (lb)

55493 (12234)

Lift

mm (in)

200 (7,87)

Weight

kg (lb)

14,7 (32,4)

Tightening torque Connection piston rod 2, piston 3

Connection cylinder, lid nuts 1

Thread

M 30x2

M 85x2

Torque Nm (lb ft)

270 (199)

370 (273)

Priority valve By including the valve in the hydraulic loop, energy saving is achieved. The valve operates as a three-way relieve valve that rectifies oil stream to the tank without any loss, when both steering wheels are idle. It operates independently of pressure in steering.

The loop includes also a logic valve, which opens the hydraulic loop following a signal from power steering when activated by the wheel motion.

Power steering tank no-05-25-5 The tank is made of steel plate, and includes cleaning cartridges, lid, oil level indicator, and venting.

Technical data: Tank volume

l (gal US) 3

–1

3 (0,8)

Through-flow, input

dm .min

Weight of empty tank

kg (lb)

5 (11)

Filtering capacity

µm

10

VP 2400

(gal US/min)

25 (6,6)

81

G - STEERING 1.3. LUBRICANTS AND GLUES Oil content Only good quality hydraulic oils are used in the hydraulic loop to ISO 6743/4 HM or HV. like DIN 51 524 part 2 HLP or DIN 51 524 part 3 HLP CETOP RP 91 H Kinetic viscosity 46 mm 2.s –1 at 40°C (104°F) - ISO VG 46

Manufacturer

Oil type

Class

HM (HLP)

HV (HVLP)

Viscosity to ISO 6743/4, DIN 51519

VG 46

VG 68

VG 46

Viscosity to CETOP RP 91H

HM 46

HM 68

HV 46

AGIP

OSO 46

OSO 68

ARNICA 46

ARAL

VITAM GF46

VITAM GF 68

VITAM HF 46

AVIA

AVILUB RSL 46

AVILUB RSL 68

AVILUB HVI 46

OH-HM 46

OH- HM 68

OH- HV46

ENERGOL HLP 46

ENERGOL HLP 68

BARTRAN HV 46

BENZINA BP BULGARIA

MX- M/46

MX- M/ 68

MX- B/46

CASTROL

HYSPIN AWS 46

HYSPIN AWS 68

HYSPIN AWH 46

CHEVRON

EP HYDR.OIL 46

EP HYDR.OIL 68

EP HYDR.OIL 46 HV

DEA

ASTRON HLP 46

ASTRON HLP 68

–

ELF

ELFOLNA 46

ELFOLNA 68

HYDRELF 46

ESSO

NUTO H 46

NUTO H 68

UNIVIS N 46

FINA

HYDRAN 46

HYDRAN 68

HYDRAN HV 46

FUCHS

RENOLIN B 15

RENOLIN B 20

RENOLIN MR 46 HV

HIDROKOMOL P 46

HIDROKOMOL P 68

HIDROKOMOL HV 46

MOBIL

MOBIL DTE 25

MOBIL DTE 26

MOBIL DTE 15

ÖMV

HLP 46

HLP 68

HLP-M46

POLAND

HYDROL 30

HYDROL 40

BOXOL 26

ROMANIA

H 46 EP

H 68 EP

-

HUNGARY

RUSSIA

IGP 30

IGP 38

-

SHELL

TELLUS OIL 46

TELLUS OIL 68

TELLUS OIL T 46

TEXACO

ALCOR OIL DD46

ALCOR OIL DD68

ALCOR OIL DD-Z 46

TOTAL

AZOLLA ZS 46

AZOLLA ZS 68

EQUIVIS ZS 46

82

VP 2400

G - STEERING Grease Synthetic grease with Lithium and of consistency to NLGI -2*, see table BENZINA

MOBIL

ESSO

SHELL

CASTROL

P-ML-A2

Mobilgrease MP

Multi-Purpouse

Retinax A

Castrolease LM

Mobilgrease Special

Grease H

Alvania

Spherol

Grease No.3

Grease RBB2

Mobilplex EP-1 * - NLGI 2 - National Lubricating Grease Institute; part 2

2. POSSIBLE DEFECTS AND REMEDIES Defect

Cause

Locating defect and remedy

Steering is non-functional, the wheel freezes up

Low oil (seepage, broken hose

Check hydraulic loop, repair, add oil

Steering doesn't function in difficult terrain

Low pressure-defective priority valve

Check pressure, should be 14 MPa (2030 PSI) with wheel in extreme position

Low pressure, defective power steering

Replace or have it repaired

Low pressure, defective pump (mechanical connection)

1. Check pressure at test point, 14 MPa (2030 PSI) with wheel in extreme position.

2. check mechanical connection of pump to CLARK1 gearbox

Faulty reversible valve in valve block of power steering

Let specialists investigate

Power steering functions only to one side

Test point of the system, see Fig. G/1.

Should steering be out of order, stop the engine. Steering pump could be damaged.

Fig. G/1

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83

G - STEERING 3. DISASSEMBLY AND ASSEMBLY OF THE STEERING ASSEMBLY

• Place the roller horizontally on a firm surface.

• Switch battery breaker off – the roller’s brakes are automatically on.

3.1. PREPARATORY WORK

• Place a notice on the steering wheel – ”THE ROLLER IS BEING REPAIRED”.

• Preparatory work and the assembly should be performed according to introductory chapter Safety Precautions and Instructions. Observe ecological and health regulations.

Fig. G/2

1 - Pump of steering

2-Q10R JIHOSTROJ

2 - Tank with filter

JIHOSTROJ

3 - Servosteering

LAGC 200LSD REXROTH

4 - Hydraulic cylinder of steering

HV80/40/200 SB INMART

5 - Valve logical

XWV8-PL PARKER

6 - Measuring quickcupler SKK20-15L-PK STAUFF 8 - Priority Valve

84

REXROTH

VP 2400

G - STEERING • When working on the hydraulic system all hydraulic elements, like hoses, pipes, devices, and assemblies installed onto the cylinder must be kept absolutely clean, all open hoses, pipes, and connecting elements must be plugged, the installed and vented system must be tested and the filter cartridge in the hydraulic loop must be replaced, the entire system must be vented when any of the hydraulic elements has been replaced. Connect completed assembly to the oil tank with filter. Turn the engine over 3x for period of 8 sec. The assembly fills with oil automatically. Oil level in the tanks should be checked.

3.2.

DISASSEMBLY OF STEERING HYDRAULIC GENERATOR U10

• Drain oil on the left side of rear wheels Fig. G/3.

• Remove floor plates in the area of the cylinder.

• Disconnect high-pressure hose 48 to the priority valve, and the low-pressure hose 50 to the oil tank, Fig. G/4.

• Remove hydraulic generator together with the O-ring.

Assembly

• Assemble in reverse order. Replace and grease O-rings.

Grease the grooved pump shaft before assembly, as in 1.3. Prevent hoses from rubbing each other, the frame, or any other part of the machine during assembly.

Fig. G/3

Fig. G/4

48

50

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85

G - STEERING 3.3. DISASSEMBLY OF POWER STEERING

3.3.1.DISASSEMBLY OF STEERING COLUMN

• Remove lid from the panel.

• Remove cover in the center of the column.

• Disconnect hoses from power steering, Fig. G/5 – before

• Remove nut (1), insert fixture no.1 under the wheel, Fig.

that, note the connection of hoses.

G/6, and with the spanner remove the wheel.

• Remove power steering from the steering column.

• Remove collar of travel control (1), Fig. G/7.

• Re-assemble in reverse order.

• After screws (2) were removed, separate power steering, and remove steering column from the bottom, Fig. G/8.

• Assemble in reverse order. Grease grooved shaft of the column, to 1.3.

Fig. G/5

Fig. G/7

1

Fig. G/6

Fig. G/8

1

2 ¹. 1

86

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G - STEERING 3.4. DISASSEMBLY OF LINEAR HYDRAULIC MOTOR

Fig. G/11

Removal from machine

• Place the roller on firm, flat surface, and a catch basin 4

under the hydraulic cylinder.

• Remove high-pressure hoses, Fig. G/9.

59

• Remove safety rings 59 and nipples 60 on the pins. Knock out pins, slide the hydraulic motor from the steering lever and bracket, Fig. G/10, G/11.

60 Removal of hydraulic motor – replacement of seals Place catch basin under the hydraulic motor, plug openings.

Drill out safety pin from the face of the front lid (1), or bend out the lid holder (1), as required by the type of motor. Remove lid (1) using fixture no 2, slide piston rod (2) with piston (3), loosen screw (5), remove nut (4), remove piston (3), and lid (1), see Fig. G/12. Replace seals, see. Fig. G/13 - dip in oil before assembly.

Fig. G/9

Fig. G/12

Fig. G/10

Fig. G/13

59

3

4

60

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87

G - STEERING 3.5. REMOVAL OF POWER STEERING TANK

Assembly of hydraulic motor Lubricate sliding faces, watch for damage of sliding faces.

Level out seals and install new seals with parts. Wait at least 15 minutes before installing new seals in the hydraulic motor.

Use fixture no.2 for mounting the piston rod with the piston in the cylinder. Tighten bolts to torque of table.

• Drain oil from steering loop on the leftt side of rear wheels, Fig. G/3.

• Drain balance of oil from tank.

• Remove front cover.

• Disconnect high- and low-pressure hoses, Fig. G/14.

Tightening torque values

• Remove fixing screw and the tank.

Connection piston rod,

Connection cylinder, lid,

piston, nuts

nuts

Thread

Torque Nm (lb ft)

Thread

Torque Nm (lb ft)

M30x2

270 (200)

M85x2

370 (273)

• Reassemble in reverse order.

Reassemble in reverse order. Lubricate pins with grease of table section 1.3.

Fig. G/14

88

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G - STEERING 3.6. REMOVAL AND INSTALLATION OF THE LEVER ASSEMBLY

Fig. G/15

Removal

• Remove linear hydraulic motor, see section 3.5.

• Remove cotter pin 2, unscrew nuts 3 from ball joint 36,

3

and knock them out from yoke holes 1, Fig G/15.

• Loosen and unscrew bolts 30, remove pad 22 and ring 20.

1

Remove from the pin the steering lever 4 together with pull rods, and the other ring 20, Fig. G/16.

• Remove nuts 72, screw 68 from holes on the circumferen-

36

2

ce of pin 3. Knock out pin 3 from frame, Fig. G/17.

• Press out bronze bushing 27 Fig. 18.

Fig. G/16

20

22

30

30

4

Fig. G/17

3 72

72

68

68

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89

G - STEERING 4. ADJUSTMENT OF TOE-IN

Installation

• Press bushing 27 into the steering lever, Fig. G/18.

• Press in and tighten ball joints of connecting rods 36 into

Installation data

the conical openings of the steering lever 4, Fig. G/19.

fork extension

mm (in)

115 (4,5)

• Press pin 3 into frame, and screw pin 3 to the frame.

piston rod extension

mm (in)

94 (3,7)

• Place ring 20 and steering lever 4 on pin 4, the other ring

steering lever swing

° (deg)

± 32

20. Insert pad 22 and tighten screws 30, secure screws with safety wire against turning.

• Insert the fixed eyelet of the linear hydraulic motor 54 in the holder on the frame, and two rings. Center out. Press pin 4 in the hole and secure with ring 59. Slide out piston rod and insert 2 rings, center out, press in pin 8, and secure with ring 59, Figs. G/10, 11.

Fig. G/18

Fig. G/19

4 4

27

36

90

36

VP 2400

G - STEERING • Slide the fork of the front axle 1 out of guiding bushings 2

Fig. G/21

to a distance of Fig. G/20.

• Place a ruler 2 to the hubs of wheels 1, and line up both axles to the ruler, see Fig. G/21.

• Extend piston rod of the linear hydraulic motor to L - 94 mm (3.7”) from end position as in Fig. G/22.

• Loosen clamping of ball joints on steering rods 36, and by turning steering rods adjust ball joints against conical holes in fork brackets 1, Fig. G/23.

• Press ball joints in the conical holes, and secure with a nut and a cotter pin.

• Fix steering rods at both ends by tightening the clamp.

• Connect hoses to hydraulic motors. Lubricate pins with grease to table in section 1.3.

Fig. G/22

94

Fig. G/20

2 Fig. G/23

36

1 1

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91

G - STEERING 5. FIXTURES no. 1 Mounting fixture (64-374-0112) - for removal of steering wheel

no. 2 Key for removing the lid 10 (92-655-0092), ( 92-655 0094)

no. 3 Guiding bushing 92-644-031

92

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H - SERVICE BRAKE

H - SERVICE BRAKE

1. SPECIFICATIONS

1. Specifications

1.1. DESCRIPTION

1.1.

Description

1.2.

Specifications

1.3.

Brake fluid

2. Defects 3. Disassembly and assembly 3.1.

Preparatory work

3.2.

Disassembly of pedal brake

3.3.

Disassembly of booster

3.4.

Disassembly of brake system

Service brake is controlled by a pedal from the driver’s position. It is a hydraulic-pneumatic loop with a built-in compressor, air dryer, brake pedal, hydraulic-pneumatic boosters, fluid tanks, pipes, and brake assemblies in rear wheels.

Pressurized air in the tank has a pressure of 0,65 MPa (94.5 PSI), and is piped to two brake pedals. When one of the pedals is depressed, the air flows from the air-tank through pipes under 0.65 MPa to the two-way valve 4 and the boosters.

In the boosters, the air pressure is transformed to brake fluid pressure, which is then piped to brake cylinders that operate the brake shoes in rear wheels. When the brakes are released, the fluid travels back under pressure to the booster. Air escapes from the air-cylinder back to the brake assembly, and through the middle of the upper release in the open air.

4. Brake shoes adjustment 5. Service brake venting 6. Machining brake drums

VP 2400

93

H - SERVICE BRAKE Fig. H/1

94

VP 2400

H - SERVICE BRAKE

Legend: 1 - Air Dryer

WABCO

2 - Control Valve

WABCO

3 - Relief Valve

WABCO

4 - Double check Valve

WABCO

5 - Water separator

KNORR AUTOBRZDY

6 - Pedal brake valve

KNORR AUTOBRZDY

8 - Air reservoir

35 l GASTEC

9 - Valve electric

EV68 AIR PRODUCTS

10 - Valve non - return

KNORR AUTOBRZDY

11 - Switch pressure

APS

12 - Switch pressure

APS

13 - Brake cylinder spring

KNORR AUTOBRZDY

15 - Measuring quickcupler

WABCO

16 - Manometer Tire

MOTOMETER

17 - Manometer Brake

MOTOMETER

18 - Air reservoir*

5 l GASTEC

19 - Booster 20 - Valve electric * - Used for machines of ser. numbers from 27 to 67

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95

H - SERVICE BRAKE 1.2. SPECIFICATIONS

AIR-FLUID BOOSTER Description

BRAKE CIRCUIT Brake cylinders

mm (in)

38 (1,5)

Air service pressure

MPa (PSI)

0,65 (94)

Diameter of brake drums

mm (in)

400 H11 (15,7)

Brake lining – gauge

mm (in)

8 (0,314)

The booster consists of its air section and the hydraulic main brake cylinder. The boosting air section is controlled by the main brake of the air loop. When the brake pedal is depressed, air under pressure enters the space of the air cylinder, and pushes the piston that exercises pressure on the main brake cylinder.

Brake pedal

Specifications

Funktion

Main cylinder

mm (in)

∅ 39 (1,53)

By depressing the pedal, the force is transferred over a spring to the upper discharge that moves downwards until it rests on a cap in the pressure chamber of the centerpiece.

The opening for the release of pressurized air from brake cylinders is closed. With further shifting, the cap is removed from the seat of the first loop, and air under pressure from the air-tank is released in the space under the upper discharge and the brake cylinders. The other loop is plugged.

Air cylinder

mm (in)

∅ 170 (6,69)

Force of air cylinder

N (lb)

12250 (2754)

Nominal pressure

MPa (PSI)

0,6 (87)

Maximal force on the pedal

N (lb)

250 (55)

Total play of the pedal

° (deg)

28

Free travel

° (deg)

8

Smooth braking

° (deg)

14

Emergency braking

° (deg)

6

Service pressure

MPa (PSI)

0,8 (116)

Weight

kg (lb)

3,5 (7,7)

kp/cm (lb/sq.in) 6 (85,3) mm (in) 3

Maximum delivered volume cm (cu.in) service air pressure Residual pressure in main cylinder within

Specifications

96

with pressure Maxim.lift of main cylinder

2

45 (1,77) 51 (3,11)

2

kp/cm (lb/sq.in) 6 (85,3) kp/cm2 (lb/sq.in)

0,8-1,3 (11,38-18,48)

VP 2400

H - SERVICE BRAKE COMPRESSOR

AIR DRYER

is the source of compressed air for the loop of brakes. The input is connected to the engine intake manifold.

Function

Use only metal (copper) connectors.

When during manual venting of the air tank oil appears mixed with water, check -

oil consumption in the compressor

-

regeneration to an excessive contra-pressure

-

whether switching off pressure has been reached, and thus, the time for the compressor to switch on.

Cleans and dries air to the compressor. Prevents corrosion and break up of lubrication films.

Drying is based on the absorption in the molecular sieve (drying, high porosity, granulated desiccant) through which pressurized air flows into the compressor. Air humidity is absorbed by the desiccant. To regenerate the desiccant, part of the dried air is released at atmospheric pressure and blown in the opposite direction through the desiccant. The drop in pressure causes the vapor pressure drop in the regenerated air (= extremely dry air). This way, the regenerated air is capable of absorbing moisture in the desiccant.

Check oil consumption With the engine warmed up to service temperature -

disconnect input and output hoses from compressor

-

let the engine run for about 2 minutes at half RPM of full range (cleaning mode)

-

Place a white piece of paper on a firm pad in the air stream for about 5 minutes at about 1500 RPM.

At low oil consumption of less than 1,5 g/hod.(low wear), the compressor will leave an oily fog on the paper.

Specifications Service pressure max.

Air flow max.

bar (PSI)

13 (188,5)

–1

–1

l.min (gal US.min ) 1000 (264)

Operation at temperature °C (°F)

–40 ÷ +80 (–40÷ +176)

Exhaust noise level

dB (A)

78

Switching off pressure

bar (PSI)

6,5 (94)

At high consumption – high wear – a black field will appear on the paper.

BRAKE SWITCH With insufficient compressor output, check -

narrowing of pressure piping (carbon deposits)

Switches on brake lights with the increased pressure of brake fluid.

-

tightness of the assembly

Specifications

-

If no defects found, remove cylinder head and recheck intake and pressure blade, and seals,

Nominal voltage

V

-

With high deposits of carbon, check temperature and oil consumption of the compressor.

Max. power

W

Max. service temperature ° C (°F)

85 (185)

Pressure for switching on kPa (PSI)

300-600 (43,5-87)

Max. service pressure

35000 (5075)

When replacing the compressor, check output piping for possible carbon deposits. If necessary, replace it, as well as the pressure regulator and air dryer.

VP 2400

kPa (PSI)

6, 12, 24 60

97

H - SERVICE BRAKE 1.3. BRAKE FLUID Fluid is according to International standards ISO 4925, SAE J 1703 f, DOT 3, and is not suitable for arctic conditions. It may be mixed with fluids of same standards The fluid may be used in systems working at –50 °C (–58 °F) to 60 °C (140 °F), and service temperatures from –50 °C (–58 °F) to 205 °C (400 °F). Also a fluid to DOT 4 (Syntol HD 260) standard may be used. The fluid should be changed within 2 years or after 2000 service hours, whichever occurs first.

2. DEFECTS Loop defect

Cause

Determination (remedy) of defect

Low efficiency of braking

Low pressure in air system

Adjust regulator to 0.65 Mpa (94 PSI)

Defective booster

Test pressure in hydraulic section- 1.2 Mpa

Air locks

Vent per par. 3.5.

Lining wear

Check, replace shoes, per 3.4.

Soiled lining (grease)

Check per 3.4.

Brake assembly defect

Cause

Remedy

With depressed pedal,

Faulty seal of the cap and

Defect remedy is not urgent. First depress pedal several times

pressure is escaping

the upper release

fast. The deposits will blow off. Should this not help,

through venting holes

disassemble, clean contact areas and inspect seats and seal, and/or apply emery paper to cap evenly, or replace.

With released pedal,

Faulty contact of caps with

pressure escapes

seats in the body

Correct defect in the same manner as above

through venting holes out.

With released pedal, pressure escape from

Plugged filter cartridge or stiff guides of releases (dried

piping and cylinders is

out grease, dirt, ground in)

Disassemble, wash filter cartridge, clean release, and/or clean with fine emery and apply a light film of anti-freezing grease.

too slow

98

VP 2400

H - SERVICE BRAKE Test point of brake system air loop Brake assembly - pressure 0÷ 0,65 MPa (0 ÷ 94 PSI) according to pressure on brake, Fig. H/2.

Spring-loaded cylinder - pressure 0,53 ÷ 0,65 MPa (77 ÷ 94 PSI), Fig. H/3.

Fig. H/2

VP 2400

Fig. H/3

99

H - SERVICE BRAKE 3. DISASSEMBLY AND INSTALLATION Perform preparations, disassembly and assembly according to the introductory chapter ”Safety precautions and instructions”, keep ecological and health precautions.

3.2.

DISASSEMBLY OF PEDAL BRAKE

• Release pressurized air from the air loop by pulling on the chain of the venting valve on the air tank.

• Remove floor cover plates at the service place.

• Unscrew fillers on both sides of the brake outlets, Fig.

3.1. PREPARATIONS • Place the machine horizontally on a firm surface.

H/4.

• Remove 4 screws and remove the brake, Fig. H/5.

• Secure front wheels on both sides with wooden blocks.

Installation

• Switch off batteries – the machine is automatically locked.

in reverse order.

• Place notice “MACHINE OUT OF ORDER” on the steering wheel.

Fig. H/4

100

Fig. H/5

VP 2400

H - SERVICE BRAKE 3.3. DISASSEMBLY OF BOOSTER

Installation of booster

• Install splitter and reduction on the booster.

• Remove floor cover plates at the service place.

• Drain brake fluid into a ready basin by unscrewing plug 8 at the output of the booster and by stepping on the pedal several times.

• Remove hose 11 of the brake fluid input from the tank to the brake cylinder, disconnect wiring from switch 22.

• Remove bolts of input 58 from the brake to the booster,

• Screw booster on brackets on the frame.

• Screw fitting of air intake between the booster and the brake.

• Attach input hose of brake fluid.

• Pour brake fluid in the container, and vent the entire system, see 3.3.

Fig. H/6.

• Remove booster from the frame.

• Remove brake fluid splitter 25 and reduction 5, Fig. H/7.

Fig. H/6

Fig. H/7

11 22 58

8

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5

25

101

H - SERVICE BRAKE 3.4. DISASSEMBLY OF BRAKE SYSTEM

Disassembly of brake cylinders in wheels

• The wheel and brake drum should be off.

Disassembly of shoes

• If the thickness of lining is less than 2 mm (0,08 in),or if the lining is considerably soiled by grease, replace the lining.

• Remove wheel (see Chapter. D).

• Remove pipes to brake cylinders in the wheels. Catch escaping fluid in a ready basin.

• Remove brake drum off flanges, use forcing-off screws in the holes of the drum, Fig. H/8.

• Remove springs and shoes, Fig. H/9.

• Remove leaking brake cylinders.

• Clean the surface of the brake cylinders and pistons.

• Remove seal collars.

• Inspect carefully inside surfaces of cylinders.

• Replace complete wheel cylinder, if damage to the active face discovered (grooves, corrosion, etc.).

• For cleaning the wheel brake cylinder (the main brake cylinder) use wood alcohol - never clean with cleaners containing mineral oils!

Installation of brake system

• Install in reverse order.

• Keep sliding faces clean and degreased. Brake components may not be exposed to oily matters.

• Following the reconnection of pipes to the brake cylinder, fill loop with brake fluid, and vent. Adjust brakes thereafter, and replace wheel.

Fig. H/8

Fig. H/9

1

2

1 1

2 102

VP 2400

H - SERVICE BRAKE 4. BRAKE SHOES ADJUSTMENT

Adjust only when the brakes are cold.

For equal braking effect replace all shoes together.

• This hydraulic power brake is self-adjustable in both brake shoes by means of a float (1). The adjustment free play between the shoe and the drum is done by the adjusting ratchet (2), Fig. H/10.

• With the wheel removed, see Chapter “D”, and installed brake drums.

• With low pressure in the brake loop, release mechanical

Always replace damaged adjustment assembly.

Let only professionals glue lining on shoes.

As replacement, use original shoes with KNOTT lining only!

Warranty lapses, if other than original spare parts were used.

brake cylinder of the disk brake (park brake) by turning the release screw (1), following the removal of plug (2) and the application of fixture (1) in the spring loaded cylinder (3), Fig. H/11.

• Turn the drum through the adjustment opening downwards to the adjustment ratchet (2), Fig. H/12.

• Turn ratchet wheel (2), Fig. H/10 until the shoe rests on the drum, and the drum cannot be turned.

• Return the ratchet wheel until the drums are released.

The drum can be turned freely without any audible friction of the drum against the shoes.

Fig. H/11

• Replace the wheels.

Fig. H/10

Fig. H/12

1

2

VP 2400

2

103

H - SERVICE BRAKE 5. SERVICE BRAKE VENTING

6. MACHINING BRAKE DRUMS

• Pour specified brake fluid in the equalizing container of

• Brake drums may be machined only if worn out or if

the brake loop, and maintain level above ”MIN” during venting.

• Loosen venting screw on the booster by two turns, Fig. H/13.

• When the booster is full, tighten the vent screw.

• Loosen venting screw on the brake cylinder and attach a hose to its head. Insert the other end in a glass containing fluid (the end must be submerged).

• Start the engine and pressurize the brake system to maximum value of 0,65 MPa (6,5 bar) (94 PSI), then switch the engine off.

damaged by deep grooves on the friction surface.

• Install brake systems on drums machined to identical diameters. It is not allowed to install brake drums of different diameters on the individual pairs of the brake system.

• The diameter of machined brake drum may not exceed the maximum allowed diameter.

Original diameter mm (in)

Maximum diameter after machining mm (in)

400 H11 (15,7)

402,5 (15,8)

• Fill the loop completely by repeated stepping on the pedal and simultaneous addition of fluid in the equalizing container.

• When bubbles stop coming out of the submerged hose, tighten the venting screw and remove the hose.

• Venting can be done on all drums simultaneously, Fig. H/14.

The friction faces are coaxial to the drum axis to ± 0,10 mm.

All drums must be machined to the same diameter.

In machined drums, brake shoes of thicker lining must be used – contact the manufacturer of the cylinder or the brakes.

• Add fluid in the equalizing container to specified level.

• Before the engine is started, the travel control must be in position ”N”, and the roller must have park brakes on.

Fig. H/14

Fig. H/13

1 1

1

2

2

3 104

1

2

2

3 VP 2400

I - PARKING BRAKE

I - PARKING BRAKE

1. SPECIFICATIONS - DESCRIPTION

1. Specifications - description

1.1. DESCRIPTION

1.1.

Description

1.2.

Specifications

2. Maintenance 2.1.

Disassembly and installation of the disk brake

2.2.

Removal and installation of the spring-loaded cylinder

The brake is used as parking or emergency brake.

When the roller stops and the engine is switched off the brake is applied automatically. The brake is released when the engine is started and the air in the loop is compressed to 0,53 MPa (5,3 bar; 77 PSI). It is signaled by the indicator going off.

Braking of the roller is accomplished by depressing the button on the dashboard. This causes the solenoid to open, air escapes from the spring-loaded cylinder and the pressure on the spring drops. The spring returns to its original position. The lever mechanism contracts the jaws on the disk of the brake, and the roller is stopped.

The roller can be stopped in case of emergency by the service brake when the push-button is depressed on the dashboard. The roller and the engine stop.

1.2. SPECIFICATIONS

VP 2400

Nominal pressure

MPa (PSI)

0,8 (116)

Lift

mm (in)

70 (2,76)

Pressure with piston rod extended (brake off)

kN

3,8

Pressure with piston rod retracted (brake on)

kN

2,5

Weight

kg (lb)

5,75 (12,7)

105

I - PARKING BRAKE 2. MAINTENANCE

Fig. I/1

After 1000 hours of service, the collars should be inspected and the sliding parts greased. Inspect the piston rod lift. It is not recommended to use more than 2/3 of the full lift of the rod.

Attention! When disassembling the base of the chamber with the spring, be careful not to get hurt, since the spring is installed in the depressed state and loaded by about 4000 N.

2.1. DISASSEMBLY AND INSTALLATION OF THE DISK BRAKE • Position the roller on a firm, flat surface, the front and rear wheels wedged on both sides.

• Remove the center floor cover.

• Unload the lever by screw (1) (accessory) into the cylinder (2) Fig. I/1.

Fig. I/2

• Remove the flange of the crankshaft (146) from the side of the brake disk (6), slide in and fold to side, Fig. I/2.

6

• Loosen and remove nut (1), Fig. I/3.

• Remove nuts (24) on yoke (20), pull-rod (7) from brake yoke (20), Fig. I/4.

• Slide disk (6) with the yoke (28) off the groove off the differential pinion.

146

• Assemble in reverse order. The safety nut may be reused, but it must be knocked into the other differential pinion groove.

Fig. I/3

106

VP 2400

I - PARKING BRAKE 2.2. REMOVAL AND INSTALLATION OF THE SPRING-LOADED CYLINDER • Unload the lever by the screw (accessory) in the cylinder, Fig. I/1.

• Disconnect the yoke (3) of the cylinder (35) from the lever (2), Fig. I/4.

• Disconnect air hose.

• Install in reverse order.

Fig. I/4

VP 2400

107

J - INFLATING THE TIRES

J - INFLATING THE TIRES

1. SPECIFICATIONS

1. Specifications

1.1. DESCRIPTION

1.1.

Description

1.2.

Specifications

2. Removal and installation 2.1.

Control valve

2.2.

Rotor

Compressed air is led through plastic tubes from the air tank over a by-pass valve to a return valve to the distributor, where it is distributed to the rear and front axles, and then over rotors to individual wheels. Each wheel has a safety valve adjusted so that other tires remain inflated to 0,18 MPa when one of them is punctured. The other control valve connected to the loop through the distributor is used to deflate the tires.

The pressure in the loop is read on the manometer on the dashboard. The assembly makes it possible to change pressure in the tires en-route.

1.2. SPECIFICATIONS Air pressure in the loop

max. 0,6 MPa

Adjustment of the safety valve

0,18 MPa

Observe safety during work with the engine off. Keep individual parts and hoses clean, screws tight. Adjust and test the air loop so that air escapes less than 0,1 atm in12 hours.

108

VP 2400

J - INFLATING THE TIRES 2. REMOVAL AND INSTALLATION

2.2. ROTOR

2.1. CONTROL VALVE

Removal

• The rotor attaches the firm part to the rotary part of the of Release pressurized air from the inflating loop by opening the release valve before starting dissembling.

the conduits, and is located in the fixed center of the wheels.

• Remove hose (2) and rotor (1), Fig. J/1 - 4x back, 2x in front.

• Remove screw (7), lid (3), safety rings (8, 9), Fig. J/2.

• Press out the shaft (1).

• Press out bearings (6), lid (4).

Installation

• Place the lid (4) on the shaft (1), and press in bearings (6) - secure with 2 safety rings (9).

• Insert collar (5) in the collar (3) body, screw into bearings (2) and secure with screw (7).

• Fill bearing (2) with grease.

• Insert shaft (1) with bearings into body (2) and secure with safety ring (8).

Fig. J/1

Fig. J/2

2

1

VP 2400

109

K - WHEELS

K - WHEELS

2. REMOVAL OF WHEELS

1. Specifications

2.1. PREPARATION FOR WORK

1.1.

Description

1.2.

Specifications

• In preparation for work and handling of wheels, follow the introductory chapter on Safety. Observe ecology and health regulations.

• The valve for inflating tires must be closed.

2. Wheel removal 2.1.

Preparation

• Place the roller horizontally on a firm surface.

2.2.

Front axle wheels

• Switch the battery breaker off – the brakes of the roller are

2.3.

Rear axle wheels

automatically on.

• Place a sign on the steering wheel saying “ROLLER OUT OF SERVICE”.

3. Removal and installation of tires

• Wedge front wheels on both sides when removing rear wheels.

4. Installation of wheels 5. Adjustment of safety valve

2.2. FRONT AXLE WHEELS

1. SPECIFICATIONS

• Lift the front of the machine by suitable means, Fig. K/1.

• Unscrew the rotor from the axle.

1.1. DESCRIPTION

• Unscrew hose (2) from the safety valve (3), thereafter also

All versions of roller VP 2400 have as standard 4 wheels on the front and rear axles. The tires are inflated from the air loop of the machine, centrally. Should any tire be punctured, the other tires maintain air pressure of (0,18 MPa) secured by the safety valve on the tire.

the valve from the tire.

• Remove wheel nuts (4) and take off the wheel, Fig. K/2.

1.2. SPECIFICATIONS Disk wheel

8,0 - 20 HD

Tire

Compactor without any design 11.00x20" PR16

Tube

11.00x20"

Protective inlay

11.00x20"

Tightening torque of wheel nuts

440 Nm

Tire inflation - see Service Manual VP 2400

110

Fig. K/1

VP 2400

K - WHEELS 2.3. REAR AXLE WHEELS outside wheels

• Wedge front wheels on both sides.

• Lift the rear end of the machine by suitable means, Fig. K/3, and support them on a pad above ground.

• Unscrew hose (2) from the axle shaft.

• Unscrew this hose also from the safety valve (4), thereafter also the valve from the tire.

• Remove wheel nuts and take off the wheel. inside wheels

• Unscrew hoses (2) and (3) from rotor (1).

• Remove rotor (1) from the center shaft of the axle.

• Remove wheel nuts and take off the wheel.

• Unscrew hose (3) from the safety valve (4), thereafter also the valve from the tire Fig. K/4.

Fig. K/2

4

1

Fig. K/3

2

3

Fig. K/4

3 2

1

VP 2400

111

K - WHEELS 3. REMOVAL AND INSTALLATION OF TIRES

5. SAFETY VALVE ADJUSTMENT

We recommend doing this on special machines in service shops, wheel balancing as well.

Loosen safety valve nut (1) and adjust the setscrew (2) so that its face is in line with the face of the nut, Fig. K/5.

4. INSTALLATION OF WHEEL TO THE MACHINE • Follow reverse order.

• Place wheel disk on wheel nuts.

• Insert and screw wheel nuts in criss-cross pattern, tighten with torque of 330 ÷ 350 Nm (245 ÷ 260 ft lb).

• In connecting tire inflation assembly, follow reverse order.

Tighten all joints well.

• When replacing tubes, check that the original filling valve has been removed before installing a new valve in a tire with a new outlet.

Fig. K/5

2

1

112

VP 2400

L - ELECTRICAL WIRING

L - ELECTRICAL WIRING

1. DESCRIPTION

1. Electrical wiring - description

Electrical wiring of the VP 2400 roller is a single conductor circuit. The other conductor is the chassis. The minus pole of the battery is grounded to the frame of the roller. The voltage is 12 V. All electrical circuits are protected with fusible strip fuses located in the fuse box on the right side of the dashboard.

1.1.

Battery breaker

2. Battery 2.1.

Specifications

2.2.

Operation

2.3.

Indications of full charge

2.4.

Service during operations

2.5.

Safety regulations

Fuses in the box, Fig. L/1: F1 (5A)

- illumination of instruments, left side marker, left rear light

F2 (5A)

- right front side marker, right rear light

F3 (15A) - headlights and indicator 3. Alternator 3.1.

Checking the alternator on the roller

3.2.

Determining defects of alternator-regulator

3.3.

Voltage regulator

4. Starter 4.1.

Operation and maintenance

4.2.

Check of idling – on the machine

4.3.

Starter defects

F4 (15A) - rear light and indicator F5 (20A) - hazard beacon, cabin illumination, brake lights, directional lights F6 (15A) - travel control, relays, steering activation indicator, forward and backward travel solenoids, engine stops, emergency brake, differential lock, service light plug F7 (5A)

- differential lock indicator, engine lubrication indicator, brake failure indicator, park brake, air filter plugging indicator, engine temperature, gearbox temperature, fuel level meter, gearbox lubrication pressure meter

F8 (15A) - windshield wipers, washer F9 (10A) - sprinkling F10 (25A) - fan F11 (10A) - solenoid clutch of the air-conditioner compressor F12

- spare

Replace fuses with fuses of same rating.

Fig. L/1

VP 2400

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12 113

L - ELECTRICAL WIRING 1.1. BAT TERY BREAKER

Electrical wiring – Location of elements - Fig. L/2 Legenda

is located on the dashboard, Fig. L/2.

1 - Starter 2 - Alternator

Disconnect battery when working on electrical wiring.

3 - Engine temperature sensor 4 - Air filter sensor 5 - Engine lubrication sensor 6 - Breaker 7 - Gear shifting connector 8 - Gearbox lubrication sensor 9 - Gearbox temperature sensor 10 - Engine tripping magnet 11 - Sprinkling pump 12 - Steering unit 13 - Battery 14 - Gear shift 15 - Switch brake fault 16 - brake pressure switch 17 - Switch box 18 - brake magnet 19 - Service plug 20 - Battery breaker 21 - Heater fan 22 - Reverse buzzer 23 - Fuel tank float gauge 24 - Brake lights switch 25 - Lock magnet 26 - Horn

114

VP 2400

L - ELECTRICAL WIRING Fig. L/2 - Electrical wiring – Location of elements

VP 2400

115

L - ELECTRICAL WIRING 2. BATTERY

2.2. OPERATION

Battery type 12 D HD 135 is located in the box on the left side of the front section of the frame, Fig. L/2.

All cells of the battery must be filled with sulfuric acid of density 1,28 g.cm-3 (0,799 lb/cu.ft) 5-15 mm above the electrodes. Electrolyte and battery to be acclimatized to 15 - 20 °C.

2.1. SPECIFICATIONS Nominal voltage

V

12

Nominal capacity

Ah

100

Volume of electrolyte

l (gal US)

12 (3,2)

Electrolyte density *

g.cm -3 (lb/cu.ft)

1,28 (0,799)

g.cm –3 (lb/cu.ft)

1,23 (0,768)

- tropics

* - electrolyte temperature 27 °C (81°F) Electrolyte – Sulfuric acid

Let the electrolyte soak into the plates and separators for about 20 minutes and add enough to raise the level to 5 to 10 mm above the plates, should a drop be noticed. Charge the battery with current I3 per table up to full charge as indicated.

Batteries older than 6 months should be let soaked for 3 hours. Charge battery with current I1 in table.

The temperature of the electrolyte should not exceed 40 °C. If necessary, cool with air or water bath, lower charging current, or stop charging.

Currents lower than those in table are beneficial to the battery. Charging time increases. The filling holes should be left open. When charging is finished, check the level and density of the electrolyte, and if needed, fill and correct density to 1,28 g.cm-3 (0,7 lb/cu.ft). Insert plugs and after about 2 hours of degassing wash the battery with water and wipe dry.

Table of charging currents

116

Charging current

[A]

I1

6

I2

13

I3

10

VP 2400

L - ELECTRICAL WIRING 2.3. INDICATIONS OF FULL CHARGE

2.4. SERVICE DURING OPERATIONS

The battery is considered fully charged when all cells produce gas vigorously, the electrolyte has density of 1,28 g.cm-3 (0,799 lb/cu ft). The voltage of each cell is 2,5 - 2,7 V. and the total voltage on the terminals over the six cells is 15 - 16 V.

Correctly working charging circuit maintains the battery nearly fully charged, and the voltage oscillates between 27,6 and 28,4 V.

Full charge is checked after two more hours and there should be no change from the listed values of voltage and density.

Discharge is indicated by density of 1,12 g.cm –3 (0,7 lb/cu ft).

The level of charge is indicated by values in table Level of charge in %

Electrolyte density in g.cm–3 (lb/cu ft)

100

1,28 (0,799)

70

1,23 (0,768)

50

1,20 (0,749)

20

1,15 (0,718)

Values apply to electrolyte temperature of 27 °C. For temperatures lower than 15 °C the measured density will be higher by 0,01 g.cm-3 . The electrolyte values are valid after 10 to 30 minutes of charging after the electrolyte has been added, depending of the current while the electrolyte is gassing vigorously. Distilled water must be used to reach a level 5 to 10 mm above the separators before recharging.

VP 2400

The level of the electrolyte will be checked every 3 months with voltage adjusted to this level. In summertime check weekly. Battery overcharging results in sizeable drop in electrolyte volume. Insufficient charging results in lower density of the electrolyte. Self-discharge current is about 1% of the capacity daily.

Battery is charged with current I2 until gassing shows up, then by current I1 up to full charge (15÷16 V). Charging may be done also with current I3 or smaller down to 0,1 x I 3 up to full charge.

Batteries must be kept clean, well fastened without deforming the battery case, the terminals must be tight.

Electrolytic vapors deposit sulfides on the terminals and must be removed. Protect clean metal parts with a thin layer of Vaseline or oil.

Stored batteries must be recharged every 2 months.

117

L - ELECTRICAL WIRING 2.5. SAFETY REGULATIONS

WHEN WORKING WITH BATTERIES, OBSERVE SAFETY!!!

• The battery electrolyte is a strong acid. Use protective rubber gloves and glasses or goggles.

• Before welding on the machine disconnect cables on terminals “B+” and “D+” of the alternator.

• Protect your skin and clothing against being splashed by electrolyte or lead particles.

• Connect the battery negative terminal to chassis, and positive terminal to the alternator’s output terminal “B+”.

Reversed connection could destroy the entire semiconductor wiring of the machine.

• Should electrolyte enter your eye, wash it thoroughly for several minutes with ample water, and seek out medical help immediately.

• Take off your clothing and wash with soapy water or a solution of soda, if splashed with electrolyte, and seek out medical help.

• Should you digest electrolyte, drink as much milk, water, or magnesia solution as possible, and seek out medical help.

• Never fill with distilled water, unless followed immediately by recharging either in the working machine or outside.

Otherwise, the result would be increased self-discharging.

• Never add acid (H2SO 4)!

• Do not turn the battery upside down. The electrolyte may run out through the gas escape holes.

• Wash the spill of acid (electrolyte) with water and neutralize with lime.

• During charging hydrogen gas escapes and creates a highly explosive mixture with air. Keep open flame away and do not smoke.

• Prevent sparks and do not handle conductors, electrical devices, or equipment that could result in sparking.

• Do not check voltage by sparking wires against chassis.

• Disconnect the battery when repairing the charging circuit to prevent accidental shorts.

• When removing the battery, disconnect cable from the negative terminal (-) and then the positive (+).

• Do not disconnect batteries while the engine is running.

• When starting using an auxiliary source, do not disconnect this source before the battery is connected.

• Observe the voltage of the auxiliary source (12 V).

118

VP 2400

L - ELECTRICAL WIRING 3. ALTERNATOR

3.1. CHECKING THE ALTERNATOR ON THE ROLLER

• The alternator is the source of electrical energy.

The control is for information only. Only when measuring under load on a test bed is this control binding.

• A semiconductor voltage regulator is part of the alternator to maintain output voltage within limits while the revolutions, load and ambient temperature vary.

• Regulated voltage is measured on terminal +B. • The alternator is cooled by a fan turning in the marked direction.

• The alternator must be always connected to the battery – positive battery to +B. It is not allowed to disconnect the battery while the engine is running.

• Avoid shorts in the alternator circuit. While repairing wiring or welding on the machine, disconnect the alternator.

When starting with an external source, it is not permitted to disconnect this source before the battery is not on. The alternator must not be run unloaded with cable removed from terminal ”+B” and the terminal ”+D” connected.

• A burnt out indicator bulb of charging must be replaced immediately. Without this bulb the alternator excitation doesn’t function. When washing the engine, prevent water from entering the ventilation openings on the alternator.

Correct operation is preconditioned by -

undamaged electrical wiring

-

proper connections on terminals of the alternator, battery, and regulator

-

sufficient pull on the driving belt – the radial force on the alternator shaft caused by the belt must be less than 800 N on the axis of the pulley.

Defective alternator or regulator may cause insufficient charging or overcharging of the battery.

Normal workshop inspection of the entire circuitry when no defects are anticipated consists of checking the regulated voltage or the reaction of the bulb indicator to increased revolutions. With a voltmeter connected to ”B+”, the regulated voltage must alternate between 27 and 28,2 V. The charge indicator on the dashboard indicates eventual defects of the alternator or regulator.

NOTE: When welding on the machine disconnect the alternator leads from terminals ”+B” and ”+D”, and electrical devices containing semiconductors. Disconnect battery when repairing other electrical devices.

VP 2400

119

L - ELECTRICAL WIRING 3.2. DETERMINING DEFECTS OF ALTERNATOR REGULATOR Inspection of alternator – regulator assembly – test bed

• Remove regulator subassembly and carbon brushes from the holder, and replace the subassembly with a guaranteed regulator.

• Test regulated voltage on test bed.

3.3. VOLTAGE REGULATOR This is an integrated voltage regulator. The excitation circuit is connected between terminal DF and D+ of the regulator.

Regulator 2 is connected to the brush holder and the entire subassembly is attached to the alternator by 3 screws, connected with three soldered circuits (B-, DF, D+) and a cable with terminal tube 6,3, which slides onto the alternator terminal ”+D”. The regulator cannot be repaired.

Inspection of the alternator without the regulator – test bed.

• Remove regulator subassembly with brush holder and attach to the alternator modified brush holder. One lead of the holder is grounded, the other lead with a soldered connector tubing is connected to terminal D+ continuing for about 20 cm for a momentary excitation from terminal B+.

• Fasten the alternator and connect to test bed with voltmeter, ammeter, load resistor, revolution meter and battery in the circuit as in Fig. L/3.

• Turn the alternator at about 1500 min -1.

• Excite the alternator with the loose end of lead from brushes and D+ for about 2-3 sec. connected to terminal B+. The alternator is defective, if excitation is not possible.

• Check the characteristic of the alternator.

• If the alternator is not found defective, then look for defects in the regulator, see section 3.3.

• The cause of the defect may be found in a bad contact between the alternator chassis and the vehicle chassis, or the battery ground.

Fig. L/3

120

VP 2400

L - ELECTRICAL WIRING 4. STARTER

4.2. CHECK OF IDLING – ON THE MACHINE

4.1. OPERATION AND MAINTENANCE

Check the starter in a position when the pinion is not engaged with the crown. With the breaker on, the pinion must slide out and turn. Unloaded starter may work for less than 10 seconds. Detail description is in section 3.1.

• Correct operation of the starter is preconditioned by correct and fully charged batteries.

• The starter has been designed for a short period operation of less than 5 seconds.

• When the engine starts, stop starting, otherwise the pinion and/or the bearing may be damaged.

Output current

Battery voltage

Unloaded revolutions

max. 130 A

23 V

Min. 4000 min–1

Minimum revolutions in the table are for information only.

Workshop measurement is problematic and is not done.

• Cables must be tight, insulation not damaged.

• The starter body is part of the circuit. Keep contact faces on the engine clean and protected against corrosion.

• Should the starter be inoperative, look for breaks between the battery and the starter, the engine and the starter, or the chassis and batteries.

• Check the crown of the flywheel and the pinion for wear, and apply grease at the same time.

• During repair or every 2 years remove the starter, check the commutator, brush springs, and the breaker contacts.

• The brushes must sit with a 3/4 surface on the commutator ring, and must be easily sliding. The contact areas of the breaker mustn’t be burnt, and must make contact for the entire flat part.

4.3. STARTER DEFECTS First, check for voltage on terminals ”30” and ”50” with the ignition key turned to ”start”. A handy method of testing starting is with headlights on. The decrease in light intensity indicates initial type of defect (battery – starter).

Checking the uninstalled starter.

Connect terminal ”30” to a charged battery with an ammeter set to high range, Fig. L/4. Start by connecting current to terminal ”50”. The current in an unloaded state must be less than 120 A, disregarding the momentary spike. The starter must run noiselessly. The pinion must slide out smoothly and return to initial position. The pinion may not turn directly on the face of the thrust ring. The starter may run for only 8 seconds after the wire was disconnected from the source.

Check the pressure of springs and their condition. The carbons must make contact on at least 2/3 of their surface and must be free in the chambers. The anchor must have a noticeable free play of less than 1.3 mm. The free wheel must turn freely when the pinion is turned in the direction of the starter. In workshop tests with sufficient experience the control without load should be ample, although we recommend checking on test bed.

Fig. L/4

VP 2400

121

L - ELECTRICAL WIRING STARTER DEFECTS AND REMEDIES Defect

Cause

Remedy

Starter doesn't turn

Open lead to terminal "30"

Repair lead

Open lead to terminal "50"

Repair lead

Defective ignition box

Replace box

Carbonized contacts

Replace contacts or the entire lid together with bridge contacts

Open winding in the starter contactor

Replace starter contactor

S/C in contactor (weak pull, heats up)

Replace starter contactor

The contactor ratchet hangs up

Loosen, clean, and lubricate

Damaged sliding mechanism

Replace, or repair

Pinion hangs up on the shaft

Repair, sometimes it is necessary to straighten the shaft

Defective ignition box

Replace ignition box

Carbonized contacts of starter contactor

Replace contacts together with the bridge contacts, or the entire contactor

Pinion seized on the shaft

Replace pinion bearing. Remove sharp edges on the shaft, clean (check shaft eccentricity)

Starter runs freely

Starter doesn't switch off, remains on. Disconnect battery immediately (terminal grounded to chassis)!

Starter doesn't slide pinion to damaged fly wheel crown engage

Repair crown or replace (find cause)

Pinion mills the fly wheel

Broken spring

Replace spring

Damaged pinion teeth

Replace pinion (find cause)

Battery discharged

Charge battery

Damaged free wheel - slippage (broken bushing)

Replace

Burnt contacts of the starter contactor

Replace

Starter engages pinion (audibly), but engine doesn't turn

122

VP 2400

L - ELECTRICAL WIRING

Defect

Cause

Remedy

Starter unreliable.

Low output

Discharged battery

Charge battery

Soiled or loose contacts in cables (transient resistance)

Clean, tighten thoroughly

Battery defective (usually gradual deterioration in starting)

Repair defects in battery

Damaged carbon brushes

Replace brushes (concomitant repair of commutator)

Soiled and burned commutator (solder)

Clean with gasoline or alcohol. If the commutator is burned or mica showing between plates (strong sparking), disassemble starter and machine commutator. Mill out insulation, polish commutator. If necessary, resolder and/or replace ratchet.

Broken or weak springs of brushes

Replace spring

S/C armature

Replace armature

Open exciting coil

Replace particular pair of coils

Starter contactor defective (transient resistance)

Replace ignition box

Open exciting winding of stator on the terminal of starter contactor

Resolder terminal

Starter loose in flange

Tighten bolts

Armature loose (seized bearings)

Repair

Mechanical defect - miscellaneous

Repair defects

Broken lid (very noisy)

Repair, replace lid

S/C in the exciter circuit

Repair short or replace particular pair of coils

Starter noisy

Starter gets very hot, low power

VP 2400

123

STAVOSTROJ a.s.

549 01 Nové Město nad Metují t e l : +420-441/ 476 111

f a x : +42 0-441/470 405

Issued by:

Literature Department of

STA Stavostroj a.s.

Nové Město nad Metují

© 9 / 2000