bomag BW180AD

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Instructions for repair

Catalogue number

008 912 53 06/2002

BW 180 AD101 870 00 ....

Tandem Vibratory Roller

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Table of Contents

BOMAG 3008 912 53

General 5

1.1 Foreword 6

1.2 Safety regulations 7

1.3 General repair instructions 9

1.4 Tightening torques 11

1.5 Connection overview 12

Tests and adjustments 15

2.1 Technical data 16

2.2 Special tools 19

2.3 Checking the rotation speeds 21

2.4 Pressure tests in the travel circuit 23

2.5 Checking / adjusting the neutral positions of the travel pump 25

2.6 Check the setting of the high pressure relief valves in the travel circuit 28

2.7 Pressure measurements in the vibration circuit 30

2.8 Check the setting of the high pressure relief valves in the vibration circuit 31

2.9 Checking / adjusting the vibrator shaft speeds 33

2.10 Checking the leakage rate of the vibration motor 34

2.11 Pressure test in steering circuit 35

2.12 Operation of display module for ESX-control 37

2.13 Driving against the closed brake 38

2.14 Adjusting the machine type 39

2.15 Calibration of the angle transducers 41

2.16 Adjusting the angle transducers 43

2.17 Automatic detection of step currents for the steering valves 45

2.18 Adjusting the type of travel range switch 47

2.19 Resetting the step currents in the travel system 49

2.20 Automatic detection of step currents in the travel system 50

2.21 Showing stored faults 53

2.22 Deleting stored faults 54

Flushing 55

3.1 Special tool: 56

3.2 Flushing shematic for front drum drive 58

3.3 Flushing schematic for rear drum drive system 60

3.4 Flashing the travel circuit 623.5 Flushing schematic for vibration drive 72

3.6 Flushing the vibration circuit 74

Trouble shooting 81

4.1 General 82

4.2 Trouble shooting diagram 83

Drum 103

5.1 Special tools 104

5.2 Repair overview for drum 106

5.3 Removing and installing the drum 108

5.4 Removing and installing the vibrator unit on the drum drive side 114

5.5 Removing and installing the vibrator unit on the vibration drive side 119

5.6 Repairing the vibrator unit on the drum drive unit 129

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Table of Contents

BOMAG4 008 912 53

5.7 Repairing the vibrator unit on the vibration drive unit 134

5.8 Dismantling, assembling the change-over weights 140

Pivot steering 143

6.1 Removing, repairing and installing the pivot steering 144

6.2 Repairing the oscillation joint 148

Suppliers documentation 153

7.1 A4VG 155

7.2 A10VG 201

7.3 MS/MSE 02 to 18 255

7.4 Vibration motor A2FM 32 305

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5008 912 53

1 General

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1.1 Foreword

Introduction

These repair instructions contain all necessary infor-mation for training and repair work.

Notes on maintenance, care and trouble shooting canbe found in the operating and maintenance instruc-

tions. 1 General

2 Tests and adjustments

3 Flushing

4 Trouble shooting

5 Drum

6 Pivot steering

7 Components

This instruction manual contains only assemblygroups needed for this type of machine.

The repair instructions describe the removal or dis-mantling and assembly of components and assemblygroups.

The repair of disassembled assembly groups is de-scribed as far as this makes sense with respect toavailable tools and spare parts supply and as far as itcan be understood by a skilled mechanic.

Danger

Danger of injury

Please observe strictly the safety regulations in

these operating instructions and the applicableaccident prevention regulations.

Spare parts needed for repairs can be taken from thespare parts catalogue for the machine.

You should only use genuine BOMAG spare parts.

These repair instructions are not subject of an updat-ing service; for this reason we would like to draw yourattention to our additional technical service bulletins.

In case of a new release all necessary changes will beincluded.

In the course of technical development we reserve theright for technical modifications without prior notifica-tion.

Information and illustrations in this repair manual mustnot be reproduced and distributed, nor must they beused for the purpose of competition. All rights accord-ing to the copyright law remain expressly reserved.

BOMAG GmbH & Co. OHG

Printed in Germany

Copyright by BOMAG

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1.2 Safety regulations

Important notes

These safety regulations must be read and ap-plied by every person involved in the repair of thismachine. The applicable accident prevention in-structions and the safety regulations in the oper-

ating and maintenance instructions must beadditionally observed.

Repair work shall only performed by appropriatelytrained personnel or by the after sales service ofBOMAG.

These repair instructions contain headers like „Note“,„Attention“, „Danger“ and „Environment“, which mustbe strictly complied with in order to avoid dangers forhealth and for the environment.

Danger

Paragraphs marked like this highlight possibledangers for persons.

Caution

Paragraphs marked like this highlight possibledangers for machines or parts of the machine.

Note

Paragraphs marked like this contain technical information for the optimal economical use of the machine.

Environment

Paragraphs marked like this point out practicesfor safe and environmental disposal of fuels andlubricants as well as replacement parts.

Observe the regulations for the protection of theenvironment.

General

Before starting repair work stand the machine onlevel and solid ground.

Always secure the machine against unintended roll-ing.

Secure the engine reliably against unintentionalstarting.

Mark a machine that is defective or being repairedby attaching a clearly visible warning tag to thesteering wheel.

On machines with articulated joint keep the articu-lated joint locked during work.

Use protective clothes like hard hat, safety bootsand gloves.

Keep unauthorized persons away from the machineduring repair work.

Tools, lifting gear, lifting tackle, supports and otherauxiliary equipment must be fully functional and insafe condition.

Use only safe and approved lifting gear of sifficientload bearing capacity to remove and install parts orcomponents from and to the machine.

Be careful with cleansing agents. Do not use easilyinflammable or harmful substances, such as gaso-line or paint thinners for cleaning.

Cleaning or repair work on the fuel tank is very dan-gerous. Do not smoke or allow any ignitable sparksor open fire in the vicinity when cleaning or repairinga tank. .

When performing welding work strictly comply withthe respective welding instructions.

Special safety regulations

Use only genuine BOMAG spare parts for repairpurposes. Original parts and accessories havebeen specially designed for this machine.

We wish to make explicitly clear that we have nottested or approved any parts or accessories notsupplied by us. The installation and/or use of suchproducts may therefore have an adverse effect onthe specific characteristics of the machine andthereby impair the active and/or passive drivingsafety. The manufacturer explicitly excludes any li-ability for damage caused by the use of non-original

parts or accessories. Unauthorized changes to the machine are prohibit-

ed for safety reasons.

If tests on the articulated joint need to be performedwith the engine running, do not stand in the articu-lation area of the machine, danger of injury!

Do not perform cleaning work while the engine isrunning.

If tests must be performed with the engine runningdo not touch rotating parts of the engine, danger ofinjury.

Exhaust gases are highly dangerous. Always en-sure an adequate supply of fresh air when startingthe engine in closed rooms.

Refuel only with the engine shut down. Ensure strictcleanliness and do not spill any fuel.

Keep used filters in a separate waste container anddispose of environmentally.

Dispose of oils and fuel environmentally when per-forming repair or maintenance work.

Do not refuel in closed rooms.

Do not heat up oil higher than 160 °C because itmay ignite.

Wipe off spilled oil and fuel.

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Do not smoke when refuelling or when checking theacid level in the battery.

Do not check the acid level of the battery with a na-ked flame, danger of explosion!

Old batteries contain lead and must be properly dis-

posed of. There is a danger of scalding when draining off en-

gine or hydraulic oil at operating temperature.

on machines with rubber tires a tire may busr if in-correctly assembled. This can cause severe injury.

Do not exceed the specified highest permissible tirepressure.

Hydraulics

Hydraulic oil escaping under pressure can pene-trate the skin and cause severe injury. You should

therefore relieve the pressure in the system beforedisconnecting any lines.

Before applying pressure to the system make surethat all line connections and ports have been prop-erly tightened and are in perfect condition.

Hydraulic oil leaking out of a small opening canhardly be noticed, therefore please use a piece ofcardboard or wood when checking for leaks. Whenbeing injured by hydraulic oil consult a physician im-mediately, as otherwise this may cause severe in-fections.

Do not step in front of or behind the drums/wheelswhen performing adjustment work in the hydraulicsystem while the engine is running. Block drumsand/or wheels with wedges.

Reattach all guards and safety installations afterall work has been completed.

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1.3 General repair instructions

General

Before removing or disassembling and parts, hosesor components mark these parts for easier assem-bly.

Before assembly oil or grease all parts, as far as this

is necessary.

Hydraulic system

Caution

Do not open any hydraulic components if youhave not been properly trained and without exactknowledge.

Please note

Cleanliness is of utmost importance. Make sure that

no dirt or other contaminating substances can enterinto the system.

Clean fittings, filler covers and the area around suchparts before disassembly to avoid entering of dirt.

Before disconnecting hoses, pipes or similar relievethe system pressure with the engine shut down.

During repair work keep all openings closed withclean plastic plugs and caps.

Do not run pumps and motors without oil.

When cleaning hydraulic components take care notto damage any fine machine surfaces.

Chemical and rubber soluble cleansing agents mayonly be used to clean metal parts. Do not use suchsubstances to clean seals and gaskets.

Rinse of cleaned parts thoroughly, dry them withcompressed air and apply anti-corrosion oil immedi-ately. Do not install parts that show traces of corro-sion.

Avoid the formation of rust on fine machined causedby hand sweat.

Grease must not used as a sliding agent for assem-bly work. Use hydraulic oil.

Do not start the engine after the hydraulic oil hasbeen drained off.

Use only the specified pressure gauges. Risk ofdamaging the pressure gauges under too high pres-sure.

Clean ports and fittings before removal so that nodirt can enter into the hydraulic system.

Check the hydraulic oil level before and after thework.

Use only clean oil according to specification.

Check the hydraulic system for leaks, find and rec-tify the cause.

Fill new hydraulic units with hydraulic oil beforestarting operation.

After changing a component thoroughly flush andbleed the entire hydraulic system.

Perform measurements at operating temperature of

the hydraulic oil (approx. 40 °C). After changing a component perform a high and

charge pressure test, if necessary check the speedof the exciter shaft.

The operating pressure of the exciter shaft to agreat extent depends on the base under the vibrat-ing drum. If the soil is too hard place the drums onold rubber tires. Do not activate the vibration on ahard, concreted base, danger of bearing damage.

After the completion of all tests perform a test runand then check all connections and fittings for leakswith the engine still stopped and the hydraulic sys-tem depressurized.

Before commissioning

After changing a component clean the hydraulic oiltank thoroughly.

Fill the housings of hydraulic pumps and motorswith hydraulic oil.

Use only hydraulic oils according to the specifica-tion in the maintenance instructions.

After changing a component clean the hydraulicsystem as described in the flushing instructions inorder to prevent all other components from beingdamaged by abrasion and metal chips remaining inthe system.

Change the hydraulic oil filter.

Commissioning

Bleed the hydraulic circuits.

Start up the system without load.

Check the hydraulic oil level in the tank, fill up oil ifnecessary.

After commissioning Check system pressures and speeds.

Check fittings and flanges for leaks.

After each repair check all adjustment data, rota-tional speeds and nominal values in the hydraulicsystem, adjust if necessary.

Do not adjust pressure relief valves and controlvalves to values above their specified values.

Electrical system

Always disconnect the battery before starting workin the electrical system.

Ensure correct polarity when connecting the bat-tery.

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Do not check voltage by tapping against ground.

When performing welding work always fasten theearth clamp of the welding unit in the immediate vi-cinity of the welding location. Strictly disconnect thecables from the generator before starting work.

Seals and gaskets

Generally use new seals and gaskets when per-forming assembly work. The required seal kits areavailable as spare parts.

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1.4 Tightening torques

Tightening torques

Tighten fastening screws and nuts according to the table of tightening torques.

Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.

Caution

Self-locking nuts must be generally renewed.

The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.

Compliance with the tightening torques is checked with torque wrenches.

Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.

The values specified in the table apply for screws black, oiled and with surface protection A4C.

The quality designation of the screws is stamped on the screw heads.

Tightening torques for screws with metric unified thread

Screw dimensionTightening torque Nm* (ft-lb)

8.8 10.9 12.9

M4 3 (2) 5 (4) 5 (4)

M5 6 (4) 9 (7) 10 (7)

M6 10 (7) 15 (11) 18 (13)

M8 25 (18) 35 (26) 45 (33)

M10 50 (37) 75 (55) 83 (61)

M12 88 (65) 123 (91) 147 (108)M14 137 (101) 196 (145) 235 (173)

M16 211 (156) 300 (221) 358 (264)

M18 290 (213) 412 (303) 490 (361)

M20 412 (304) 578 (426) 696 (513)

M22 560 (413) 785 (559) 942 (695)

M24 711 (524) 1000 (738) 1200 (885)

M27 1050 (774) 1480 (1092) 1774 (1308)

M30 1420 (1047) 2010 (1482) 2400 (1770)

Tightening torques for screws with metric fine thread

Screw dimension

Tightening torques Nm* (ft-lb)

* Strength classes for screws with untreated, non-lubricated surface.

8.8 10.9 12.9

M8 x 1 26 (19) 37 (27) 48 (35)

M10 x 1.25 52 (38) 76 (56) 88 (65)

M12 x 1.25 98 (72) 137 (101) 126 (119)

M12 x 1.5 93 (69) 127 (94) 152 (112)

M14 x 1.5 152 (112) 216 (159) 255 (188)

M16 x 1.5 225 (166) 318 (235) 383 (282)

M18 x 1.5 324 (239) 466 (344) 554 (409)

M20 x 1.5 461 (340) 628 (463) 775 (572)

M22 x 1.5 618 (456) 863 (636) 1058 (780)

M24 x 2 780 (575) 1098 (808) 1294 (1416)

M27 x2 1147 (846) 1578 (1164) 1920 (1416)M30 x 2 1568 (1156) 2254 (1662) 2695 (1988)

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Fig. 1

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1 Proportional valve, travel system

2 Pressure test port X4, control chamber pressure,travel pump

3 Pressure test port MB high pressure, reverse trav-

el

4 High pressure port B to rear travel motor, highpressure reverse travel

5 High pressure port B to front travel motor, highpressure reverse travel

6 Adjustment screw, high frequency

7 High pressure port A to rear travel motor, highpressure forward travel

8 High pressure port A to front travel motor, highpressure forward travel

9 Port T1, leak oil tank A

10 High pressure port B, to vibration shut-off valve,

high pressure low frequency11 High pressure port A, to vibration shut-off valve,

high pressure high frequency

12 Magnetic coil Y57, low frequency

13 High pressure test port, low frequency

14 High pressure relief valve, vibration, 420 bar

15 Magnetic coil, high frequency

16 Pressure test port X2, vibration pump

17 Pressure test port X1, vibration pump

18 Pressure test port R, vibration pump case pres-sure

19 Proportional valve, travel system

20 Pressure test port X2, travel pump

21 Adjustment screw, hydraulic neutral position

22 Pressure test port R, travel pump case pressure

23 Pressure test port X2, travel pump

24 Pressure override valve 380 bar, vibration pump

25 Port T, flushing oil, travel motors

26 Pressure test port MA high pressure, forward trav-el

27 Pressure override valve 400 bar, travel pump

28 Travel pump

29 Leak oil connection T1 travel pump - T2 vibrationpump

30 Port G, charge oil from steering valves

31 Port T2, flushing oil, vibration motors

32 High pressure relief valve, forward travel, 440 bar

33 Charge pressure relief valve 25 bar, travel pump

34 High pressure relief valve, reverse travel, 440 bar35 High pressure relief valve, vibration, 400 bar

36 Connecting line, charge pressure supply to vibra-tion pump

37 High pressure test port, high frequency

38 Vibration pump

39 Port B, leak oil to cooler

40 Port E, leak oil, front travel motor

41 Port A, flushing/leak oil, travel/vibration pump

42 Port I, leak oil from brake valve

43 Port D, leak oil, rear travel motor44 Port F, leak oil from vibration shut-off valve

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2 Tests and adjustments

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2.1 Technical data

Fig. 1

Dimensions inmm

A B C D H H1 K L O W

BW 180 AD 3300 1920 815 1400 2400 30500 350 4700 60 1800

* BW 180 AD

Weights

Operating weight (CECE)with ROPS-cabin

kg 11870

Front axle load (CECE) kg 5935Rear axle load (CECE) kg 5935Static linear load, front/ rear

kg/cm 33/33

Dimensions

Steering/oscillation angle ± 20/8Track radius, inner/outer mm 3900/5700

Travel characteristics

Travel speed (1) km/h 0 ... 4Travel speed (2) km/h 0 ... 8Travel speed (3) km/h 0 ... 11Max. gradability without/ with vibration (soil de-pendent)

% 35/30

Drive

Engine manufacturer CumminsType 4 BT3.9-CCooling WaterNumber of cylinders 4Rated power ISO 9249IFN

kW 76

Nominal speed 1 rpm 2500low idle speed 1 rpm 950 ±50

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high idle speed 1 rpm 2725 ±55Electrical equipment V 12Battery V/AH 12/100Drive system hydrostaticDriven axles front + rear

Electrical equipment

Voltage supply V 12Battery V/AH 12/100Generator V/AHStarter V/kW 12/2,9

Travel pump

Manufacturer HydromatikType A4VG 71 EPSystem Axial piston/swash plateMax. displacement cm3 /rev. 71High pressure (pressurelimitation)

bar 440 ±10

High pressure (pressureoverride)

bar 400 ±10

Charge pressure bar 26 ±1

Drum drive motors

Manufacturer PoclainType MS 18 1CXSystem Radial pistonDisplacement cm3 /rev. 2100max. leak oil rate l/min 2

Vibration pump

Manufacturer HydromatikType A10VG 45 EZSystem Axial piston/swash plateMax. displacement cm3 /rev. 45Start-up pressure (pres-sure override)

bar 380 ±20

Operating pressure (soildependent)

bar approx. 100

Vibration motorsManufacturer HydromatikType A2FM 32System Axial piston/bent axleDisplacement cm3 /rev. 32max. leak oil rate l/min 1

Brakes

Service brake hydrostaticParking brake Releasing the mech.Brake releasing pressure bar

SteeringType of steering 2 point pivotSteering operation hydrostaticSteering angle ± 25

* BW 180 AD

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Crabwalk, lateral offset-ting of drum

mm 1220

Steering/charge pump

Manufacturer BoschType HY/ZFFS11/14+14System Tandem gear pumpDisplacement cm3 /rev. 2x14max. steering pressure bar 200 ±10

Steering valves

Manufacturer BucherType L.8SSystem Electrically proportional

Vibration system

Drive system hydrostaticFrequency 1/2 Hz 42/55Amplitude 1/2 mm 0,83/0,33

Filling capacities

Engine oil l approx. 9.5Fuel (diesel) l 170Sprinkler system l 900Hydraulic oil l approx. 60Coolant l approx. 20Exciter shaft tube l approx. 50

* The right for technical modifications remains reserved

* BW 180 AD

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2.2 Special tools

1. Vibration Reed frequency meter

BOMAG part-no.: 300 120 80

2. Engine RPM-meter


3. Hydraulic test case


4. Electric test case


Fig. 1

Fig. 2

Fig. 3

Fig. 4

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5. Gear pump testing device


6. Vacuum pump for hydraulic oil tank

BOMAG part-no.: 007 610 04 (12V)

Fig. 5

Fig. 6

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2.3 Checking the rotation speeds

Special tools

Vibration Reed frequency meter, engien RPM-meter

Caution

Perform measurements at operating tempera-ture (40 °C).

1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).

Checking the engine speed

Note

If necessary, the engine speed may also bechecked with the vibration Reed frequency meter.

1. Connect the RPM-meter to the injection line (Fig.2).

2. Measure the rotation speeds.

Nominal value low idle speed

950 ±50 rpm

3. Run the engine with maximum speed .

4. Measure the rotation speeds.

Nominal value high idle speed

2725 ±55 rpm

5. Switch on vibration of both drums.

Nominal value nominal speed

2500 rpm

Evaluation of test

If the nominal value is not reached, perform trou-ble shooting for the engine.

Fig. 1

Fig. 2

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Checking the vibrator shaft speed

1. Switch the vibration on at max. engine speed.

2. Measure the speed of the vibrator shaft, rest thetester on your thumb (Fig. 3).

Nominal value

high amplitude/ low frequency = 42 Hz, 2520 rpm

low amplitude/ high frequency = 55 Hz, 3300 rpm

Evaluation of test

If the nominal value is not reached, perform trou-ble shooting in the vibration circuit.

Fig. 3

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2.4 Pressure tests in the travel circuit

Special tools

Hydraulic test case

Caution

Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).

1. Block the wheels with suitable chocks (Fig. 1).

2. Enter code number 500 on the display module(Fig. 2) to close the brake.

3. Connect a 600 bar pressure gauge (Fig. 3) to testport MA.

Fig. 1

Fig. 2

Fig. 3

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4. Connect a 600 bar pressure gauge (Fig. 4) to testport MB.

5. Connect a 60 bar pressure gauge (Fig. 5) to thecharge pressure test port.

6. Start the engine and run it with maximum speed.

7. Read high pressure and charge pressure gaug-es.

Nominal value

Charge pressure 26 ±1bar

High pressure 400 bar ±10 bar

Evaluation of test

If the nominal value is not reached, check thesteering/charge pump.

8. Move the travel lever quickly to forward and back-ward, read the pressure gauges.

Nominal value

Charge pressure min. 25 bar

High pressure 400 bar to both travel directions.

Evaluation of test

If the specified high pressure is not reached,check the travel pump.

If the charge pressure drops considerably duringthe high pressure test, check the components in-dividually.

Fig. 4

Fig. 5

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2.5 Checking / adjusting the neutral posi-tions of the travel pump

Special tools

Hydraulic test case

Caution




3. Connect a 600 bar pressure gauge (Fig. 3) eachto test ports MA and MB.

Fig. 1

Fig. 2

Fig. 3

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Mechanical neutral position

1. As a measure to avoid signal residues from thehydraulic neutral position connect both controlchambers X1 and X2 with a hose (Fig. 4).


3. Read the pressure gauges (Fig. 5).

Note

For a more exact adjustment repeat the test with60 bar pressure gauges

Nominal value

Both pressure gauges must show identical pres-sure, if necessary correct the mechanical neutralposition.

4. Adjust the neutral position (Fig. 6) so that bothpressure gauges show identical pressure (chargepressure).

Note

Equalize the dead range of the neutral position.

Fig. 4

Fig. 5

Fig. 6

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Hydraulic neutral position

1. Remove the hose connection between the controlchambers and screw the plugs back in (Fig. 7).


3. Read the pressure gauges (Fig. 8).

Note

For a more exact adjustment repeat the test with60 bar pressure gauges

Do not actuate the travel lever, since this may de- stroy the pressure gauges.

Nominal value

Both pressure gauges must show identical pres-sure (charge pressure), if necessary correct thehydraulic neutral position.

4. For this purpose loosen the clamping (Fig. 9).

Caution

Do not adjust the eccentric beyond the ± 90°position.

5. Adjust the neutral position on the eccentric (2), sothat both pressure gauges show identical pres-sure (charge pressure).

6. Retighten the clamping.

Fig. 7

Fig. 8

Fig. 9

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2.6 Check the setting of the high pressurerelief valves in the travel circuit

Special tools

Hydraulic test case

Caution





Fig. 1

Fig. 2

Fig. 3

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4. Turn the setscrew (Fig. 4) of the pressure over-ride completely in to block the valve.


Caution

Perform the following pressure test for max. 3seconds, otherwise pump damage caused byoverheating.

6. Move the travel lever quickly to both travel direc-tions and read the pressure gauges.

Nominal value

445 ±5 bar

Evaluation of test:

If the nominal value is only reached to one direc-tion, clean or replace the valve (Fig. 5) if neces-sary.

If the nominal value is not reached to both direc-tions check the travel pump, replace if necessary.

Adjusting the pressure override

Caution

To assure a reliable function of the pressureoverride, the pressure override valve must beadjusted 10% lower than the high pressure re-lief valve.

1. Turn the setscrew (Fig. 6) back out again, untilthe high pressure is limited to 400 ±10 bar whenthe drums are blocked.

Fig. 4

Fig. 5

Fig. 6

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2.7 Pressure measurements in the vibra-tion circuit

Special tools

Hydraulic test case

Caution




3. Connect a 60 bar pressure gauge to the chargepressure test port.


5. Switch on vibration at high or low frequency andread the pressure gauge.

Nominal value

Charge pressure 26 ±1bar

Starting pressure 380 bar ±20 bar

Operating pressure (soil dependent) approx. 80... 100 bar

Evaluation of test

If the charge pressure drops, check the compo-nents individually.

If the starting pressure is not reached, check the

vibration pump.If the starting pressure is only reached for one fre-quency, check the high pressure relief valves.

Fig. 1

Fig. 2

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2.8 Check the setting of the high pressurerelief valves in the vibration circuit

Special tools

Hydraulic test case

Caution




3. Turn the setscrew (Fig. 3) of the pressure over-ride completely in to block the valve.


Caution

Perform the following pressure test for max. 3seconds, otherwise pump damage caused byoverheating.

5. Switch on vibration at high or low frequency andread the start-up pressure on the pressuregauge.

Fig. 1

Fig. 2

Fig. 3

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Evaluation of test:

If the nominal value is only reached for one fre-quency, clean or replace the valve (Fig. 4) if nec-essary.

If the nominal value is not reached for both fre-

quencies check the travel pump, replace if neces-sary.

Nominal value

400 ±5 bar

Adjusting the pressure override

Caution

To assure a reliable function of the pressureoverride, the pressure override valve must beadjusted 10% lower than the high pressure re-lief valve.

1. Turn the setscrew (Fig. 5) back out again, so thatthe start-up pressure for the vibrator shafts is lim-ited to 380 bar.

Fig. 4

Fig. 5

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2.9 Checking / adjusting the vibrator shaftspeeds

Special tools

Hydraulic test case

Caution



2. Start the diesel engine and shift the throttle leverto max. speed position.

3. Select the frequency and switch the vibration on.

4. Measure the speed of the vibrator shaft (Fig. 2),rest the tester on your thumb.

Nominal value

high amplitude/ low frequency = 42 Hz, 2520 rpm

low amplitude/ high frequency = 55 Hz, 3300 rpm

Evaluation of test

In case of deviations exceeding 10% determinethe cause, perform trouble shooting for engine /vibration circuit.

5. Adjust the speed on the corresponding adjust-ment screw (Fig. 3).

NoteTurning the adjustment screw in reduces thespeed, turning the screw out increases thespeed.

Fig. 1

Fig. 2

Fig. 3

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2.10 Checking the leakage rate of the vibra-tion motor

Special tools

Hydraulic test case

Caution



2. Block the wheels with suitable chocks.

3. Disconnect the leak oil and flushing oil hose (Fig.2) and close it with plugs.

4. Connect a leak oil hose to the leak oil port of themotor and hold it into a measuring vessel

5. Start the diesel engine and shift the throttle lever

to max. speed position.

6. Select the frequency and switch the vibration on.

7. Measure the leak oil over a period of one minute.

Caution

This measurement detects only the externalleak oil quantity.

Internal leaks, directly from the high to thelow pressure side, are not detected.

Nominal valuemax. 1.5 litre/min

Evaluation of test

If the permissible leak oil rate is exceeded, re-place the vibration motor.

Fig. 1

Fig. 2

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2.11 Pressure test in steering circuit

Special tools

Hydraulic test case

NoteThe steering is actuated against an „electronic“

stop by the ESX-control. To actuate the steeringagainst the mechanical stop the ESX-controlmust be switched to the mode „Calibration of angle transducers“. After the pressure test the calibration process can be aborted.

Danger

Danger of squashing!

Do not stand in the range of rotation of the

pivot steering.

Caution


Measuring the front steering pressure

1. Enter code number „600“ on display module (Fig.1).

The steering can now be actuated against themechanical stop.

2. Enter code number „620“ or switch the ignition offto stop this fuction.

3. Connect a 600 bar pressure gauge (Fig. 2) to thesteering pressure test port.

4. Start the engine and run it at idle speed.

Fig. 1

Fig. 2

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5. Adjust the front steering control (Fig. 3) and turnthe steering against an end stop.

6. Read the pressure gauge.

Nominal value

approx. 200 ±10 bar

Evaluation of test

If the nominal value is reached, check the steer-ing cylinder.


Measuring the rear steering pressure


The steering can now be actuated against themechanical stop.

2. Enter code number „620“ or switch the ignition offto stop this fuction.

3. Connect a 600 bar pressure gauge to the rearsteering pressure test port (Fig. 5).

4. Start the engine and run it at idle speed.

5. Adjust the rear steering control (Fig. 6) and turnthe steering against an end stop.

6. Read the pressure gauge.

Nominal value

approx. 200 ±10 bar

Evaluation of test

If the nominal value is reached, check the steer-ing cylinder.


Fig. 3

Fig. 4

Fig. 5

Fig. 6

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2.12 Operation of display module for ESX-control

Description

The display module (Fig. 1) is used for the output

of fault codes and display values and for the inputof code numbers.

The module consists of a three digit display andtwo keys, F1 and F2.

Faults are indicated by flashing, if several faultshave occurred the displayed fault codes are alter-nately displayed in 3 second cycles. Display val-ues are permanently displayed.

Values from 000 ... 999 can be displayed. Highervalues are displayed in form of „---“. Negative val-ues are indicated by a minus symbol.

Entering code numbers

For calibration of the angle transducers and diag-nostics of the control inputs and outputs variouscode numbers must be entered on the displaymodule.

Code numbers are entered as follows:

1. Press both keys (F1 and F2) together for approx.two seconds.

The display shows „000“, whereby the first digit is

flashing. 2. Press key F1 as often as required to adjust the

flashing digit.

If key F1 is pressed again when figure „9“ is dis-played, the display will jump back to the value „0“.

3. Press key „F2“ to adjust the next digit.

The flashing display moves one digit to the right.

4. Press key F2 to change to the third digit and adjust the desired value with the F1-key.

5. Press the F2-key again to confirm the adjusted

values and to execute the corresponding func-tion.

6. To cancel a display function you must either enterthe code number „000“ or switch the ignition off.

Fig. 1

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2.13 Driving against the closed brake

Note

On this machine the electric plug connection tothe brake valve must not be pulled off, because

the ESX-control would in this case detect a lineinterruption in the current path to the brake.


The brake will not be released when actuating thetravel lever.

The warning buzzer sounds to inform the opera-tor about this status.

2. Enter code number „501“ or switch the ignition offto stop this function.

Fig. 1

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2.14 Adjusting the machine type

Note

Only available from program version 16.

For simple control of the machine type, the ad-

justed machine type is displayed in the displaymodule for about three seconds after switchingthe ignition on.

Danger

Danger of injury!

Since the same control is used for all pivotsteered tandem rollers, it is strictly necessaryto specify the correct machine type when re-placing the ESX-control.

The machine must not be operated with awrong type setting.

Caution

Adjustments should only be made with theengine shut down.


The function „Change machine type“ is activated.

Table „Assignment machine type – machinetype code“

2. Select and enter the correct code from the table

above.

The display then permanently shows the enteredcode number.

Fig. 1

Machine type Serial-No. Code

BW 180 AD 101 870 00 .... 740BW 184 AD 101 870 30 .... 740BW 184 AD/AM 101 870 50 .... 740BW 170 AD 101 870 01 .... 731BW 170 AD 101 870 02 .... 733BW 170 AD/AM 101 870 11 .... 733BW 174 AD 101 870 31 .... 732BW 174 AC 101 870 41 .... 732BW 174 AD/AM 101 870 31 .... 732

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3. To store the machine type enter code number„726“ on the display module (Fig. 2).

When entering code “726“ the machine type codeis permanently stored.

NoteThe conversion process takes a few seconds.During this time the display permanently showsthe code number, the minus point flashes in an interval of one second.

Caution

During this time the ignition must not beswitched off! Otherwise the complete adjust-ment process must be repeated.

The new machine type will only become ac-

tive after the ignition has been switched offand on again!

By changing the machine type all settings aredeleted and must be reset as described here-under.

Fig. 2

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2.15 Calibration of the angle transducers

In order to assure a correct steering of the ma-chine, both angle transducers for front and reardrums must be calibrated.

NoteCalibration of the angle transducers is only necessary during initial start-up in the factory, after adisassembly or replacement of the angle transducers and after changing the ESX-control.

Caution

Calibration must always be performed forboth drums.

Calibration is only possible in steering modeselection „Steering front“ and „Steering

rear”. With any other steering selection thisfunction is not active. When changing to an-other, unpermitted steering mode during theadjustment, the complete adjustment proce-dure must be repeated.

During the calibration process the machinemust not drive faster than 3 km/h, as other-wise the complete adjustment proceduremust be repeated.

The new values will only become active afterthe ignition has been switched off and onagain.


This code number activates the function „Calibra-tion of the angle sensors“. In this case the displaypermanently shows the value „600“.

Calibrating the front stops

1. Steer the front drum (Fig. 2) to the left hand stop.

2. When the stop is reached enter code number601.

In this case the display permanently shows thevalue „601“.

3. Steer the front drum to the right hand stop.



Fig. 1

Fig. 2

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Calibrating the rear stops

1. Steer the rear drum (Fig. 3) to the left hand stop.


In this case the display permanently shows the

value „611“.

3. Steer the rear drum to the right hand stop.



Calibrating the straight ahead posi-tion

1. Steer the front drum (Fig. 4) to straight ahead po-

sition. 2. When the stop is reached enter code number

602.


3. Steer the rear drum to straight ahead position.



Note

The function „Calibration“ is automatically termi- nated after all codes have been entered.

If the function „Calibration“ is to be aborted pre- maturely, enter code 620 and switch off the ignition.

5. Switch the ignition off and on again to activate thenew values.

Fig. 3

Fig. 4

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2.16 Adjusting the angle transducers

In order to assure an optimal function of the posi-tion detection in the steering system, both angletransducers for front and rear drums must be adjusted.

This adjustment determines the position of theangle transducers to the transom bed.

Note

Calibration of the angle transducers is only required during initial start-up in the factory and after disassembly or replacement of the angletransducers.

Caution

For the adjustment the angle transducers

must have been calibrated, as otherwise thestraight ahead position will not be reached(see previous section).

Even if only one angle transducer has beenadjusted both transducer must be adjustedanew (see previous section).

1. Align both drums to straight ahead position.

Note

In order to bring both drums to straight ahead position deactivate the crab-walk (green light goes

out) and change from „steering front“ to „steeringrear“ and back to „steering front“ while driving..

This utilizes the automatic neutral setting of thedrums when changing the steering mode.

Steering must be stopped when switching overand it must be assured that the automatic neutralsetting of the drum is completed.

Then stop steering, stop the machine and shutdown the engine.

Checking the front adjustment

Caution

For the following steps shut the engine downand switch the ignition off.

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1. Enter code number „250“ on display module (Fig.1) and read the following display.

Nominal value:

117 to 123, ideal value 120

Evaluation of display

If the value is outside this range, the angle trans-ducer must be adjusted.

Adjusting the angle transducer

1. Loosen fastening screws 3 (Fig. 2) in the slots ofangle transducer (2) and turn the transducer, until

the value is in the permissible range.

Note

If the adjustment range in the slots is not sufficient, loosen coupling 2 (Fig. 2) between transducer and transom bed and turn also.

2. Retighten all fastening screws and check the dis-play module once again.

Caution

Even if only one angle transducer has been

adjusted both transducer must be adjustedanew (see previous section).

Check the rear adjustment

Caution

For the following steps shut the engine downand switch the ignition off.

1. Enter code number „260“ on display module (Fig.3) and read the following display.

Nominal value:

117 to 123, ideal value 120

Evaluation of display

If the value is outside this range, the angle trans-ducer must be adjusted. (see previous descrip-tion).

Fig. 1

Fig. 2

Fig. 3

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2.17 Automatic detection of step currentsfor the steering valves

For a sensitive and exact control of the steeringthe step currents must be determined for the fourcontrol solenoids of both steering valves. The

step currents are automatically adjusted after en-tering the code number, so that no additional me-ter is required.

After entering the respective code number thecurrent is increased by the control solenoid in 5mA steps. After each current increase the systemwaits for two seconds. If the ESX-control has de-tected a considerable angle change of the drumafter the expiration of the waiting time, the stepcurrent is reached.

In order to enhance the measuring result themeasurement is performed three times. The final

step current is the mean value of the three meas-urements. This step current is automaticallystored and is valid from the next time the machineis started.

Note

The determination of the step currents is only required during initial start-up in the factory, afterreplacing a steering valve, the steering valve control or after changing the ESX-control

The measurement is identical for all solenoids.

Caution

For the determination of the step current parkthe machine ón firm and level ground.

The steering system must be thoroughly bledbefore performing this measurement.

Align the drum to straight ahead position.


Danger

Danger of injury!

During the measuring process the machinecannot be steered, the machine should there-fore not be driven during the detection of thestep current.

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1. Start the engine and run it with maximum speed(Fig. 1).

2. Release the brake (Fig. 2).

3. Enter code number „630“ on display module (Fig.

3).This code activates the function „Automaticmeasurement of step currents for the steeringvalves“. In this case the display shows the value„630“.

Each of the four measurements for the four con-trol solenoids must be started separately by en-tering a code number.

The code number for the four control solenoids isas follows:

4. Enter the corresponding code number for stepcurrent detection.

During the measurement the present control cur-rent is displayed (display x 10 = current [mA]).

Once the measuring process is finished the dis-play value „000“ appears for two seconds, thenthe code number „630“ is displayed again. The

next measurement can be started. 5. After all four step currents have been measured

shut down the engine to terminate the function.

The new step currents apply after the next start.

Fig. 1

Fig. 2

Fig. 3

Solenoid Code No.

Control front left 631Control front right 632Control rear left 633Control rear right 634

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2.18 Adjusting the type of travel rangeswitch

For the selection of the travel speed a 3-stageswitch (Fig. 1) is installed as standard.

A 24 stage switch (Fig. 2) can alternatively be in-

stalled.

The switch type must be entered using the re-spective code, so that the ESX-control is able toevaluate the travel speed switch correctly.

Note

The 3-stage switch is set as standard value, i.e. astandard machine does not require any adjustments.

Caution

Adjustments should only be made with theengine shut down.


Adjusting the machine for the 24-stage switch


This code activates the function „Parameterchange speed range switch“. In this case the dis-play shows the value „650“.

Note

This code number must be entered before the following step can be performed.

Fig. 1

Fig. 2

Fig. 3

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2. Enter code number „652“ on display module (Fig.4) to select the „24-stage switch“.

The display reading disappears.

3. Switch off the ignition.

With the next start the 24-stage switch is evaluat-

ed.

Adjusting the machine for the 3-stageswitch


This code activates the function „Parameterchange speed range switch“. In this case the dis-play shows the value „650“.

Note

This code number must be entered before the following step can be performed.

2. Enter code number „651“ on display module (Fig.6) to select the „3-stage switch“.

The display reading disappears.


With the next start the 3-stage switch is evaluat-ed.

Fig. 4

Fig. 5

Fig. 6

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2.19 Resetting the step currents in the trav-el system

This function allows the resetting of step currentsin the travel system to their minimum value.

This measure avoids that the travel system is

controlled with a too high step current.

Note

This measure is only required after replacing thetravel pump control or the complete travel pump.It helps to move the machine before performingthe function „Automatic detection of step currents“.

This function does not need to be performed afterreplacing the ESX-control, because a new ESXcontrol is always set for minimum step current.

Caution

During the input the engine must not be run-ning.



This code activates the function „Resetting thestep currents in the travel system“. In this case

the display shows the value „665“.


Eith this code the step current is reset to the min-imum value (350 mA).


The minimum step currents apply after the nextstart.

Fig. 1

Fig. 2

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2.20 Automatic detection of step currentsin the travel system

For a sensitive and exact control of the travel sys-tem the step currents must be determined forboth travel directions. The step currents are auto-

matically adjusted after entering the codenumber, so that no additional meter is required.

After entering the respective code number thecurrent is increased by the control solenoid in 5mA steps, starting with 350 mA. After each cur-rent increase the system waits for three seconds.If the ESX-control has detected a considerablemovement of the drum after the expiration of thewaiting time, the step current is reached.

In order to enhance the measuring result themeasurement is performed three times. The finalstep current is the mean value of the three meas-

urements. This step current is automaticallystored and is valid from the next time the machineis started.

Note

The determination of the step currents is only required during initial start-up in the factory, afterreplacing the travel pump, the travel pump controlor after changing the ESX-control

The measurement is identical for both travel directions.

Caution

For the determination of the step current parkthe machine ón firm and level ground.

Ensure sufficient space in front of and behindthe machine (approx. 10 m), because the ma-chine will move during the measuring proc-ess.

Align the drum to straight ahead position.

The new values will only become active afterthe ignition has been switched off and on

again.

Danger

Danger of injury!

During the measuring process the machinewill start to move when the step current isreached.

Do not leave the machine during the measur-ing process.

The areas in front of and behind the machine

must be free of persons.Before starting the measurement it must beassured that the speed sensor on the frontright hand drum drive motor works correctly.

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The measurement must not be performed ifthe sensor is defective.

1. Align the seat in forward direction.

2. Switch off the Speed Control.

3. Start the engine and run it with maximum speed

(Fig. 1).

Checking the function of the speedsensor


This code shows the number of travel pulses ofthe sensor.

2. Move the machine to both directions.

The displayed value must change when the ma-chine is moving.

Detecting the step currents

Danger

Danger of accident!

After entering the code number the machine

can no longer be controlled with the travel le-ver. The function of the travel lever is only re-established after the engine is shut down andrestarted.

In case of a danger the machine can bestopped by shifting the travel lever to neutralposition. In this case the complete measuringprocess must be repeated.

Fig. 1

Fig. 2

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This code activates the function „Automaticmeasurement of step currents in the travel sys-tem“. In this case the display shows the value„660“.


The code number for both control solenoids is asfollows:


2. Enter the corresponding code number for stepcurrent detection according to the table.

3. Move the travel lever (Fig. 4) forward or backwardas required by the entered code number.

During the measurement the present control cur-rent is displayed (display x 10 = current [mA]).

Once the measuring process is finished the dis-play value „000“ appears, then the code number„660“ is displayed again. The next measurementcan be started.

4. After both step currents have been measuredshut down the engine to terminate the function.

The new step currents apply after the next start.

Fig. 3

Travel direction Code No.

Forward 661Backward 662

Fig. 4

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2.21 Showing stored faults

Note

Besides stored faults, current faults are also displayed.

Switching the function on


The function “Show stored faults“ is switched on.

Switching the function off


The function “Show stored faults“ is switched off.

Fig. 1

Fig. 2

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2.22 Deleting stored faults

Note

Stored faults can only be deleted when the engine is not running.


All stored faults are deleted.

Fig. 1

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3 Flushing

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3.1 Special tool:

1. Filling and filtering unit with oil bag


2. Filter element


3. Flushing filter


4. Filter element 1µ


5. Flushing hose 25S - 20S (2 pieces)


6. Screw socket R1“ -- 25S (2 pieces)


7. Double-end union 20 S


8. Double-end union 16 S


Fig. 1

Fig. 2

Fig. 3

Fig. 4

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9. Reducing fitting 25S - 20 S


10. Elbow 20S


11. Elbow 16S


Fig. 5

Fig. 6

Fig. 7

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Fig. 1 Schematic for front travel system

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After changing a component

1. Always flush the closed circuit.

Caution

Solid particles remaining in the circuit willdamage the components again within ashort period of time.

In case of excessive oil contamination

(abrasion)

1. Open and clean all other components.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

1. Change the hydraulic oil filter element.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Note

For filtering use the filling and filtering unit.Pump the tank contents through a fine filter intothe oil bag or a clean container.

Environment

Catch hydraulic oil and dispose of environ-mentally! For filling use also the filteringunit.

Change the oil:in case of excessive contamination,

oil discoloration,

oil change interval almost reached.

Flushing filter installation (Fig. 1)

1. Connect the flushing filter outlet "OUT" with thetravel pump.

2. Connect the flushing inlet „IN“ with the hosefrom the front drum drive motor.

Caution

The flushing filter must be installed in thelow pressure side in the return flow to the

pump, so that only cleaned oil will enter thetravel pump.

With the connection shown in the illustra-tion the travel pump must therefore be actu-ated to reverse direction.

Flushing of the hoses

1. Take the front drum drive motor out of the cir-cuit, for this purpose join the high pressure linesat the drum drive motor together.

Flushing the complete system

1. Reconnect the drum drive motor.

2. Jack the front drum up for flushing.

Bleeding

1. Always bleed the closed hydraulic circuit if lineshad been removed or connected.

1 Travel pump

2 Elbow 20S

3 Flushing fi lter

4 Screw socket 1“ - 25S

5 Flushing hose 25S - 20S

6 Front drum drive motor

7 Double end union 20S

8 Elbow 20S


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Fig. 1 Schematic of rear travel system

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Caution



(abrasion)




Befor flushing




Note


Environment



oil discoloration,



1. Connect the flushing filter outlet "OUT" with thetravel pump.

2. Connect the flushing inlet „IN“ with the hosefrom the rear drum drive motor.

Caution



With the connection shown in the illustra-tion the travel pump must therefore be actu-ated to reverse direction.


1. Take the rear drum drive motor out of the cir-cuit, for this purpose join the high pressure linesat the drum drive motor together.


1. Reconnect the drum drive motor.

2. Jack the rear drum up for flushing.

Bleeding


1 Travel pump

2 Elbow 20S

3 Elbow 20S


5 Rear drum drive motor

6 Flushing filter




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3.4 Flashing the travel circuit

Cleaning the hydraulic oil tank

Environment

Catch hydraulic oil and dispose of environ-mentally!

1. Pump the hydraulic oil from the hydraulic oil tankinto a clean container or an oil bag using the fillingand filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them fromthe tank cover.

3. Unscrew the fastening screws for the cover andremove the cover.

4. Clean the hydraulic oil tank thoroughly from in-side, reassemble cover and hoses.

Filter installation for flushing of thefront travel circuit

CautionBefore installing the flushing filter check hos-es and connections for cleanliness, clean ifnecessary.

1. Disconnect the high pressure hose (Fig. 2) fromthe travel pump.

Fig. 1

Fig. 2

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2. Connect the flushing hose (Fig. 3) from filter out-let port „OUT“ to the travel pump using an anglefitting.

3. Connect the filter inlet port „IN“ (Fig. 4) with thedisconnected high pressure hoses from the travelpump using a connecting socket.

4. Flushing hose (Fig. 5) from filter port „IN“ must be

connected with the high pressure hose from thetravel pump (port A).

5. Flushing hose from filter port „OUT“ must be con-nected with the travel pump (port A).

6. Unscrew the high pressure hoses 3 (Fig. 6) fromthe front drum drive motor and join them togetherwith angle fittings (2) and socket (1).

7. Fill the hydraulic oil tank again with the filling andfiltering unit.

Note

If the hydraulic oil change interval is almostreached use new hydraulic oil.

Fig. 3

Fig. 4

Fig. 5

Fig. 6

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Bleeding the travel circuit

1. Pull the plug (Fig. 7) off the engine shut-down so-lenoid, so that the engine cannot start.

2. Secure the drums with chocks .

Environment

Catch hydraulic oil and dispose of environ-mentally.

3. Install pressure test hoses to the charge pressuretest port and to the high pressure test ports in thetravel system.

4. Hold the open ends of the pressure test hoses(Fig. 8) into a container.

5. Crank the engine approx. 30 seconds with thestarter motor. Wait one minute and repeat thisprocedure, until oil starts to run out from the pres-sure test hoses.

6. Disconnect the pressure test hoses from the highpressure test ports.

7. Reconnect the plug to the engine shut-down so-lenoid.

8. Connect a 60 bar pressure gauge to the chargepressure test hose (Fig. 9) and run the enginemax. 15 seconds at idle speed.

9. Wait for approx. 30 seconds and repeat the pro-cedure, until the pressure gauge shows a con-stant charge pressure.

Caution

Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.

10. For bleeding shift travel lever (Fig. 10) approx. 1/ 3 in travel direction backward while running theengine with idle speed.

11. After running the engine 1 to 2 minutes with idlespeed pause for approx. one minute.

Fig. 7

Fig. 8

Fig. 9

Fig. 10

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Note

This waiting time is necessary to allow air bub- bles to escape through the leak oil return line.

Repeat this measure, until the charge pressurereading immediately drops to zero when shutting

the engine down.In this case the closed travel circuit is properlybled.

Flushing the lines of the front travelcircuit

Caution

Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-

tion.

1. Shift the travel lever (Fig. 11) to travel directionbackward.

2. Perform the flushing process at various enginespeeds for approx. 15 minutes.

3. Shut down the engine.

Environment


4. Reconnect the high pressure hoses to the frontdrum drive motor.

Flushing the front drum drive motor

Danger


Do not lay under the jacked up machine. 1. Jack up the front of the machine (Fig. 12), so that

the drum can rotate freely.

2. Secure the rear drum with chocks .

Fig. 11

Fig. 12

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Caution





Filter installation for flushing of therear travel circuit


1. Disconnect the high pressure hose (Fig. 14) fromthe travel pump.

2. Connect flushing hose 1 (Fig. 15) from filter outletport „OUT“ to the travel pump using an angle fit-ting.

3. Connect flushing hose (2) from filter inlet port „IN“with the disconnected high pressure hoses from

the travel pump using a connecting socket.

Fig. 13

Fig. 14

Fig. 15

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4. Flushing hose (Fig. 16) from filter port „IN“ mustbe connected with the high pressure hose fromthe travel pump (port A).

5. Flushing hose from filter port „OUT“ must be con-nected with the travel pump (port A).

6. Unscrew the high pressure hoses 3 (Fig. 17) fromthe rear drum drive motor and join them togetherwith angle fittings (2) and socket (1).


Note


Bleeding the travel circuit

1. Pull the plug (Fig. 18) off the engine shut-downsolenoid, so that the engine cannot start.


Environment


3. Install pressure test hoses to the charge pressuretest port and to the high pressure test ports in thetravel system.





Fig. 16

Fig. 17

Fig. 18

Fig. 19

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Caution

Move the travel lever only to travel directionbackward, as otherwise the flushing filter will

be subjected to oil flow from the wrong direc-tion.

10. For bleeding shift travel lever (Fig. 21) approx. 1/ 3 in travel direction backward while running theengine with idle speed.

11. After running the engine 1 to 2 minutes with idlespeed pause for approx. one minute.

Note


Repeat this measure, until the charge pressurereading immediately drops to zero when shuttingthe engine down.

In this case the closed travel circuit is properlybled.

Fig. 20

Fig. 21

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Flushing the lines of the rear travelcircuit

Caution

Move the travel lever only to travel direction

backward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.




Environment


15. Reconnect the high pressure hoses to the reardrum drive motor.

16. Repeat the bleeding process.Fig. 22

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Flushing the rear drum drive motor

Danger


Do not lay under the jacked up machine.

1. Jack up the rear of the machine (Fig. 23), so thatthe drum can rotate freely.

2. Secure the front drum with chocks .

Caution



4. Perform the flushing process at various engine

speeds for approx. 15 minutes. 5. Shut down the engine.

Function test

1. Check the hydraulic oil level (Fig. 25) in the tank,fill up if necessary.

2. Cleaning the machine

3. Perform a test drive, load the travel system in for-ward and reverse, e.g. by driving uphill or startingon a gradient.

4. Check all ports and connections for leak tightness(visual inspection).

Servicing the flushing filter kit

1. Replace the filter element of the flushing filterwhen the red control pin of the contamination in-dicator is pressed out during the filtering process.

Fig. 23

Fig. 24

Fig. 25

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Note

This is also possible with very cold oil.

2. Clean hoses and connections and store the flush-ing kit in a clean and protected environment.

3. Change the flushing filter element of the filling

and filtering unit when the red control pin of thecontamination indicator is pressed out.

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Fig. 1

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Caution



(abrasion)




Befor flushing




Note


Environment



oil discoloration,



1. Connect the flushing filter outlet "OUT" with thevibration pump.

2. Connect the flushing inlet „IN“ with the hosefrom the shut-off valve.

Caution



For the connection schematic shown herethe vibration must always be filtered with„low frequency / high amplitude“.


1. Take the vibration motor out of the circuit, forthis purpose join the high pressure lines togeth-er.


1. Reconnect the vibration motor and pull it out ofthe coupling for flushing.

Bleeding


1 Shut-off valve

2 Elbow 20S


4 Vibration pump



7 Flushing filter

8 Rear vibration motor

9 Front vibration motor

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3.6 Flushing the vibration circuit

Cleaning the hydraulic oil tank

Environment


1. Pump the hydraulic oil from the hydraulic oil tankinto a clean container or an oil bag using the fillingand filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them fromthe tank cover.

3. Unscrew the fastening screws for the cover andremove the cover.

4. Clean the hydraulic oil tank thoroughly from in-side, reassemble cover and hoses.

Filter installation for flushing of the vi-bration drive


1. Disconnect the high pressure hose (Fig. 2) fromthe vibration pump.

Fig. 1

Fig. 2

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2. Connect flushing hose 3 (Fig. 3) to high pressurehose (5) using connecting socket (4).

3. Connect flushing hose (2) to the vibration pumpusing elbow fitting (1).

4. Connect the flushing hose (Fig. 4) from the highpressure hose to flushing filter inlet „IN“.

5. Connect the flushing hose from the vibration

pump to the flushing filter outlet „OUT“.

6. Disconnect hydraulic hoses 2 (Fig. 5) from both

vibration motors and join them together withsocket (1).


Note


Bleeding the vibration circuit

1. Pull the plug (Fig. 6) off the engine shut-down so-lenoid, so that the engine cannot start.


Environment


3. Install pressure test hoses to the charge pressure

test port and to the high pressure test ports in thevibration system.

Fig. 3

Fig. 4

Fig. 5

Fig. 6

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Caution

Use only low frequency, as otherwise theflushing filter will be subjected to oil flow fromthe wrong direction.

10. For bleeding switch on low frequency (Fig. 9) forboth drums at idle speed.

11. After running the engine 1 to 2 minutes pause forapprox. one minute.

Note


Repeat this measure, until the charge pressurereading immediately drops to zero when shuttingthe engine down.

In this case the closed travel circuit is properlybled.

Fig. 7

Fig. 8

Fig. 9

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Flushing the hoses in the vibrationcircuit

Caution

Use only low frequency, as otherwise the

flushing filter will be subjected to oil flow fromthe wrong direction.

1. For bleeding switch on low frequency (Fig. 10) forboth drums at full engine speed.

2. Run the flushing procedure for approx. 10 min-utes. Switch the vibration on and off at intervals ofapprox. 30 seconds.


Environment


4. Reconnect both high pressure hoses to both vi-bration motors.

Flushing the vibration motors

1. Unscrew the fastening screws for both vibrationmotors and pull the motors out of their couplings(Fig. 11).

Caution

Use only low frequency, as otherwise theflushing filter will be subjected to oil flow from

the wrong direction. 2. For bleeding switch on low frequency (Fig. 12) for

both drums at full engine speed.

3. Run the flushing procedure for approx. 10 min-utes. Switch the vibration on and off at intervals ofapprox. 30 seconds.


Fig. 10

Fig. 11

Fig. 12

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Function test

1. Check the hydraulic oil level (Fig. 13) in the tank,fill up if necessary.

2. Cleaning the machine

3. Perform a test drive, load the travel system in for-

ward and reverse, e.g. by driving uphill or startingon a gradient.

4. Check all ports and connections for leak tightness(visual inspection).

Servicing the flushing filter kit

1. Replace the filter element of the flushing filter

when the red control pin of the contamination in-dicator is pressed out during the filtering process.

Note

This is also possible with very cold oil.

2. Clean hoses and connections and store the flush-ing kit in a clean and protected environment.

3. Change the flushing filter element of the fillingand filtering unit when the red control pin of thecontamination indicator is pressed out.

Fig. 13

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4 Trouble shooting

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4.1 General

General notes on trouble shooting in hy-draulic systems

The following tests are performed for fault diagnosticsand should enable you to encircle a fault in the hy-draulic system.

At this point it is assumed that there is no fault in theelectric system, i.e. trouble shooting in the electricsystem has already been performed.

In some cases these tests may also be conducted toidentify faults on hydraulic components of the powertransmission system.

On the basis of preliminary tests the individual meas-urements have the purpose to limit the cause of thefault first of all to a general area and then to determineexactly which oil circuit or hydraulic component is notworking correctly.

Important points for trouble shooting andfault rectification

Danger

Danger of injury!

Do not touch rotating parts of the engine.

When working on the travel pump and performingtests in the travel circuit block the drums withsuitable wheel chocks.

Hydraulic oil escaping under pressure can pene-

trate the skin and cause severe injury. You shouldtherefore relieve the pressure in the system be-fore disconnecting any lines. Before repressuriz-ing the system make sure that all line connectionsand ports are in perfect condition.

When being injured by hydraulic oil consult a phy-sician immediately, as otherwise this may causesevere infections.

Caution

It is not recommended to open or repair hydraulic

units and components without comprehensiveknowledge.

Risk of damage to pressure gauges if incorrectlyconnected.

When performing trouble shooting it is assumed thatthe machine is correctly equipped and connected, thatconnections and hoses are free of faults and that set-screws have not been deadjusted without permission.

Progressive tests drawn up in the trouble shooting di-agram lead to the detection of faults and their rectifi-cation by trained personnel.

Ensure strict cleanliness, clean ports and fittingsbefore disconnecting.

Cover all openings and ports or close with plugs.

Check the hydraulic oil level before and after thework.

Use only clean oil according to specification.

Check the hydraulic system for leaks, find and rec-tify the cause.

Ensure strict cleanliness, clean ports and fittingsbefore disconnecting.

Fill new hydraulic units with hydraulic oil beforestarting operation.

After changing a component thoroughly flush andbleed the hydraulic system.

AS far as possible conduct all measurements at op-erating temperature 40 ... 50 °C.

After changing a component check charge and highpressure, if necessary check the rotational speed.

Hydraulic hoses

Danger

Danger of injury

Hydraulic hoses must be visually inspected atregular intervals.

Hydraulic hoses must be immediately replaced if:

the outer layer is damaged down to the inlay (e.g.chafing, cuts, cracks, etc.)

the outer layer is brittle (formation of cracks in the

hose material) the hose shows deformations in pressurized and

depressurized condition, which do not comply withthe genuine shape of the hydraulic hose

the hose shows deformations in bends, e.g.squeezing, buckling, layer separation, formation ofblisters

the hose is leaking

the hydraulic hose has separated from the fitting

the fitting shows corrosion that impairs both function

and strength the fitting is deformed in a way that both function

and strength are affected

the storage time and utilization period has expired.

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4.2 Trouble shooting diagram

The machine drives with the travel lever in „NEUTRAL“

Neutral position

OK?

no

yes

Check the mechanical neutral position

- Enter code number 500 to close the brake

- Connect control chamber ports X1 and X2 with

a hose

Adjust the hydraulic neutral position

- Remove the hose connecting X1 and X2

- Run the engine with maximum speed.

- Adjust the hydraulic neutral position so that

identical pressures are indicated at MA and

MB (charge pressure)

Adjusting the mechanical neutral position

- Connect 600 bar pressure gauges to MA and

MB


- Adjust the mechanical 0-position so that identi-

cal pressures are indicated at MA and MB

(charge pressure)

- For a more exact adjustment repeat the testwith 60 bar pressure gauges

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Machine does not drive / insufficient travel performance

High pressureOK?

no

yes

Brake valve

OK?

yes

no Replace the brake valve

Check high and charge pressure

- Connect 600 bar pressure gauges to the high pressure testport

- Connect a 60 bar pressure gauge to the charge pressure test

port

- Start the engine and run it with maximum speed

- Drive the machine against the closed brake, for this purpose

enter code number 500, actuate the travel lever for a moment

and read the pressure gauge

Nominal value:

High pressure approx. 400 bar ±10 bar,charge pressure approx. 26 bar

Check the brake releasing pressure

- Install a 60 bar pressure gauge to the

brake releasing line

- Start the engine and check whether

the brake valve opens when the

brake is released

Nominal value:

approx. 26 bar (charge pressure)

Mechanical fault,

blocked drive

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Charge

pressure OK?

yes

no

Check the front steering pressure

- Connect a 600 bar pressure gauge to

the steering pressure test port

- Enter code number 600

- Pull the plug off the starter solenoidand crank the engine with the starter

- Turn the front steering against one of

the end stops and read the pressure

gauge

Nominal value:

approx. 200 bar (battery fully charged)

Steering

pressure OK?

yes

no Perform trouble shooting

for front steering system

Check the rear steering pres-

sure

- Connect a 600 bar pressure

gauge to the steering pressure

test port


- Pull the plug off the starter so-

lenoid and crank the engine

with the starter

- Turn the rear steering against

one of the end stops and readthe pressure gauge

Nominal value:

approx. 200 bar (battery fully

charged)

Steering

pressure OK?

yes


for rear steering system

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Check leakage

of brake

- Release the brake and perform acharge pressure test

Charge pressure

OK?

no

yes

- Disconnect the brake releasing

lines one after the other from thedrum drive motors and close them

with plugs; repeat the charge pres-

sure test with the brake closed

- Repair the unit with which the

charge pressure is OK after thebrake line has been disconnected

Valve OK?

yes

no Replace the charge pres-

sure relief valve

Check the charge pres-

sure relief valve

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Flushing valve

OK?

noyes Replace the flushing valve

Check the flushing valve

Check the travel pump

- Close the high pressure ports on the

pump with plugs

- Repeat the pressure test

High pressure

OK?

no

Check the control chamber pres-

sure

- Install pressure test ports with 60

bar pressure gauges to X3/X4

Pressure OK?

no

yes

yes

- Actuate the travel pump to fulldisplacement and read the pres-

sure gauge

Nominal value: approx. 15 bar

Replace/repair

the travel pump

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Nozzles OK?no

yes

Check the swash time nozzles

- Unscrew the nozzles and check

for blockage

Clean the nozzles

Check the case pressure

- Install a pressure test port witha 10 bar pressure gauge to G

Pressure OK?no

yesCheck the leak oil return

line to the tank

- Actuate the travel pump to full dis-

placement and read the pressuregauge

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Test the travel motors individually

- Close the high pressure test ports on

the drum drive motors one after the

other with plugs

- Repeat the pressure test

- If the high pressure is O.K., replace

the travel motor excluded from the

hydraulic circuit.

Replace/repair

the travel pump

Servo control

OK?

no

Repair the servo

control

Check the servo control

- Remove the servo control

- Check the nozzles, clean if nec-

essary.

- Check the linkage, repair if nec-

essary

yes

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Hydraulic oil overheating >90 °C

Valves

OK?

yes

no

Check the high pressure relief valves in

the travel circuit

- Enter code number 500 to close the

brake

- Fully actuate the travel lever

- Check the high pressure relief valves for

excessive heat

Check high pressure relief valves in vi-

bration circuit

- Stand the drums on rubber tires

- Switch the vibration on

- Check high pressure relief valves for ex-

cessive heat

Check the high pressure

relief valves/pressure override

Check the thermostat valve

- Check whether the hose to the cool-

er heats up when a hydraulic oil

temperature of > 60 °C is reached

Thermostat

OK?

yes

no Replace the thermostat

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Check the flushing valve in the travel sys-

tem

- Check the moveability of the flushing valve

Check the flushing valve in the vibration

system

- Check the moveability of the flushing valve

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No vibration at front and rear

Travel system O.K.

Current

OK?

yes


in the electric system

Check the control chamber pressure

- Install pressure test ports to X1 and X2

- Connect a 60 bar pressure gauge

- Run the engine with maximum speed

- Switch the vibration on and read the pres-

sure gauge


Pressure

OK?

yes

no

Check the electric power supply for the

solenoid valves

- Switch the vibration on and measure the

current consumption of both solenoids

Nominal value: approx. 1.7 A

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Check the vibration pump

- Connect 600 bar pressure gauges to the vi-

bration pump- Close high pressure ports A and B with plugs

- Run the engine with maximum speed .

- Switch the vibration on for a moment and read

the pressure gauge


Check the control unit

- Remove the control unit

- Check the nozzle, clean if neces-sary.

- Check the control piston, if nec-

essary replace the control unit

Pressure

OK?

yes

no Replace/repair

the vibration pump

yes

no Replace / repair

the coupling

Replace/repair

the vibration motor

Check the vibrator shaft bearings

- Remove the vibration motor

- Check end float and moveability

of the vibrator shafts

- Check the coupling

Bearing /

coupling

OK?

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Speed of front and rear vibrator shafts too low

Rated speed

OK?

yes

no Perform engine

trouble shooting

Checking the engine speed

- Switch vibration on and measure the speed

Nominal value:

Nominal speed 2600 rpm

yes

no

- Adjust high

and low fre-

quency

yes

no

Check the pressures in the vibration circuit

- Connect 600 bar pressure gauges to the high pressure test

port

- Connect a 60 bar pressure gauge to the charge pressure

test port


- Switch the vibration on and read the pressure gauge

Nominal value:

Start up pressure: 380 ±20 bar

Operating pressure: approx. 100 bar (depending on soil)

Charge pressure: approx. 26 bar

Charge

pressure OK?

Drop in vibrator

shaft speed

>10%

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no, to high

yesOperating

pressure OK?

no

yesStart-up

pressure OK?

Check the leak oil rateof both vibration mo-

tors

- Measure the leak oil

rate at a vibration

measure of approx.

100 bar

Nominal value:max. 1 l/min

yes

noLeak oil OK? Replace the respective vi-bration motor

Check the vibrator shaft bearings

- Check end float and moveability of the vibra-

tor shafts

End float:

1,0 ... 3.3 mm

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Check the vibration pump

- Close high pressure ports A and B with plugs

- Switch the vibration on for a moment and

read the pressure gauges

Nominal value:

380 ±20 bar

Pressure OK?

yes

no

Test the individual vibration

motors

- Close the high pressure hoses

of the individual vibration mo-

tors one after the other with

plugs and repeat the pressure

test

- If the high pressure is O.K., re-

place the travel motor excluded

from the hydraulic circuit.

Pressure OK?yes

no

Check the control cham-ber pressure

- Install pressure test ports

with 60 bar pressure

gauges to X1and X2

- Switch the vibration on

and read the pressure

gauge

Nominal value:

approx. 15 bar

Replace/repair

the vibration pump

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Replace/repairthe travel pump

Servo control

OK?

no Replace the servo

control

Check the servo control

- Remove the servo control

- Check the nozzles, clean if

necessary.

yes

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No front steering steering sticky

Steering

pressure OK?

yes

no

Check the front steering pressure

- Connect a 600 bar pressure gauge to the

steering pressure test port


- Pull the plug off the starter solenoid and

crank the engine with the starter

- Turn the front steering against one of the

end stops and read the pressure gauge

Nominal value:


Check the front steering pump

- Close the pump outlet with a 200bar pressure relief valve


gauge

- Crank the engine with the starter

- Read the pressure gauges

Nominal value:

approx. 200 bar (battery fullycharged)

Pressure OK?

yes

no

Change the steering /

charge pump

Check / replace thefront steering cylinder

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yes

noSteering

pressure OK?Replace the steering valve

Check the front steering valve- Install a 600 bar pressure gauge to the

steering pressure outlet


- Turn the front steering against an end stop

Nominal value:

approx. 200 bar

Check the moveability

of steering cylinders

and pivot bearing

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No rear steering steering sticky

Steering

pressure OK?

yes

no

Check the rear steering pressure

- Connect a 600 bar pressure gauge to the

steering pressure test port


- Pull the plug off the starter solenoid and

crank the engine with the starter

- Turn the rear steering against one of the

end stops and read the pressure gauge

Nominal value:


Check the rear steering pump

- Close the pump outlet with a 200

bar pressure relief valve


gauge

- Crank the engine with the starter

- Read the pressure gauges

Nominal value:

approx. 200 bar (battery fully

charged)

Pressure OK?

yes

no

Change the steering /

charge pump

Check / replace therear steering cylinder

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yes

noSteering

pressure OK?Replace the steering valve

Check the rear steering valve- Install a 600 bar pressure gauge to the

steering pressure outlet


- Turn the rear steering against an end stop

Nominal value:

approx. 200 bar

Check the moveability

of steering cylinders

and pivot bearing

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5 Drum

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5.1 Special tools

1. Lifting device for vibrator unit

BOMAG part-no. 007 215 08

2. Screw bolt for vibrator unit lifting device

Fig. 1

Fig. 2

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Fig. 1 Drum

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1 Vibrator housing

2 Vibrator shaft

3 Drum drive motor

4 Rubber buffer

5 Vibrator shaft coupling

6 Change-over weight

7 Vibrator shaft bearing

8 Travel bearings

9 Vibration motor

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5.3 Removing and installing the drum

Note

Removal and installation of the drum is exempla- ry described for the front drum. The rear drum

must be removed and installed in the same way.

Removal

1. Drain the water from the corresponding watertank for the water sprinkling system.

2. Fasten lifting gear to front and rear frame (Fig. 1).

3. Lift the machine up, until the rubber buffers areunloaded.

4. Remove the cover plates (Fig. 2) from both sides.

5. Disconnect water hoses 1 (Fig. 3) from the sprin-kling tubes.

6. Remove scraper brackets (2) with the sprinklingtubes .

Fig. 1

Fig. 2

Fig. 3

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7. Mark the hydraulic hoses (Fig. 4) on the vibrationmotor and disconnect them from the ports.

Caution

Close all openings with plugs.

Environment

Catch running out oil and dispose of environ-mentally.

8. Mark the hydraulic hoses on the travel motor (Fig.5) and disconnect them from the ports.

CautionClose all openings with plugs.

Environment


9. Open the hose brackets (Fig. 6) on both sides of

the support legs and pull the hoses out of thesuport legs.

10. Unscrew fastening screws (Fig. 7) from the sup-port legs.

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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Danger


Do not step under suspended loads.

11. Fasten lifting gear to the support leg and unscrewfastening screws (Fig. 8).

12. Pull the support leg off and lay it down.

13. Remove the support leg also from the oppositeside.

14. Lift the machine up (Fig. 9), so that the drum canbe removed from under the frame.

15. Support the frame safely.

16. Check rubber buffers (Fig. 10), replace if neces-

sary.

Fig. 8

Fig. 9

Fig. 10

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Installation

Danger



1. Lift up the frame and roll the drum parallel underthe frame (Fig. 11).

2. Assemble the support legs to the drum (Fig. 12).

3. Tighten all fastening screws for both support legs

and remove the lifting gear.

4. Align the bores in the support leg with the boresin the traverse, turn in and tighten the fasteningscrews (Fig. 13).

5. Connect the hydraulic hoses for the travel motor(Fig. 14) by following the marking and tightenthem.

Fig. 11 872739

Fig. 12 872740

Fig. 13 872741

Fig. 14 872734

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6. Connect the hydraulic hoses for the travel motor(Fig. 15) by following the marking and tightenthem.

7. Fasten the hose bracket (Fig. 16) to the supportlegs on both sides.

8. Fasten the cover plates (Fig. 17) on both sides.

9. Install scrapers and water sprinkling tubes (Fig.18).

Fig. 15 872733

Fig. 16 872732

Fig. 17 872730

Fig. 18 732731

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5.4 Removing and installing the vibratorunit on the drum drive side

1. Remove the drum.

Environment


2. Drain the oil from the drum.

Removing the vibrator unit

1. Unscrew the fastening nuts (Fig. 1) and take offthe angle plate.

2. Examine all rubber buffers 1 (Fig. 2) for wear, re-place if necessary.

3. Unscrew the fastening screws (Fig. 3) and take

off the drive disc with rubber buffers.

Fig. 1

Fig. 2

Fig. 3

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4. Unscrew two fastening screws opposite each oth-er (Fig. 4) and turn in guide bolts.

5. Unscrew all other fastening screws.

6. Turn adapter 1 (Fig. 5) of the lifting device withthree washers (2) into the travel motor.

DangerDanger of squashing!


7. Fasten the lifting device to a crane and slide itover the adapter.

8. Pull the travel motor off the flange.

Caution

If dirt or chips are found in the travel motorflush the hydraulic system before restarting

the machine. 9. If necessary unscrew the fastening screws (Fig.

6) and take off the flange.

Fig. 4

Fig. 5

Fig. 6

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10. Unscrew two fastening screws opposite each oth-er (Fig. 7) and turn in guide bolts.

11. Unscrew all other fastening screws and force thehousing off with the help of two screws.

12. Fasten the lifting device to the flange and pull thehousing out of the drum (Fig. 8).

13. Take off the O-ring.

Installing the vibrator unit

Caution

Fitting and contact surface of the connectionbetween vibration unit and drum must be ab-solutely dry and free of grease, oil, paint andconserving agent.

Note

Always assemble the vibration unit on the drumdrive side first.

1. Grease and assemble the O-ring (Fig. 9).

2. Fasten the lifting device to the flange and turn twoguide bolts into the drum(Fig. 10).

3. Insert the vibrator unit into the drum.

Fig. 7

Fig. 8

Fig. 9

Fig. 10

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4. Remove the guide bolts (Fig. 11).

5. Turn in and tighten the fastening screws.

6. Attach the flange to the drum drive motor, turn inand tighten the fastening screws (Fig. 12).

7. Turn adapter 1 (Fig. 13) of the lifting device with

three washers (2) into the travel motor.

Danger



8. Fasten the lifting device to a crane and slide itover the adapter.

Caution

If dirt or chips are found in the travel motor

flush the hydraulic system before restartingthe machine.

9. Turn in two guide bolts.

10. Push on the drum drive motor, turn in and tightenthe fastening screws (Fig. 14).

Fig. 11

Fig. 12

Fig. 13

Fig. 14

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11. Attach the drive disc with rubber buffers, turn inand tighten the fastening screws (Fig. 15).

12. Attach the angle plate, turn on and tighten thefastening nuts with washers (Fig. 16).

Fig. 15

Fig. 16

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5.5 Removing and installing the vibratorunit on the vibration drive side

1. Remove the drum.

Environment


2. Drain the oil from the drum.

3. Remove the vibrator unit on the drum drive side.

Removing the vibrator unit

1. Unscrew the fastening nuts (Fig. 1) and take offthe angle plate.

2. Examine all rubber buffers (Fig. 2) for wear, re-place if necessary.

3. Unscrew fastening screws 1 (Fig. 3) and take offthe vibration motor (2).

Caution

If dirt or chips are found in the travel motorflush the hydraulic system before restartingthe machine.

Fig. 1

Fig. 2

Fig. 3

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4. If necessary unscrew fastening screw 1 (Fig. 4)and pull off coupling hub (2).

5. Remove coupling element 1 (Fig. 5)and pull offcoupling hub (2).

6. Unscrew the fastening screws (Fig. 6) and re-

move the cover.

7. Unscrew the fastening screws (Fig. 7) and takeoff the intermediate ring.

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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8. Take off the V-ring (Fig. 8).

9. Remove the circlip (Fig. 9).

10. Attach the lifting gear side plate (Fig. 10).

Danger



11. Pull the side plate off the flange using a specialpulling device (Fig. 11).

Fig. 8

Fig. 9

Fig. 10

Fig. 11

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12. Press the travel bearing (Fig. 12) out, check itscondition and replace if necessary.

13. Take off the V-ring (Fig. 13).

14. Unscrew the fastening screws (Fig. 14) and take

off the flange.

15. Turn two guide bolts into the drum and unscrewthe fastening screws (Fig. 15).

Fig. 12

Fig. 13

Fig. 14

Fig. 15

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16. Fasten the lifting device to the flange and pull thehousing out of the drum (Fig. 16).

17. Take off the O-ring.

18. Remove circlip 3 (Fig. 17) from coupling sleeve(1).

19. Pull off coupling and disc (2).

Installing the vibrator unit

Caution

Fitting and contact surface of the connectionbetween vibration unit and drum must be ab-solutely dry and free of grease, oil, paint andconserving agent.

Note

Always assemble the vibration unit on the drumdrive side first.

1. Grease and assemble the O-ring (Fig. 18).

2. Push on coupling sleeve 1 (Fig. 19).

3. Insert disc (2) and assemble circlip (3).

Fig. 16

Fig. 17

Fig. 18

Fig. 19

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4. Turn two guide bolts into the drum (Fig. 20).

5. Attach the lifting gear to the flange and insert thehousing carefully into the drum.

Caution

Ensure correct engagement of the coupling!

After installation the vibrator shaft must stillhave sufficient end float.

6. Unscrew the guide bolts, turn in and tighten thefastening screws (Fig. 21).

7. Attach the flange, turn in and tighten the fastening

screws (Fig. 22).

8. Press the travel bearing with spacer disc (Fig. 23)into the drive disc.

Fig. 20

Fig. 21

Fig. 22

Fig. 23

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9. Assemble the V-ring . (Fig. 24)

10. Attach the lifting gear to the side plate and placeit onto the flange (Fig. 25).



11. Pull the side plate onto the flange using a special

pulling device (Fig. 26).

12. Insert the circlip into the groove (Fig. 27).

Fig. 24

Fig. 25

Fig. 26

Fig. 27

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13. Assemble the V-ring (Fig. 28).

14. Assemble the intermediate ring, turn in and tight-en the fastening screws (Fig. 29).

15. Attach the cover, turn in and tighten the fastening

screws (Fig. 30).

16. Pull the vibrator shaft towards you (Fig. 31) (musttouch the collar of the bearing on the drive side).

Fig. 28

Fig. 29

Fig. 30

Fig. 31

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17. On the vibration drive side of the drum measurethe depth to the stop of the coupling hub on thevibrator shaft (Fig. 32).

Nominal value:

122 ... 121.8 mm

18. Compensate the difference to the measured val-ue with shims between coupling hub and vibratorshaft.

19. Insert shims (Fig. 33) of calculated thickness.

Note

If the fitting key is already assembled the shimsmust be punched out accordingly.

20. Press the coupling have 2 (Fig. 34) onto the vibra-

tor shaft and insert coupling element (1).

Caution

Mind the fitting key!

21. Slide coupling hub 2 (Fig. 35) onto the shaft andtighten fastening screw (1).

Fig. 32

Fig. 33

Fig. 34

Fig. 35

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22. Install the vibration motor 2 (Fig. 36), turn in andtighten the fastening screws (1).

23. Assemble the angle plate, turn on and tighten thefastening nuts (Fig. 37).

24. Fill in oil as specified in the maintenance instruc-

tions.

Fig. 36

Fig. 37

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7. Take the vibrator unit (Fig. 4) out of the housing.

8. Check the condition of the inner bearing race(Fig. 5), replace if necessary.

9. Pull coupling pinion 1 (Fig. 6) off the exciter shaft.

10. Check the condition of the inner bearing race (2),pull off if necessary.

11. Remove circlip 1 (Fig. 7).

12. Press bearing (2) out of the housing.

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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Assembling the vibrator unit

1. Press bearing 2 (Fig. 8) into the housing.

2. Assemble circlip (1).

Danger

Danger of burning!

Wear protective gloves.

3. Heat the inner bearing race up to approx. 80 °C.

4. Push inner bearing race 3 (Fig. 9) with the collartowards the eccentric weight all the way againstthe end stop.

5. Insert circlip (2) into the groove in the vibratorshaft.

6. Insert the fitting key into the keyway in the vibratorshaft.

7. Heat coupling pinion (1) up to approx. 80 °C and

slide it onto the shaft against the stop.

Danger

Danger of burning!




10. Insert circlip (1) into the groove in the vibrator

shaft.

Fig. 8

Fig. 9

Fig. 10

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16. Attach the flange to the housing (Fig. 15).

17. Insert and tighten fastening screws 1 (Fig. 16).

18. Insert the plugs into the forcing off bores (2) withseal rings.

19. Check the end float of the vibrator shaft (Fig. 17).

Nominal value:

0.6 ... 1.2 mm

Fig. 15

Fig. 16

Fig. 17

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5.7 Repairing the vibrator unit on the vi-bration drive unit

1. Remove the vibrator unit.

Dismantling the vibrator unit

1. Unscrew the fastening screws (Fig. 1) and takethe flange off the housing.

2. Take the flange off the housing (Fig. 2).

3. Take off the O-rings.

4. Pull radial seal 1 (Fig. 3) out of the flange.

5. Unscrew plugs (2).

Note

The bores with the plugs (2) are used to force offthe cylinder roller bearings.

Fig. 1

Fig. 2

Fig. 3

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7. Force bearing (2) out of the flange with the helpof screws.

8. Take the vibrator unit (Fig. 5) out of the housing.

9. Check the condition of inner ring 1 (Fig. 6) for ra-

dial seal and inner bearing race (2), pull off if nec-essary.

10. Pull coupling pinion 1 (Fig. 7) off the exciter shaft.

11. Check the condition of the inner bearing race (2),pull off if necessary.

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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13. Press bearing (2) out of the housing.

Assembling the vibrator unit



Danger

Danger of burning!





6. Insert fitting key (4) into the keyway in the vibrator

shaft.

7. Slide locking ring (3) and washer (2) to fasten thecoupling onto the shaft.

8. Heat coupling pinion (1) up to approx. 80 °C andslide it onto the shaft against the stop.

Fig. 8

Fig. 9

Fig. 10

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Danger

Danger of burning!


9. Heat the inner ring and inner bearing race up toapprox. 80 °C.



12. Slide inner ring (1) with the chamfered side to-wards the outside onto the shaft.

13. Move the vibrator unit (Fig. 12) carefully into thehousing, until the inner bearing race is seated inthe bearing.



16. Grease the O-ring and lay it into the groove (Fig.14).

Fig. 11

Fig. 12

Fig. 13

Fig. 14

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17. Grease the O-ring and lay it around the collar(Fig. 15).

18. Attach the flange to the housing (Fig. 16).

19. Turn in and tighten the fastening screws (Fig. 17).

20. Press the new radial seal 1 (Fig. 18) into thehousing with the sealing lip pointing down.

21. Insert the plugs into the forcing off bores (2) withseal rings.

Fig. 15

Fig. 16

Fig. 17

Fig. 18

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22. Check the end float of the vibrator shaft (Fig. 19).

Nominal value:

0,6 ... 1.2 mm

Fig. 19

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9. Attach the cover (Fig. 8) to the housing.

10. Cover the fastening screws with LOCTITE green(No. 601).

11. Tighten the fastening screws evenly with 35 Nm.

Fig. 8

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6 Pivot steering

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6.1 Removing, repairing and installing thepivot steering

Removal

1. Remove the respective drum (see respective

section). 2. Disconnect the steering cylinders (Fig. 1) on both

sides from the cross-member.

3. Unscrew all fastening screws from the hood (Fig.2) and take off the hood.

4. Remove steering angle transducer 1 (Fig. 3) andcover (2).

Fig. 1

Fig. 2

Fig. 3

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5. Pull hydraulic hoses and electric cables (Fig. 4)out of the cross member.

6. Attach the lifting tackle to the cross-member (Fig.5).



7. Unscrew all fastening screws (Fig. 6) from both

sides and lower the cross-member to the ground.

8. Unscrew all fastening screws (Fig. 7) and lowerthe transom bed to the ground.

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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9. Check four point bearing , replace if necessary.

Danger


Support the bearing so that it cannot fall

down.

10. Unscrew all fastening screws (Fig. 8) from thefour-point bearing and take the bearing off.

Installation

Danger



1. Lift up the cross-member and place it in front ofthe transom bed (Fig. 9).

2. Turn in and tighten the fastening screws (Fig. 10).

3. Route hydraulic hoses (Fig. 11) and electric ca-bles through the cross member.

Fig. 8

Fig. 9

Fig. 10

Fig. 11

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4. Assemble the steering angle transducer (Fig. 12)with the angle plate.

Caution

Adjust the angle transducers before starting

operation of the machine!

5. Connect the steering cylinders (Fig. 13) with thecross-member.

6. Reinstall the drum (see corresponding section).

7. Calibrate and adjust the steering angle transduc-ers (see respective section).

8. Reassemble the hood (Fig. 14) and perform atest drive.

Fig. 12

Fig. 13

Fig. 14

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6.2 Repairing the oscillation joint

Dismantling the oscillation joint

1. Remove drum and pivot steering (see corre-sponding section).

2. Unscrew the fastening screws (Fig. 1) and re-move the cover.

3. Pull out the rocker bearing (Fig. 2) and take offthe supporting disc.

4. Remove the cover (Fig. 3) also on the other sideand pull out the rocker bearing.

Fig. 1

Fig. 2

Fig. 3

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5. Press the joint bolt out using three screws (Fig.4).

6. Lift the beam out of the cross member (Fig. 5).

Assembling the oscillation joint

1. Insert the beam into the cross member and knockin the joint bolt (Fig. 6).

2. Insert the support ring and press the joint ring(Fig. 7) onto the joint bolt.

3. Spray the joint ring with sliding agent OKS 571(BOMAG part-no. 009 700 26).

Caution

Insert the rocker bearing without grease, useonly sliding agent OKS 571 (BOMAG part-no.009 700 26).

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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7 Suppliers documentation

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Reparaturanleitung A4VG

Repair Instructions A4VG

RDE 92003-01-R/05.99

Brueninghaus Hydromatik 3

Schnittbild

Sectional view

HWD

EPD

DAD

HDD

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Turcon-Glyd-Ring Dichtung

Turcon-Glyd-ring seal

Deckel Stelldruck

Stellzylinder

Lecköl

Führungsbuchse

Turcon-Glyd-Ring

Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstel-lung der Verstellung auf Turcon-Dichtungen.Die Stückliste der kompletten Einheit erhält dabei eineneue Ident.- Nummer.Typenschlüssel, Typnummer und Außenabmeßungenbleiben dabei unverändert. (Pumpengehäuse ändert sichnur im Bereich vom Stellkolben. Stellkolben ändert sich ineine angefaste Ausführung).

Alten Stellkolben nicht bei Turcon-Dichtung ver-wenden (scharfkantig - Dichtungen werdenbeschädigt).

Pumpengehäuse / Pump housingmit Lagerbuchse / with bush ALT / OLD

At present the change of the control into Turcon seal ismade for A4VG.The parts list of the complete unit will receive a newidentification number.Type reference and outside dimensions remainunchanged (pump housing will change at the area of thepositioning piston. Positioning piston will change intochamfering design).

Do not use old positioning piston with Turcon seal(sharp edged - seal will be damaged)

Pumpengehäuse / Pump housingmit Turcon-Dichtung / with Turcon seal NEU / NEW

Die Umstellung der Verstellung auf Turcon-Dichtung ist im allgemeinen mit einer Funktions-verbesserung verbunden (DA-Verhalten, geringererTemperatureinfluß auf Stellzeiten).

Bei gleicher Düsenbestückung können sich dieStellzeiten geringfügig verändern.

The change of the control into Turcon seal designimproves in general the function (DA-behaviour,lower temperature-influence on control times).

The control times will slightly change with thesame throttle sections. Therefore our customershave to be informed about this change.

* *

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6 Brueninghaus Hydromatik

Achtung!Nachfolgend Hinweise bei allen Reparaturarbeitenan Hydraulikaggregaten beachten!

Attention!Observe the following notices when carrying out repairwork at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.Nur original BRUENINGHAUS HYDROMATIK-Ersatzteileverwenden.

Replace all seals.Use only original BRUENINGHAUS HYDROMATIKspare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.Achtung: Nacharbeiten an Dichtflächen z.B. durchSchleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.Attention: Rework of sealing area f. ex. with abrasivepaper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mitBetriebsmedium befüllen.

Fill up hydraulic aggregates with mediumbefore start- up.

Allgemeine Reparaturhinweise

General repair instructions

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Dichtsätze und Baugruppen

Seal kits and sub assembly groups

1 Dichtsatz für Triebwelle.

Seal kit for drive shaft.

3 Gehäuse

Housing

2 Äußerer Dichtsatz.

External seal kit.

4 Triebwerk komplett.

Complete rotary group.

5 Stellkolben

Positioning piston

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Baugruppen

Sub assemblies

6 Anschlußplatte

Port block

8 Ansteuergeräte HD - DA

Control moduls HD - DA

7 Ansteuergeräte HW - EP

Control moduls HW - EP

9 Hilfspumpe

Boost pump

10 Regelventil

Control valve

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Triebwelle abdichten

Sealing of the drive shaft

13 Blechschraube in die mit Gummi gefülltenLöcher eindrehen.Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holesfitted with rubber.Pull out shaft seal with pliers.

14 Wellendichtring mit Buchse aufAnschlag einpressen.

Press-in shaft seal with bush to stop.

12 Triebwelle abkleben.Sicherungsring ausbauen.

Protecting the drive shaft.Remove retaining ring.

11

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Stellkolbendeckel abdichten

Sealing of the control piston cover

23 Über 0-Lagen-Einstellschraube Deckel abdrückenund drehen.

Pull cover off using zero position adjustment screw.

25 Gewinde abdecken, kleinen O-Ring aufschieben.Montage in umgekehrter Reihenfolge.

Cover threads, push on small O-ring.Assemble in reversed order.

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

Check!O-ring (19, groove (2), housing (3).

26 Achtung!Korrekte mechanische Nullageneinstellung muß nachEinbau im Gerät bzw. Prüfstand erfolgen.

Attention!Adjustment of the correct zero position to be carried out

after installation into the machine or on the test bench.

27 Mechanische Nullage neu einstellen, dazu X1 mit X

2

verbinden (>NW6).

Reset mechanical zero position. To do this, connectX

1 to X

2 (size > 6).

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Ventile abdichten

Sealing of the valves

29 Gewinde vor Montage des neuen O-Ringes abkleben.(Beschädigungsschutz).

Cover threads before fitting new O-rings.(Damage protection).

30 Ventilkegel mit Druckfeder ausbauen.* mit Bypassfunktion

Remove valve poppet with spring.* with bypass-function

31 Gewinde vor Montage des neuen O-Ringes abkleben.(Beschädigungsschutz).

Cover threads before fitting new O-rings.(Damage protection).

PSP

-Ventil

PSP

-valve

*

PHD

-Ventil mit Bypass

PHD

-valve with bypass-function

28

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Druckabschneidung abdichten

Sealing of the pressure cut-off valve

31

33 Wechsel der Dichtmutter.Einstellmaß festhalten (*).

Change of the sealing nut.Note setting measure (*).

Achtung!Nach Einbau "Ventileinstellung" überprüfen.

Attention!After assembly check "valve setting".

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Regelventil abdichten

Sealing of the control valve

36 Blendendurchmesser nicht beschädigen.

Do not damage throttle diameter.

37 Gewinde vor Montage des neuen O-Ringes abkleben.

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

35 Regelventil ausbauen.

Remove control valve.

34

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Steuergerät demontieren

Removing of the control module

40 Ansteuergerät abdrücken.

Pry-off the control module.

41 KontrolleDichtfläche (1), Flachdichtung (2), O-Ringe (3).

CheckSealing surface (1), gasket (2), o-rings (3).

39 Befestigungsschrauben demontieren.

Remove fixing screws.

38

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Ansteuergeräte

Control modules

44 Hydraulische Nullage (1) neu einstellen. BeideManometer müssen gleichen Druckwert anzeigen.

Reset hydraulic zero position (1).Both gauges must indicate the same pressure.

Ansteuergerät HW

HW control module

42

Ansteuergerät HD - EP

HD - EP control module

43

HD

HD

EP

EP

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Pumpe demontieren

Pump disassembly

46 Lage der Hilfspumpe und Anschlußplatte markieren.Hilfspumpe abbauen.

Mark position of the boost pump and the port plate.Remove the boost pump.

45

47 Lage der Verdrillschraube markieren (1).Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).Set the indexing screw to disassembly position (2).

48 Anschlußplattenbefestigung lösen. Anschlußplatte abheben.Achtung! Dichtfläche.

Release port plate fitting.Take off port plate. If necessary, use screwdriver.Attention! Sealing surface.

Verschlußschraube / Stift

Locking screw / pin

VerdrillschraubeTiming adjustment screw

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Pumpe demontieren

Pump disassembly

49 Steuerplatte abdrücken.Lage notieren.

Lift off control plate.

Note position.

51 Zylinder nach unten drücken (1).Verdrillschraube herausdrehen (2).Triebwerk ausheben (3).

Press the cylinder to the bottom (1).Remove fiming indexing screw (2).Lift out rotary group (3).

50 Kontrolle!O-Ring mit Nut (1), Gehäuse (2), Quad-Ring undQuad-Ring Nut (3).

Check!

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

"Ausbauen"1. Zylinder2. Schwenkwiege3. Gelenkstift

"Remove"1. Cylinder

2. Swash plate3. Joint pin

52

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Triebwerk ausbauen

Removal of the rotary group

56

53 Seegerring, WDR ausbauen.

Remove retaining ring, radial seal ring.

54 Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slight hammer strokes.

55 Lagerschalen ausbauen.

Remove bearing cups.

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60 Vorrichtung aufsetzen und Feder vorspannen.Aufnahmering ausbauen.

Mount fixture and tension spring.Remove receiving ring.

Stellkolben demontieren

Disassembly of the positioning piston

57

61 Ringe ausbauen.Sicherungsring ausbauen.Achtung! Teile stehen unter Federvorspannung.

Take out rings.Remove retaining ring.Note! Parts are spring loaded.

59 Stellkolben (1) ziehen.

Pull out control piston (1).

58 Steuergerät abbauen.

Remove control module.

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Überprüfungshinweise

Inspection notes

62 Alle Lager erneuern.

Replace all bearings.

64 Stellkolbenlaufbüchse (1) riefenfrei, nicht ausgelaufen.

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

63 Kontrolle!1. Verzahnung, ausgeschlagen, Passungsrost.2. Lauffläche.3. Einlaufrillen vom Wellendichtring.

Check!1. Splines for damage or fretting.2. Running surfaces.3. Groove cut by shaft seal.

65 Kontrolle!Stellkolben (1) riefenfrei.

Check!Control piston (1) is not scored.

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Kontrolle der Triebwerksteile

Inspection of rotary group parts

66 Kontrolle!Gleitfläche riefenfrei.

Check!

Sliding surface free of grooves.

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

Check!Check that return device is free of grooves (1) no wearin slipper pad area.

67 Kontrolle!Verbindung Gleitstein/Schwenkzapfen spielfrei.

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

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

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

70 Kontrolle!Zylinderbohrungen (1), Verzahnungen (2).

Check!Cylinder bores (1), splines (2).

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Kontrolle der Triebwerksteile

Inspection of rotary group parts

71 Kontrolle!Zylindergleitfläche (1) riefenfrei, nicht eingelaufen, keineEinlagerungen, Steuerplatte (2) nicht riefig (nur satzweiseaustauschen).

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

73 Hinweis:Bohrung bei DA-Regelung offen. OhneDA-Regelventil geschlossen.

Information:Boring for DA-control open.Without DA-control closed.

72 Kontrolle!DU-Lagerbuchse (1) nicht ausgelaufen.

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

74 Kontrolle!Lagerbahnen (1)

Check!Bearing surfaces (1)

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Stellkolben, Triebwerk einbauen

Positioning piston, rotary group assembly

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

82

Pos. / Item 1: Stangenführungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

2

3

3

2

1

1

Montage / Assembly A4VG

Pos. / Item 1

Pos. / Item 2 / 3

Pos. / Item 2 / 3

Pos. / Item 1

Hilfswerkzeuge / Auxiliary tools:

Montagezange / Assembly pliers: B+S x M22 Führungsdorn / Guide thorn: A4VG28 I: 277 4 347A4VG40 I: 277 4 049A4VG56 I: 277 4 050A4VG71 I: 277 4 051A4VG90 I: 277 4 052A4VG125 I: 277 4 053A4VG180 I: 277 4 054A4VG250 I: 277 4 072

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Dichtring (Pos. 2) in die Montagezange einlegen.

Fit the seal ring (Item 2) into the assembly tool.

Führungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

Führungsdorn leicht einfetten.Stellkolben mit Führungsdorn einbauen.

Grease slightly guide thorn.Install positioning piston with guide thorn.

Dichtring ins Gehäuse einführen und in der Aufnahmenutplazieren. Dann Spannung lösen und Montagezange herausziehen. Lage des Dichtringes prüfen - eventuell mit dem

Finger egalisieren.Position the seal ring into the housing and place it into thegroove. Release the tension and withdraw the assembly tool.Check the position of the seal ring if necessary straightenusing a finger.

Dichtring mit Zangenschenkel nierenförmig zusammen-drücken. Die Verformung von Turcon-Dichtungen istsorgfältig vorzunehmen, damit die Dichtkanten nichtbeschädigt werden.

Press the seal ring into the kidney shape using the assemblytool. The deformation of the Turcon seal has to be done withcare so as not to damage the sealing edges.

Stellkolben, Triebwerk einbauen

Positioning piston, rotary group assembly

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

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Triebwerk einbauen

Installation of the rotary group

75 Stellkolben ins Gehäuse einsetzen.Hinweis:Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.Instruction:Oil positioning piston before assembly.

Lager, Draht, Gleitstein und Gelenkstiftmontieren.Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble bearing, wire, gliding stoneand articulating pin.Assistance: Devices e.g. - Clamp / rubber rings / grease

77

76 Lagerschalenpaar einsetzen.

Insert bearing cup set.

78 Schwenkwiege komplett ins Gehäuse einsetzen.Auf korrekten Sitz der Schwenklager im Gehäuse "achten".

Montagehilfe ausbauen.

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

the housing.

Remove auxiliary device.

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Triebwerk einbauen


80 Gelenkstift montieren.

Fit joint pin.

Kontrolle: Sitz der Schwenklager in derLagerbahn.

Schwenkwiege mit Stellkolben verschwenken "Leicht-gängig".Mittig stellen mit Meßvorrichtung (Uhr oder Tiefenmaß)Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearingin the bearing.

Swivel the swivel bearing by using the control piston"it should move easily".Centralise by using a measuring device (dial gaugeor depth measurement).Check points 1 and 2 - they should have the samedimension.

79

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Triebwerk einbauen


82 Neue Montageposition!Triebwelle mit Lager und Wellendichtring einbauen.

Assemble drive shaft with bearings and radial seal rings.

82

84 Scheibe 1, 2

Disc 1, 2

21

85 Kolben mit Rückzugeinrichtung montieren.Hinweis:Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.Note:Oil piston and piston pad.

83

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86 Vorrichtung ausbauen.Zylinder mit Kolben und Rückzugeinrichtung einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

87 Montagehilfe:Mit O-Ring Kolben festhalten.

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

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89 Steuerplatte Rechtslauf - in Drehrichtung verdreht.Achtung!Geräuschkerben sind drehrichtungsbezogen eingeschliffen.

Control plate clockwise rotation - indexed in the directionof rotation.Note!Noise grooves are machined - in based on directionof rotation.

91 Zylinderflächen und DU-Lager einölen, neue O-Ringemit Fett einreiben und einsetzen.

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

90 Steuerplatte Linkslauf - in Drehrichtung verdreht.Achtung!Geräuschkerben sind drehrichtungsbezogen eingeschliffen.

Control plate counter clockwise rotation - indexed

in the direction of rotation.Note!Noise grooves are machined - in based on directionof rotation.

92 Grundeinstellung - VerdrillschraubeA4VG...40 * = 24 ± 0,75 mm.A4VG...56 * = 21 ± 0,75 mm.

Basic setting - indexing screwA4VG...40 * = 24 ± 0,75 mm.A4VG...56 * = 21 ± 0,75 mm.

93 Zylinder nach unten drücken (1).Verdrillschraube einbauen (2).Kerbe in Montageposition.

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

Triebwerk einbauen


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Pumpe montieren

Assembly of the pump

94 Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

96 Lagerichtig aufsetzen.Hinweis:HW, HD, EP - Steuerplatte mit Fett aufAnschlußplatte.

Place in correct position.Note:HW, HD, EP - Put control plate with greasto the port block.

95 Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise rotation.

97 Schrauben über Kreuz anziehen.Verdrillschraube auf Markierung drehen.

Tighten screws (Cross-corner).Turn the indexing screw to marking.

98 Hilfspumpe montieren.

Assemble boost pump.

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Pumpe montieren

Assembly of the pump

99 Ansteuergerät montieren.

Mount control module.

100

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Anziehdrehmomente

Tightening torques

Anziehdrehmomente für Schaftschrauben(Metrisches ISO-Regelgewinde)

Die nebenstehenden Werte für An-ziehdrehmomente gelten nur für

Schaftschrauben mit metrischem ISO-

Regelgewinde und Kopfauflagemaßennach DIN 912, DIN 931 und DIN 933.

Außerdem gelten diese Werte nur für

leicht oder nicht geölte, unbehandelte

Oberflächen, sowie nur bei Verwen-

dung von Drehmoment- und Kraftbe-

grenzungsschlüsseln.

Festigkeitsklassen

Gewinde 8.8 10.9 12.9

größe Anziehdrehmoment(Nm)

M 3 1,3 2,0 2,3

M 4 3,1 4,5 5,3

M 5 6,1 8,9 10,4

M 6 10,4 15,5 18.0

M 8 25 37 43

M10 51 75 87

M12 87 130 150

M14 140 205 240

M16 215 310 370

M18 300 430 510

M 20 430 620 720

M 22 580 830 970

M 24 740 1060 1240

M 27 1100 1550 1850

M 30 1500 2100 2500

Anziehdrehmomente für Verschlußschrauben VSTI(Metrisches Feingewinde)

Gewindegröße Bezeichnung Anziehdrehmoment(Nm)

M 8 x 1 VSTI 8 x 1 -ED/SA = 5

M 10 x 1 VSTI 10 x1 -ED = 10

M 12 x 1,5 VSTI 12 x 1,5 -ED = 20

M 14 x 1,5 VSTI 14 x 1,5 -ED = 30

M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 30

M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 40

M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 50

M 22 x 1,5 VSTI 22 x 1,5 -ED = 60

M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 70

M 27 x 2 VSTI 27 x 2 -ED = 90M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 100

M 33 x 2 VSTI 33 x 2 -ED/SA = 120

M 42 x 2 VSTI 42 x 2 -ED/SA = 200

M 48 x 2 VSTI 48 x 2 -ED = 300

Die nebenstehenden Werte für An-

ziehdrehmomente gelten nur für Seal-

Lock Bundmuttern der Festigkeits-

klasse 8.8 mit metrischem ISO-Regel-

gewinde.

Festigkeitsklassen

Gewinde 8.8 10.9 12.9

größe Anziehdrehmoment (Nm)

M 6 10

M 8 22

M 10 40M 12 69

M 14 110

M 16 170

Anziehdrehmomente für Seal-Lock Bundmuttern(Metrisches ISO-Regelgewinde)

Festigkeitsklassen

Gewinde 8.8 10.9 12.9

größe Anziehdrehmoment(Nm)

M 3 1,1

M 4 2,9

M 5 6

M 6 10

M 8 25

M10 49

Die nebenstehenden Werte für An-

ziehdrehmomente gelten nur für Lin-

senschrauben mit Kreuzschlitz DIN

7985 der Festigkeitsklasse 8.8 mit

metrischem ISO-Regelgewinde

Anziehdrehmomente für Linsenschrauben mit Kreuz-schlitz DIN 7985

(Metrisches ISO-Regelgewinde)

Strength Classes

Thread 8.8 10.9 12.9

size Tightening T orque(lb.ft)

M 3 1,3 2,0 2,3

M 4 3,1 4,5 5,3

M 5 6,1 8,9 10,4

M 6 10,4 15,5 18.0

M 8 25 37 43

M10 51 75 87

M12 87 130 150

M14 140 205 240

M16 215 310 370

M18 300 430 510

M 20 430 620 720

M 22 580 830 970

M 24 740 1060 1240

M 27 1100 1550 1850

M 30 1500 2100 2500

Tightening torques for shaft bolts(Metric ISO Standard Thread)

The values for tightening torques

shown in the table are valid only for

shaft bolts with metric ISO- standard

threads and head support surfacedimensions in accordance with DIN 912,

DIN 931 and DIN 933. These values are

also valid only for light or unoiled,

untreated surface as well as for use only

with torque-indicating

wrenches and force limiting tools.

Tightening torques for locking screws VSTI(Metric ISO fine thread)

Thread size Designation Tightening torques (lb.ft)

M 8 x 1 VSTI 8 x 1 -ED/SA = 4

M 10 x 1 VSTI 10 x1 -ED = 7

M 12 x 1,5 VSTI 12 x 1,5 -ED = 15

M 14 x 1,5 VSTI 14 x 1,5 -ED = 22

M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 22

M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 29

M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 37

M 22 x 1,5 VSTI 22 x 1,5 -ED = 44

M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 51

M 27 x 2 VSTI 27 x 2 -ED = 66M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 74

M 33 x 2 VSTI 33 x 2 -ED/SA = 88

M 42 x 2 VSTI 42 x 2 -ED/SA = 147

M 48 x 2 VSTI 48 x 2 -ED = 220

The values for tightening torques shown

in the table are valid only for seal-lock

nuts of the strength class 8.8 and with

metric ISO-standard thread.

Strength classes

Thread 8.8 10.9 12.9

size Tightening torque (lb.ft)

M 6 7,4

M 8 16,2

M 10 29,5M 12 50,9

M 14 81,1

M 16 125,3

Tightening torques for seal-lock nuts(Metric ISO-Standard Thread)

Strength classes

Thread 8.8 10.9 12.9

size Tightening torques (lb.ft)

M 3 0,8

M 4 2,1

M 5 4,4

M 6 7,4

M 8 18,4

M10 36,1

The values for tightening torques shown

in the table are valid only for cross-

slotted lens head screws DIN 7985 of the

strength class 8.8 and with metric ISO-

standard thread.

Tightening torques for cross-slotted lens head screwsDIN 7985

(Metric ISO- Standard Thread)

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General advice

· Make yourself familiar with the equipment of the

machine.· Only operate the machine if your are completely

familiar with the operating and control elements as

well as the functioning of the machine.

· Use your safety equipment like helmet, safety shoes

and hearing protection.

· Make yourself familiar with your working field.

· Only operate the machine for its intended purpose.

Please observe the guidelines of the Professional

Association and the machine manufacturer.

Before starting

· Observe the operating instructions before starting.

· Check the machine for obvious faults.

· Do not operate the machine with defective

instruments, warning lights or control elements.

· All safety devices must be in a secure position.

· Do not carry with you movable objects or securethem to the machine.

· Keep oily and inflammable material away from the

machine.

· Before entering thc driver’s cabin, check if persons

or obstacles are beside or beneath the machine.

· Be careful when entering the driver’s cabin, use

stairs and handles.

· Adjust your seat before starting.

Sicherheitsbestimmungen

Safety regulations

Allgemein

· Machen Sie sich mit der Ausstattung der Maschine

vertraut.· Fahren Sie die Maschine nur, wenn Sie sich völlig

mit den Bedien- und Steuerelementen sowie der

Arbeitsweise der Maschine vertraut gemacht haben.

· Benutzen Sie Ihre Schutzausrüstung wie

Schutzhelm, Sicherheitsschuhe und Gehörschutz.

· Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.

· Benutzen Sie die Maschine nur für den ihr zuge-

dachten Zweck.

Beachten Sie bitte die Richtlinien der Berufsge-

nossenschaft und des Maschinenherstellers

Vor dem Start

· Beachten Sie die Bedienungshinweise vor dem

Starten.

· Prüfen Sie die Maschine auf auffällige Fehler.

· Fahren Sie die Maschine nicht mit defekten

Instrumenten, Kontrolleuchten oder Steuerorganen.

· Alle Schutzvorrichtungen müssen fest auf ihremPlatz sein.

· Nehmen Sie keine losen Gegenstände mit bzw.

befestigen Sie diese an der Maschine.

· Halten Sie die Maschine von öligem und zünd-

fähigem Material frei.

· Prüfen Sie vor dem Besteigen der Maschine, ob

sich Personen oder Hindernisse neben oder unter

der Maschine befinden.

· Vorsicht beim Besteigen der Maschine, benützen

Sie Treppen und Griffe.

· Stellen Sie vor dem Start Ihren Sitz ein.

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Start

· When starting all operating levers must be in

“neutral position”.

· Only start the machine from the driver’s seat

· Check the indicating instruments after start toassure that all functions are in order.

· Do not leave the machine unobserved when the

motor is running.

· When starting with battery connection cables

connect plus with plus and minus with minus.

Always connect negative (-) cable last and

disconnect negative cable first.

Attention

· Exhaust gas is dangerous. Assure sufficient freshair when starting in closed rooms!

Hydraulic equipment

1. Hydraulic equipment is standing under high

pressure.

High pressure fluids (fuel, hydraulic oil) which

escape under high pressure can penetrate the

skin and cause heavy injuries.

Therefore immediately consult a doctor asotherwise heavy infections can be caused.

2. When searching leakages use appropriate auxiliary

devices because of the danger of accidents.

3. Before working at the hydraulic equipment, lower

pressure to zero and lower working arms of the

rnachine.

4. When working at the hydraulic equipment, absolutely

stop motor and secure machine against rolling away

(parking brake, shim)!

5. When connecting hydraulic cylinders and motor pay

attention to correct connection of hydraulic flexiblehoses.

6. In case of exchanging the ports, the tunctions are

vice versa (f. ex. lift-up/lower) - danger of accidents!

7. Check hydraulic flexible hoses regularly and replace

them in case of dammage or wear! The new hose

pipes must comply with the technical requirements

of the machine manufacturer!

Orderly disposal or recycling of oil, fuel and

filters!

Sicherheitsbestimmungen

Safety regulations

Starten

· Beim Starten müssen alle Bedienhebel in “Neutral-

stellung” stehen.

· Die Maschine nur vom Fahrersitz aus Starten.

· Prüfen Sie die Anzeigeinstrumente nach dem Start,um sicher zu gehen, daß alles ordnungsgemäß

funktioniert.

· Lassen Sie die Maschine nicht unbewacht, während

der Motor läuft.

· Beim Start mit Batterieverbindungskabeln verbinden

Sie Plus mit Plus und Minus mit Minus. Massekabel

(Minus) immer zuletzt anschliesen und zuerst ab-

trennen.

Vorsicht

· Auspuffgase sind lebensgefährlich. Bei Start ingeschlossenen Räumen für ausreichende Luftzufuhr

sorgen!

Hydraulikanlage

1. Hydraulikanlage steht unter hohem Druck!

Unter hohem Druck austretende Hochdruck-

Flüssigkeiten (Kraftstoff, Hydrauliköl) können

die Haut durchdringen und schwere Ver-

letzungen verursachen. Daher sofort einen

Arzt aufsuchen, da anderenfalls schwereInfektionen entstehen können!

2. Bei der Suche nach Leckstellen wegen Ver

letzungsgefahr geeignete Hilfsmittel verwenden!

3. Vor Arbeiten an der Hydraulikanlage diese un-

bedingt drucklos machen und angebaute Geräte

absenken!

4. Bei Arbeiten an der Hydraulikanlage unbedingt

Motor abstellen und Maschine gegen Wegrollen

sichern (Feststellbremse, Unterlegkeil)!

5. Beim Anschließen von Hydraulikzylindern und

-motoren ist auf vorgeschriebenen Anschluß derHydraulikschläuche zu achten!

6. Bei Vertauschen der Anschlüsse umgekehrte

Funktionen (z.B. Heben/Senken) - Unfallgefahr!

7. Hydraulikschlauchleitungen regelmäßig kontrol-

lieren und bei Beschädigung und Alterung aus-

tauschen! Die Austauschschlauchleitungen müs-

sen den technischen Anforderungen des Geräte-

herstellers entsprechen!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

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Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

Achtung!Sicherheitsbestimmungen beachten!Mit Schlauch NW6 beide Stellkammern

verbinden. Vermeidung von Restsignalaus hydraulischer Nullage.Manometer an M

A und M

B anschließen.

Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Totband der Nullage - vermitteln.

Attention!Observe safety regulations!Connect both control chambers with hoseNW6. Avoidance of rest signal from hydraulic

zero position.Connect manometer to M

A and M

B. Adjust

zero position so that at blocked drive bothmanometer indicate the same pressure valve.Note:Adjust death line of zero position.

102

HW HD EP DA

101

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Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung!Sicherheitsbestimmungen beachten!

Hinweis:Nachjustierung nur bei Betriebstemperatur.

Manometer an "G" anschließen.

Achtung!* Speisedruckeinstellung!Nenndruck p

H - 18 bar

Höchstdruck pH - 40 bar

Bei Max.-Drehzahl.

Hinweis:Einstelldaten nach Werksauftrag.

* bei DA-Ausführung

Attention!Observe safety regulations!

Note:

Readjusting only at operating temperature.

Connect manometer to "G".

Attention!* Boost pressure setting!Nominal pressure p

H - 18 bar

Peak pressure pH - 40 bar

at max. speed.

Note:Adjusting data according to order.

105

"G"*

*

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Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off


HD-Ventil ohne Bypass

1 . HD- Ventile sind immer 10% höher eingestellt als dieDruckabschneidung.Bei Veränderung eines Einsteilwertes immer beidekontrollieren.2. Nachjustierung nur bei Betriebstemperatur

Manometer an MA und M

B anschließen.

Druckabschneidung: Maß X Einstellschrauben notieren!Einstellschraube auf Block drehen.

HD- Ventile: Mit geringer Pumpenmenge über Ventilefahren. Einstellwert kontrollieren.(Nur kurzzeitig "Temperatur“.)Drucklos "Einstellwert“ verändern - Kontrolle

Druckabschneidung:Einstellschraube auf Maß (*) zurückdrehen.Druckwert kontrollieren bzw. nachjustieren.Achtung! Differenz von 10% HD- Ventile undDruckabschneidung beachten!Hinweis: Einstelldaten nach Werksauftrag.

DruckabschneidungPressure cut-off

HD- VentileHP- valves

107

106

Attention!Observe safety regulations.

HP valve without bypass-function

1 . HP valves are always adjusted 10% higher than thepressure cut-off.If one setting value is changed, always check bothvalues.2. Readjusting only at operating temperature.

Connect manometer MA and M

B.

Pressure cut-off: Note measure X setting screw! Turnsetting screw on block.HP valves: Operate valves with small pump flowvolume.Check setting value. ("temperature“ only for a shorttime).Change "setting value“ - check.

Pressure cut-off:Turn back setting screw to measure (*).Check pressure value and readjust.Attention! Observe 10% pressure difference HP valves

and pressure cut-off!

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Einstellhinweise - Bypassventil

Adjustment instructions - Bypass valve

Vehicle with hydrostatic transmission and gear shiftwithout idling setting position (free wheeling).

Hydrostatic transmission / Bypass-switching

In this case the travel transmission is switched on tofree wheeling.For this purpose the variable displace-ment pump has incorporated high pressure relief valves

with bypass function.The screw (item 1) is unscrewed to such an extent, thatthe valve cartridge is released and free oil circulation ispossible.

Bypass: Screw in item1 up to planeness with nut. Screw up nut again.

Towing speedThe max. towing speed of 2 km/h should not beexceeded.

- Higher admissible towing speeds depend on theavaiable hydr. motor speed and engagedgear shift.

Towing distanceThe towing distance should not exceed 1 km.

- If there is a lack of oil boosting, the hydrauliccircuit will get empty.Take care of the heat development in the hydr.motor-rotary group.

Towing operation terminatedAfter termination of the towing operation turn item 1back. The original pressure value setting of the highpressure relief valves will be avaiable again.

Valve function: Screw back item 1 up to stop.

Screw up the nut.

Fahrzeuge mit rein-hydrostatischem Fahrantriebbzw. mit hydrostatischem Fahrantrieb und Schalt-getriebe ohne Leerlaufstellung (Freilauf).

Hydrostatischer Antrieb / Bypaß-Schaltung

In diesem Fall wird der Fahrantrieb auf freienUmlauf geschaltet. Zu diesem Zweck haben diein der Verstellpumpe integrierten Hochdruck-

begrenzungsventile eine sogenannte Bypaß-Funktion.D.h. durch Drehen der entsprechendenSchraube (Pos.1) wird der Ventil-Einsatz so entspannt,daß ein freier Öl-Umlauf möglich ist.

Bypass:Pos.1 einschrauben bis eben mit Mutter.Mutter wieder anziehen.

SchleppgeschwindigkeitDie maximale Schleppgeschwindigkeit sollte2 km/h nicht überschreiten.

- Höhere zulässige Schleppgeschwindigkeitensind abhängig von der Hydromotordrehzahlbzw. dem eingelegten Gang.

AbschleppdistanzDie Schleppentfernung sollte 1 km nicht überschreiten.

- Bei fehlender Einspeisung entleert sich derHydraulik-Kreislauf.Zu beachten ist die Wärmeentwicklung imHydromotor-Triebwerk.

Abschleppvorgang beendetNach beendetem Abschleppvorgang Pos.1 zurück-drehen. Der ursprüngliche Einstellwert der Hochdruck-ventile liegt somit wieder vor.

Ventilfunktion: Pos.1 zurückschrauben bis

Anschlag. Mutter anziehen.

108

1

11

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Check setting data.Operating temperature should be kept largelyconstant during the check procedure.Start prime mover, idle speed.

Block positionDrive direction switch - "0“.Slowly increase motor speed up to the max.motor speed and thereby observe measuringinstruments.

Boost pressure:

Idle speed of prime moverPsp = approx. 15 - 20 barmax. motor speedPsp = . . . . . . . . . bar*

Block positionDrive direction switch - forward(Road gear and fully applied brake)

Check setting data pump A4VIDABegin of control:HD 40 - 50 barMotor speed . . . . . rpm* Psp . . . . . . . bar*

HD . . . . . . . bar*Readjusting - control start screw

End of controlHD . . . . . . . . barMotor speed . . . . . . rpm* Psp . . . . . . . bar*Readjusting timing adjustment screw

Note:Eccentric adjusting - observe direction ofrotation

* Setting data according to order!

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

112

Begin of control

111

Timingadjustment screw

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Telex 765321, Fax (07451) 8221

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7.2 A10VG

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Reparaturanleitung / Repair instructionsA10VG ... 28-63 Baureihe/Series 10

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

Mobile Hydraulics

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RDE 92750-01-R/10.01


HINWEIS

Bezeichnungen, Beschreibungen und Darstellungen

entsprechen dem Informationsstand zum Zeitpunkt derDrucklegung dieser Unterlage.

Änderungen können den Service am Produkt beein-flussen, Verpflichtungen entstehen uns daraus nicht.Methoden und Vorrichtungen sind Empfehlungen, fürderen Resultat wir keine Haftung übernehmen können.BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga-be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu-ren.

Einstell- und Prüfarbeiten sind bei Betriebstemperatur aufdem Teststand vorzunehmen.

Schutz von Personen und Eigentum ist durch Vor-kehrungen sicherzustellen.

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

INHALT Seite/Page

A10VG

Schnittbild 3-4Allgemeine Reparaturhinweise 5Dichtsätze und Baugruppen 6-8Triebwelle abdichten 9Hilfspumpe abdichten 10-12Stellkolbendeckel abdichten 13Ventile abdichten 14Druckabschneidung abdichten 15Regelventil abdichten 16Steuergerät demontieren 17

Ansteuergeräte 18-22Pumpe demontieren 23-25Triebwerk ausbauen 26Stellkolben demontieren 27-28Überprüfungshinweise 29-31Turcon-Glyd-Ring montieren 32Pumpe montieren 33-35Triebwerk einbauen 36-38Pumpe montieren 39Montageanweisung für Anziehdrehmomente 40-43Sicherheitsbestimmungen 44-45Einstellhinweise 46-52

NOTICE

Specifications, descriptions and illustrative material

shown herein were as accurate as known at the time thispublication was approved for printing.

BRUENINGHAUS HYDROMATIK reserves the right todiscontinue models or options at any time or to changespeci-fications, materials, or design without notice andwith-out incurring obligation.

Optional equipment and accessories may add cost to thebasic unit, and some options are available only incombination with certain models or other options.

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

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

Protection of personnel and property has to be guar-anteed by appropriate measures.

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

CONTENTS

A10VG

Sectional viewGeneral repair instructionsSeal kits and sub assembly groupsSealing of the drive shaftSealing of the boost pumpSealing of the control piston coverSealing of the valvesSealing of the pressure cut-off valveSealing of the regulator valveRemoval of the control unit

Control unitsPump disassemblyRemoval of the rotary groupDisassembly of the positioning pistonInspection notesTurcon-Glyd-ringAssembly of the pumpInstallation of the rotary groupAssembly of the pumpAssembly guidelines for tightening torquesSafety regulationsAdjustment instructions

Hinweis / Inhalt

Notice / Contents

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RDE 92750-01-R/10.01


Schnittbild

Sectional view

HW

EPDHDD

mit Druckabschneidungwith pressure cut-off

ohne Druckabschneidungwithout pressure cut-off

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RDE 92750-01-R/10.01


Schnittbild

Sectional view

DA

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RDE 92750-01-R/10.01


Ansteuergerät HW

Control unit HW

Ansteuergerät HD

Control unit HD

Ansteuergerät HWmit Nullagenanzeige

Control unit HWwith zero indicator

AnsteuergerätEP

Control unit EP

Ansteuergerät DA

Control unit DA


Seal kits and sub-assemblies

alt / old

neu / new

alt / old

neu / new

alt / old

neu / new

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RDE 92750-01-R/10.01



Seal kits and sub-assemblies

Hilfspumpe mit Verschleißplatte

Boost pump with wear plates

Druckabschneidung

Pressure cut-off

1. DA - Regelventil, verstellbar mit Hebel2. DA - Regelventil, festeingestellt3. Zuschaltventil

1. DA control valve, adjustable via a lever2. DA control valve, fixed3. Switching valve

1. HD - Ventil2. HD - Ventil mit Bypass3. ND - Ventil

1. High pressure valve2. High pressure valve with bypass function3. Low pressure valve

1 2

32

1

3

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RDE 92750-01-R/10.01


Druckabschneidung abdichten

Sealing of the pressure cut-off valve

Wechsel der Dichtmutter.Einstellmaß festhalten (*).

Exchanging the sealing nut.Ascertsion the adjustment dimension (*).

Achtung!Nach Einbau "Ventileinstellung" überprüfen.

Attention!After assembly check "valve setting".

*

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RDE 92750-01-R/10.01


Ansteuergeräte

Control units

Ansteuergerät HW

HW control unit

NG / Size 28

NG / Size 45

Ansteuergerät DA

DA control unit

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RDE 92750-01-R/10.01


Ansteuergerät HD - EP altHD - EP control unit old

EP alt / old

Ansteuergeräte

Control units

HD alt / old

EP alt / old

HD alt / old

214,4 mm

202,0 mm

131,0 mm

77,4 mm

Neues Ansteuergerät HD - EPNew HD - EP control unit old

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RDE 92750-01-R/10.01


Ansteuergeräte

Control units

Ansteuergerät HD neuHD - control unit new

Ansteuergerät EP neuEP - control unit new

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RDE 92750-01-R/10.01


Pumpe demontieren

Pump disassembly

Druckabschneidung

Pressure cut-off

Excenterschraube

Eccentric screw

EP alt/old

EP neu/new

DA neu/newDA alt/old

HD alt/old

HD neu/new

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RDE 92750-01-R/10.01


Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A10V - Düsen / orifices

Gewinde / Anziehdremomente Nm /

ThreadTightening torques Nm

bisher / up to neu / new

M6 6,5 3

M10 28 12

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RDE 92750-01-R/10.01


Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

Achtung!Sicherheitsbestimmungen beachten!Mit Schlauch NW6 beide Stellkammernverbinden. Vermeidung von Restsignalaus hydraulischer Nullage.Manometer an M

A und M

B anschließen.

Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Totband der Nullage - vermitteln.

Attention!Observe safety regulations!Connect both control chambers with a nominalsize 6 hose. Avoidance of residual signals fromhydraulic zero position.Connect pressure gauges to M

A and M

B. Adjust

the zero position so that with at blocked driveboth pressure gauges indicate the samepressure valve.Note:Ascertain the zero position dead band.

HW

HD

HWmit NullagenschalterHW with zero position switch

EP

DA

neu / new

alt / old

neu / new

alt / old

neu / new

alt / old

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HW

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

Manometer an X1 und X2 anschließen.Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Excenterjustierung- nicht über ±90° verdrehen.

Connect pressure gauges to X1 and X2.Adjust the zero position so that with a blockdrive both pressure gauges indicate thesame pressure value.Note:Eccentric adjusting- Do not turn more than ±90°.

Achtung!Sicherheitsbestimmungenbeachten!


EPneu/new

HW mit NullagenschalterHW with zero positionswitch

EPalt/old

HDneu/new

HDalt/old

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RDE 92750-01-R/10.01


Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)


Note:Readjusting only at operating temperature.

Connect pressure gauge to "G".

Attention!* Boost pressure setting!Nominal pressure pH - 18 barPeak pressure pH - 40 barat max. speed.

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

* with the DA version


Hinweis:Nachjustierung nur bei Betriebstemperatur.

Manometer an "G" anschließen.

Achtung!* Speisedruckeinstellung!Nenndruck pH - 18 barHöchstdruck pH - 40 barBei Max.-Drehzahl.

Hinweis:Einstelldaten nach Werksauftrag.

* bei DA-Ausführung

*

"G"*

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7.3 MS/MSE 02 to 18

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MSHydraulikmotorenHydraulic motors

Reparaturen

Repairs

Ref : 800378128J

REPAR MS2-18 D/GB

Rev : A - Avr - 00

POCLAIN HYDRAULICS Industrie

B.P. 106 60411 VERBERIE CEDEX - FRANCE Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 www.poclain-hydraulics.com

POCLAIN HYDRAULICS

Certifié ISO 9001

02 05 08 11 18MS

MSE

StörungsbeseitigungTrouble Shooting

WartungsarbeitenMaintenance

ReparaturenRepairs

ErsatzteileSpare Parts

5767

0549 5766

0550

0545 5763

5764

5765

0547

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POCLAIN HYDRAULICS

2 REPAR MS2-18 D/GB 800378128J

Dieses Dokument richtet sich an die Hersteller von Maschinen und Sy-stemen, die Produkte von POCLAIN-HYDRAULICS einbauen, derenArtikelnummer auf der Titelseite genannt sind. Es beschreibt die Instal-lationsangaben und den Inbetriebnahmevorgang, damit ihre optimaleFunktionsweise gewährleistet wird.Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer an-gemessene Ausbildung durchgeführt werden. Sie müssen die Informa-tionen in diesem Dokument gelesen und verstanden haben und vom

Hersteller der Maschine bevollmächtigt sein.Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheitund zur Unfallverhütung beachten.

Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werdenauf folgende Weise gekennzeichnet:

! Sicherheitshinweis.

Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Be-trieb des Produkts sowie allgemeine Informationen. Sie werden auf fol-gende Weise gekennzeichnet:

Wesentliche Anweisung.

Allgemeine Information.

POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer-den, die auf die Anwendung der in diesem Dokument empfohlenen Ver-fahren zurückgehen.POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktionund die Betriebsbedingungen der Maschinen und Systeme, die mit PH-Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we-der für die Folgen eines falschen Einbaus der Produkte noch für ein fal-sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll-ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau-chern von den Maschinenherstellern zur Verfügung gestellt worden sind,verantwortlich.Jegliche Änderung einstellbarer Parameter der PH Produkte kann eineNeuzulassung der Maschinen erforderlich machen.Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- DRAULICS prüfen und freigeben zu lassen.Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nurOriginal-Ersatzteile von POCLAIN HYDRAULICS . Die Montage vonTeilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy-stems sowie die Sicherheit beeinträchtigen.

Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sichPOCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigungalle Änderungen vorzunehmen, die als nützlich für die in diesem Doku-ment beschriebenen Produkte bewertet werden.Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab-schnitte, die Übersetzung in englischer Sprache darstellen.

Im Zweifelsfall ist die französische Version ausschlaggebend.Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungenin anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter-richtung angegeben.Die Abbildungen haben unverbindlichen Charakter.

POCLAIN HYDRAULICS Industrie 1998.Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von PO- CLAIN HYDRAULICS SA.Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Indu-strie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftli-ches Einverständnis weder gesamt noch teilweise verwendet, vervielfäl-tigt, kopiert oder an Dritte weitergegeben werden.FACOM ist ein eingetragenes Warenzeichen der FACOM SA.LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA.AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.

This document is provided to machine manufacturers integrating PO- CLAIN-HYDRAULICS products.. It suggests processes that manufacturers may utilize to repair products after the warranty period.

It is recommended that all operations be performed by technicians trained accordingly. The technicians should read and understand the information given in this document and be authorized by the machine manufacturer.It is essential that the technicians comply with safety instructions to prevent injury.

This document includes major safety warnings announced in this way:

! Safety warning.

Additionally, this document includes instructions essential to product function as well as those providing general information. Both are announced similar to the following examples:

Essential instruction.

General information.

POCLAIN HYDRAULICS designs products that are integrated by its customers in the machines they design.

Subsequently POCLAIN HYDRAULICS disclaims liability for conse- quences of improper integration of its products and of improper set-up of adjustable devices. In the same way, POCLAIN HYDRAULICS may not be liable for incomplete or improper operating and maintenance instructions provided to the end user by the machine manufacturer nor for failures resulting from operations performed by any person using these suggested procedures.

A re-certification of the machine may be required for every change in set-up of adjustable devices.

In order to offer the best quality service, POCLAIN HYDRAULICS rec- ommends to its customers to have applications approved by POCLAIN HYDRAULICS.Opening of products voids the warranty contract.Use only POCLAIN HYDRAULICS genuine spare parts. Using parts from different sources could reduce the performance of the product and pose a safety hazard..

In accordance with its policy of continuous improvement, POCLAIN HYDRAULICS reserves the right to modify the specifications of all products described herein without prior notice.

This document contains sections written in German and sections printed in italics composing the English translation of the French sec-

tions. The French sections will be the reference in case of dispute.All measures are expressed in metric units. Converted values to other systems (notably US and UK) are given for reference only.

The illustrations for information only.

© POCLAIN HYDRAULICS Industrie 1998.The trademark POCLAIN HYDRAULICS is the property of POCLAIN HYDRAULICS S.A.This document is the property of POCLAIN HYDRAULICS Industrie.It is strictly confidential. It must not be used, duplicated, copied or dis- closed to a third party in full or in part without our prior written consent.FACOM is FACOM SA registered trademark.LOCTITE is LOCTITE SA registered trademark.AUTO-TOP is AGIP SPA registered trademark.

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 3

Inhaltsverzeichnis

INHALTSVERZEICHNIS ............................................. 3

SICHERHEIT UND QUALITÄT ................................... 4

VOR DEN WARTUNGSARBEITEN ....................................... 4WÄHREND DER WARTUNGSARBEITEN............................... 4NACH DEN WARTUNGSARBEITEN ..................................... 4IDENTIFIZIERUNG DES BAUTEILS....................................... 5

STÖRUNGSBESEITIGUNG........................................ 6

WARTUNGSARBEITEN.............................................. 8

AUSTAUSCHEN DES MOTORS........................................... 8Ausbau..................................................................... 8Einbau...................................................................... 8

MECHANISCHE BREMSLÖSUNG ........................................ 9KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10

REPARATUREN. ...................................................... 11

AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11Demontage ............................................................ 11Wiedereinbau......................................................... 13

AUSWECHSELN DES LAGERTEILES (070)......................... 16Demontage ............................................................ 16Wiedereinbau......................................................... 18

AUSWECHSELN DER BREMSBACKEN ............................... 20Demontage ............................................................ 20Wiedereinbau......................................................... 23

AUSWECHSELN DES NOCKENRINGS (026)....................... 27Demontage ............................................................ 27

Wiedereinbau......................................................... 27AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010)28Demontage ............................................................ 28Wiedereinbau......................................................... 28

AUSWECHSELN DES VERTEILERS (047). ......................... 29Demontage ............................................................ 29Wiedereinbau......................................................... 29

AUSWECHSELN DER DECKELDICHTUNG (045).................. 32Demontage ............................................................ 32Wiedereinbau......................................................... 33

AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34Demontage ............................................................ 34Wiedereinbau......................................................... 35

WERKZEUG-LISTE .................................................. 36Standard Werkzeug................................................ 36Spezialwerkzeuge .................................................. 37

ANZIEHDREHMOMENTE NM ± 10%........................... 38

ERSATZTEILE.......................................................... 39

MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 02-05-08-11-18. .............................................................. 42MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE02-05-08-11-18. ......................................................... 44

Contents

CONTENTS................................................................. 3

SAFETY AND QUALITY ............................................. 4

B EFORE SERVICING ........................................................ 4 D URING SERVICING ......................................................... 4 AFTER SERVICING ........................................................... 4 I DENTIFICATION OF THE COMPONENT ................................. 5

TROUBLE SHOOTING ............................................... 7

MAINTENANCE.......................................................... 8

R EPLACING THE MOTOR .................................................. 8 Removal................................................................... 8 Installation................................................................ 8

M ECHANICAL BRAKE RELEASE .......................................... 9 C HECKING THE PARKING BRAKE EFFICIENCY ..................... 10

REPAIRS. ................................................................. 11

R EPLACEMENT OF THE O- RING OF THE BRAKE PISTON ....... 11Disassembly........................................................... 11Reassembly. .......................................................... 13

R EPLACEMENT OF THE BEARING SUPPORT (070).............. 16 Disassembly........................................................... 16 Reassembly ........................................................... 18

R EPLACING THE BRAKE SHOES ....................................... 20 Disassembly........................................................... 20 Reassembly ........................................................... 23

R EPLACEMENT OF THE CAM (026) .................................. 27 Disassembly........................................................... 27

Reassembly ........................................................... 27 R EPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28

Disassembly........................................................... 28 Reassembly ........................................................... 28

R EPLACEMENT OF THE VALVING (047). ........................... 29 Disassembly........................................................... 29 Reassembly ........................................................... 29

R EPLACEMENT OF THE O- RING (045) OF THE END COVER . 32 Disassembly........................................................... 32 Reassembly ........................................................... 33

R EPLACING THE SENSOR ( OPTIONAL ) .............................. 34 Disassembly........................................................... 34 Reassembly ........................................................... 35

TOOLING INVENTORY............................................. 36

Standard tools ........................................................ 36 Special tools........................................................... 37

TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38

SPARE PARTS LIST ................................................ 39

S INGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-11- 18. ............................................................................. 42 D UAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44

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POCLAIN HYDRAULICS

4 REPAR MS2-18 D/GB 800378128J

Sicherheit und QualitätVor den Wartungsarbeiten• Alle notwendigen Sicherheitsvorkehrungen treffen

(Menschen und Material) und die geltenden Sicher-heitsvorschriften beachten.

• Parkbremse betätigen und Maschine mit Keilenfestsetzen.

• Energieerzeugung (Motor) des Hydrauliksystemsabstellen und die Stromversorgung ausschalten.

• Gegebenenfalls eine Sicherheitszone einrichten.

• Die Außenflächen der Bauteile reinigen, umSchmutz und Fett restlos zu entfernen.

• Warten, bis das Hydrauliksystem vollständig abge-kühlt und druckentlastet ist (die Speicher entlasten).

!Das heiße oder unter Druck stehende Ölkann zu schweren Verbrennungen mitEntzündung führen.Bei einem Unfall einen Arzt hinzuziehen.

Während der Wartungsarbeiten• Bestimmte Bauteile sind sehr schwer. Sie müssenbei der Abnahme vom Rahmen mit einer angemessenausgelegten Hebevorrichtung gehalten werden.

• Die Sauberkeit ist wesentlich beim Betrieb der Hy-draulikbauteile. Die meisten Teile können mit einemsauberen Lösungsmittel gereinigt werden.

• Während der Handhabung alle empfindlichen Ober-

flächen gegen Stöße schützen (Zentrierungen, gleitendeTeile, Auflagen, Dichtungs- und Lagerauflagen usw.).

• Diese Flächen vor dem Wiederzusammenbau reinigen.

• Systematisch die demontierten Dichtungen beimWiederzusammenbau durch neue ersetzen. Wir emp-fehlen, vor der Montage alle Dichtungen zu fetten.

• Alle gleitenden Flächen durch Aufbringen eines Filmssauberer Hydraulikflüssigkeit ölen, der eine korrekteSchmierung beim ersten Neustart gewährleistet.

• Niemals die Hydraulikflüssigkeit, die sich bei hohenTemperaturen entzünden kann, erwärmen. Einige Lö-sungsmittel sind ebenfalls entzündlich.

Während der Arbeiten nicht rauchen.

Nach den WartungsarbeitenDie Bauteile wieder einbauen und das Hydrauliksystemgemäß den Anweisungen in den folgenden Dokumen-ten wieder in Betrieb nehmen:• INSTALLATION MS D/GB (ref: 800078173V)

• INSTALLATION CIRCUITS D/GB (ref. 677777853U)

!Die Einstellung der Sicherheitsventilenicht erhöhen.

Safety and Quality

Before servicing

• Be extremely careful to prevent personal injury and to avoid damage to material. Comply with all safety regulations.

• Apply the parking brake and prevent the machine from rolling with tire blocks.

• Stop the hydraulic system power source (engine)and disconnect the battery.

• If necessary, block off the safety area.

• Wash dirt and grease from exterior of the components.

• Await the complete cooling down and depressuriza- tion of the hydraulic system (accumulators must be purged).

!

Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body.Consult a physician in case of accident.

During servicing

• Some hydraulic components are very heavy. Se- cure them with a lifting device of adequate capacity when removing from the machine frame.

• Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned with a clean solvent.

•

During handling, protect all sensitive surfaces from

shocks (piloting and interface surfaces, thrust & bearings surfaces, seal races, etc...)

• Clean up these surfaces before reassembling.

• Always install new O-rings, seals & gaskets dis- carding the old ones. We recommend lubricating all seals prior to assembly.

• Lubricate all surfaces which have relative motion between parts by coating them with a film of clean hydraulic fluid to assure lubrication at first start.

• Never heat hydraulic fluid, as it may flame at high

temperature. Some solvents are also flammable.

Do not smoke during servicing.

After servicing

Reinstall the components and restart the hydraulic system according to instructions defined in the following documents:

• INSTALLATION MS F/GB (ref . 677777844K )

• INSTALLATION CIRCUITS F/GB (ref . 677777831V )

! Do not overset relief valves.

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 5

Identifizierung des Bauteils Identification of the component

A : Handelsbezeichnung:Ex : MSE18-2-D11-F19-2A10-K000

B : Code :Artikelnr.:Ex : 000143896J

C : Serie :HerstellungsnummerEx : 001

D : Num : Chronologische OrdnungsnummerEx : 40712

Bei sämtlichen Ersatzteilbestellungenmüssen die Artikelnummer und die chro-nologische Ordnungsnummer angege-ben werden.

A: Commercial description: E.g : MSE18-2-D11-F19-2A10-K000

B: Code:Part number.E.g : 000143896J

C: Series: Manufacturing batch number.E.g : 001

D: Num: Chronological serial number.E.g : 40712

The part number and the chronological serial number must be specified to order

spare parts.

C

B D

A

0349

MS18-2-D11-F19-2A10-K000

000143896J

001 40712

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POCLAIN HYDRAULICS

6 REPAR MS2-18 D/GB 800378128J

Störungsbeseitigung

BECHÄDIGUNG ABRIEB ERKENNUNG DURCH FILTER VORBEUGUNG……

Störung Ursachen Abhilfe

RegelmäßigesBrummen

Lagerteil verschlissen Lagerteil ersetzenOhneLast

VibrationenLockere Befestigungenund / oder Anschlüsse

Mit entsprechendem Drehmo-ment anziehen

Klappern Speisedruck zu niedrigSpeise- und Austauschdruck-

ventil kontrollieren.

LAUTE GERÄUSCHE DES

MOTORS

UnterLast

Kavitation Interne Lecks zu großZylinderblock und Ölverteiler

ersetzen

Der Motor wird nicht ver-

sorgt

Den Antrieb der Pumpe und ih-

re Versorgung überprüfenKein Druckanstieg im

KreisHochdruck-Begrenzungsventile

kontrollieren (Regler)

Interne Lecks zu großZylinderblock und Ölverteiler

ersetzen

MOTOR DREHT SICHNICHT

Die Bremse bleibt angezo-gen

Den Steuerkreis der Bremsekontrollieren

Der Fördermenge derPumpe ist unzureichend

Die Antriebsdrehzahl und denZustand der Pumpe kontrollie-

ren

Interne Lecks zu groß Den Zustand des Zylinder-blocks und des Ölverteilersüberprüfen

DER MOTOR DREHT

SICH NICHT MITNORMALER LAST-DREHZAHL

Der Betriebsdruck ist zuniedrig

Den Zustand des Sicherheits-ventils kontrollieren (Regler)

Die Fördermenge derPumpe schwankt

Steuerdruck und Fördermengeder Pumpe kontrollierenDER MOTOR DREHT

SICH UNREGEL-MÄSSIG Interne Lecks zu groß

Den Zustand des Zylinder-blocks und des Ölverteilers

überprüfen.

Gehäusedruck zu groß Den Leckagekreis und den Zu-stand des Filters überprüfen

Dichtungen beschädigt Die Dichtungen ersetzenÄUSSERE ÖLUN-DICHTIGKEITEN

Fehlerhafte Montage

Das Anziehmoment der Monta-geschrauben, der Entlüftungs-schrauben und der Anschlüsse

kontrollieren

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 7

Trouble shooting

DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION……

Troubles Causes Remedies

Regular rum- bling

Worm bearing support Replace the bearing support

Without load

Vibrations Mountings and/or hydraulic

piping becoming loose Tighten to torque

Clattering Boost pressure too low Check the setting and condition of counter-pressure valve

NOISY MOTOR

Under load

Cavitation Excessive internal leaks Replace the cylinders- block and distribution valve assem-

bly

No supply to the motor Check pump drive and pump inlet

The circuit does not reach working pressure

Check condition of safety valve (regulator)

Excessive internal leaks Replace the cylinders block

and distribution valve assembly

THE MOTOR DOES NOT REVOLVE

The brake stays engaged Check the brake pilot circuit

Pump flow is too low Check drive speed and condi-

tion of the pump

Excessive internal leaks Check condition of cylinders- block and distribution valve

assembly

THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED

UNDER LOAD

Working pressure is too low

Check safety valve setting pressure (regulator)

Irregular flow Check the pump flow THE MOTOR RE- VOLVES IRREGU-

LARLY Excessive leaks Check condition of cylinders- block and distribution valve

assembly

Too high casing pressure Check the leakage circuit and

filter condition

Seals damaged Replace seals EXTERNAL OILLEAKS

Incorrect assembling Check tightening of mounting

screws, bleed screws and unions

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POCLAIN HYDRAULICS

8 REPAR MS2-18 D/GB 800378128J

Wartungsarbeiten

Austauschen des Motors

Ausbau

• Druck im Arbeitskreis abbauen.• Leckageleitung am Tank abschrauben, um ein

Leerlaufen zu verhindern.• Die Rohre oder Schläuche, die am Motor ange-

schlossen sind, abklemmen.• Drehzahlsensor abklemmen.• Die Befestigungsschrauben demontieren und den

Motor ausbauen.• Das Motorgehäuse entleeren.

Einbau

Die zum Ausbau angegebenen Arbeitsgänge in umge-kehrter Reihenfolge ausführen.

Für weitere Informationen beziehen Sie sich bitte auffolgende Dokumente:• INSTALLATION MS D/GB (ref: 800078173V)• INSTALLATION CIRCUITS D/GB (ref: 677777853U)

Maintenance

Replacing the motor

Removal

• Release the pressure in the supply circuit.

• Disconnect the drain line at the tank level to avoid its siphoning.

• Disconnect and plug the pipes or hoses which are connected to the motor.

• Disconnect the speed sensor.

• Disconnect the mounting screws, and remove the motor.

• Drain the casing.

Installation

Execute the removal operations in the reverse order.

Please refer to the following documentation brochures:

• INSTALLATION MS F/GB (ref : 677777844K )

• INSTALLATION CIRCUITS F/GB (ref: . 677777831V )

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POCLAIN HYDRAULICS

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Mechanische Bremslösung Mechanical brake release

Bei bestimmten Reparaturfällenoder zum Abschleppen der Maschi-ne muß die integrierte Parkbremse

gelöst werden.

In certain service situations, it may be necessary to release the motor brake.

• Stopfen (142) aus der Schutz-kappe (141) herausziehen.

• Extract and release the plug (142) from the brake cover (141).

• Schraube im Kolben festziehen • Tighten the screw in the piston

• Mutter so weit anziehen, bis dieWelle frei dreht.

• And tighten the nut until the motor shaft turns freely.

Bremsen Brakes Kraft N Force [lbf] Entsprechendes

Drehmoment NmEquivalent torque [lbf.ft] Mutter Nut

F02-F04 18000 [4.000] 42 [30.9] M12F05-F07 20000 [4.500] 47 [34.6] M12

F08 34000 [7.600] 110 [81.1] M16

F11 45000 [10.000] 140 [103] M16

F12 45000 [10.000] 140 [103] M16

F19 45000 [10.000] 140 [103] M16

!Nach Bremslösung, einen neuen Stopfen(142) einbauen. !

After brake release, mount a new plug (142) .

6556

142

6499

6555

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POCLAIN HYDRAULICS

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Kontrolle der statische Haltebremse.

!Bei fahrbaren Maschinen den Test auf ebenemGrund durchführen.

Bremssteuerdruck: mini 12 barMaxi 30 bar.

• Sich vergewissern, daß der Bremsversorgungs-druck gleich Null ist,• Die Bremse über die höchstgelegene Schraube(112) entlüften,• Den Motor mit Maximaldruck beaufschlagen,

• Die Motorwelle darf sich nicht drehen, da andern-falls die Bremse ausgetauscht werden muß :

! Mehrscheibenbremsen nicht einfahren.

Checking the parking brake efficiency.

!For a rolling machine, make the test on a hori- zontal ground .

Pilot brake pressure : minimum 12 bar [174 PSI] Maximum 30 bar [435 PSI]

Make sure that the brake supply pressure is zero,

• Purge the brake using the screw (112) located at the highest level,

• Supply the motor up to the setting pressure.

• The motor shaft must not turn, otherwise it is necessary to replace the brake :

! Do not run multidisc brakes in.

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 11

Reparaturen. Repairs.

Auswechseln der Brems-kolbendichtung

Demontage

Replacement of the O-ring of the brake piston.

Disassembly

• Den Motor ausbauen.• Motor auf das Lagerteil stellen.

!Muttern zum Schutz derGewindebolzen wiederaufsetzen

• Remove the motor.

• Place the motor on the bearing support.

!Protect the studs by reinstalling the nuts

• Schutzkappe (141) abnehmenund beseitigen.

• Remove and discard the brake cover.(141)

• O-Ring (143) herausziehen undbeseitigen.

• Extract and discard the O-ring (143).

• Tellerfeder (108) zusammen-drücken:

• Mit Hilfe des Dorns und Ab-ziehers (siehe Werkzeug Seite36) (fig 6502)• Mit Hilfe des Dorns und einer

Schraube Klasse 12.9 (sieheWerkzeug Seite 36)• Mit Hilfe des Dorns und einerPresse (fig 6503). Die Kraft Fbeibehalten (siehe SchaubildSeite 9)

Einsatzrichtung des Si-cherungsrings markieren.

• Compress the washer (108).

• Using a mandrel and an extractor (see tools page 36)(fig 6502)

• Using a mandrel and a

screw class 12.9 (see tools page 36)

• Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

Mark the mounting direction of the snap ring .

6500

6501

6502

6503

141

143

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POCLAIN HYDRAULICS

12 REPAR MS2-18 D/GB 800378128J

• Sicherungsring (109) mit Hilfeeiner Zange für Innenringe heraus-nehmen (siehe Werkzeuge Seite36)

• Abzieher und Zange (fig6504 und 6505)• Presse und Zange (fig 6506und 6507)

!

Bei Verwendung der Pres-se das Lagerteil nicht aufden Gewindebolzen ab-stützen.

• Remove the snap ring (109)using internal snap ring pliers. (see tools page 36)

• Extractor and pliers (fig 6504 and 6505)

•

Press and pliers (fig 6506 and 6507)

!If you use the press do not place the bearing support on the studs.

• Tellerfeder (108) herausziehen. • Extract the washer (108).

• Bremskolben (107) herauszie-hen.

• Extract the brake piston (107)

• O-Ring (106) beseitigen. • Discard the O-ring (106).

6504 6505

6506 6507

6508

6513

6511

108

106

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269008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 13

Wiedereinbau.

Vor dem Wiedereinbau ist unbedingtsicherzustellen, daß alle Teile, Nutenund Dichtungs-Auflageflächen saubersind.

!Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein

Mit Korrosionsschutzfett (sieheWerkzeug Seite 36) einschmieren:die Nut, die obere Fläche desBremskolbens, die Tellerfeder, denSicherungsring und die Auflageflächeder Kolbendichtung im Bremsgehäuse.

Reassembly.

Before reassembling, it is necessary to ensure that all parts, the surface condition of the piston seal contact surface and the grooves are clean.

!All traces of rust, mud,water must be removed.

Coat with anti-oxidizing grease (see tools page 36), the grooves, the top of the brake piston, the spring washer, the snap ring and the piston seal contact surface in the brake body.

• Neuen O-Ring (106) auf den

Kolben (107) montieren.

!Der Ring muß fest anden Kolben gepreßt undnicht verdreht werden.

• Install a new O-ring (106) on

the piston (107).

!The ring should be tight on the piston and not twisted.

• Bremskolben (107) einsetzen.

!

Achtung, wenn dieDichtung über die Nut

des Sicherungsringsgeführt wird.

• Install the brake piston (107).

!

Take care when passing the seal over the snap ring groove.

• Tellerfeder (108) einlegen. Install the spring washer (108).

6512

6509

6513

107

108

106

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POCLAIN HYDRAULICS

14 REPAR MS2-18 D/GB 800378128J

• Tellerfeder (108) zusammen-drücken:

• Mit Hilfe des Dorns und Ab-ziehers (siehe Werkzeug Seite36) (fig 6502)• Mit Hilfe des Dorns und einerPresse (fig 6503). Die Kraft Feinbehalten (siehe SchaubildSeite 9)

!

Bei Verwendung derPresse das Lagerteilnicht auf den Gewinde-bolzen abstützen.

• Compress the spring washer (108).

• Using a mandrel and an extractor (see tools page 36)(fig 6502)

•

Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

!If you use the press do not place the bearing support on the studs.

• Sicherungsring (109) mit Hilfeeiner Zange für Innenringe gemäßder bei der Demontage ange-brachten Kennzeichnung montie-ren: (siehe Werkzeuge Seite 36)

• Abzieher und Zange (fig6504 und 6505)• Presse und Zange (fig 6506und 6507)

• Install the snap ring (109) using internal snap ring pliers in line with the mark made during disassembly . (see tools page 36)

• Extractor and pliers (fig 6504 and 6505)

• Press and pliers (fig 6506 and 6507)

• Neuen, mit Korrosionsschutzfetteingeschmierten O-Ring (143) indie Nut einsetzen (siehe Werkzeu-ge Seite 36).

• Install a new O-ring (143)coated with anti-oxidizing grease in its groove. (see tools page 36)

• Neue Schutzkappe (141) aufden Anschnitt legen.

• Place the new cover (141) on the entry chamfer .

6503

6504 6505

6506 6507

6515

6516

6502

143

141

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 15

• Schutzkappe mit Hilfe desDorns einrasten lassen (sieheWerkzeug Seite 36).

!

Sich vergewissern, daßder Außenrand des

Schutzkappe in die Nuteingreift ist.

• Click the cover into place using the right mandrel. (see tools page 36).

!Make sure that the outer edge of the cover is en-

gaged in the groove.

• Neuen Stopfen (142) einsetzen.

!

Sich vergewissern, daßzwischen Schutzkappeund Stopfenrille ein-wandfreier Kontakt be-steht.

• Install a new plug (142).

!Make sure about the contact between the cover and the plug groove.

• Motor wieder einsetzen. • Install the motor.

6517

6518

142

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POCLAIN HYDRAULICS

16 REPAR MS2-18 D/GB 800378128J

Auswechseln des Lager-teiles (070)

Replacement of the bearing support (070)

Demontage Disassembly

Motor herausnehmen.Motor auf der Bremse oder Ver-schlussplatte abstützen (Motor ohneBremse).

Remove the motor.Place the motor on the brake or on the end cover (motor without brake).

• Position des Lagerteiles(070) in Bezug auf Nockenring(026) und Verteilerdeckel (040)kennzeichnen.

• Mark the position of the bearing support (070) in relation to the cam (026) and to the valving cover (040).

• Schrauben (042) heraus-nehmen.

• Remove the screws (042).

• Lagerteil (070) herausneh-men.

• Remove the bearing support (070).

• Nockenring (026) heraus-nehmen.

• Remove the cam (026).

6519

6520

6521

6524

070

025

040

042

070

026

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 17

• O-Ring (027) vom Verteiler-deckel (041) entfernen.

• Discard the O-ring (027)from the valving cover (041).

• O-Ring (027) vom Lagerteil(071) entfernen.

• Discard the O-ring (027)from the bearing support (071)

6522

6525

027

041

027

071

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POCLAIN HYDRAULICS

18 REPAR MS2-18 D/GB 800378128J

Wiedereinbau Reassembly

Vor dem Wiedereinbau ist unbe-dingt sicherzustellen, daß die Nutsauber ist

!Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein.

Before reassembling it is necessary to ensure that the groove is clean

!All traces of rust, mud,water must be removed

• Neuen, mit Korrosions-schutzfett eingeschmierten O-Ring(027) in die Nut des Lagerteiles(071) einsetzen (siehe WerkzeugeSeite 36) .

• Install a new O-ring (027)coated with anti-oxidizing grease (see tools page 36) in the groove of the bearing support (071).

• Neuen, mit Korrosions-schutzfett eingeschmierten O-Ring(027) in die Nut des Verteilerdek-kels (041) einsetzen (siehe Werk-zeuge Seite 36) .

• Install a new O-ring (027)coated with anti-oxidizing grease (see tools page 36) in the groove of the valving cover (041)

• Nockenring (026) gemäß derbei der Demontage markiertenKennzeichnung montieren.

!Große Ansenkungen inRichtung Lagerteil

Den Nockenring anhand von zweieinander gegenüberliegendenSchrauben (042) zentrieren.

• Install the cam (026) in line with the marks made during disassembling.

!The big chamfers oriented towards bearing support

Center the cam using two screws (042) diametrically opposite.

6523

027

071

026

6526

041

6525

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 19

• Lagerteil montieren

!

Bei Wellenmotorenmüssen die Anschlüssequer zur Einbauachsedes Motors liegen.

(Abb. 6521)

• Install the bearing support

!

For shaft motors the ports must be perpen- dicular to the mounting axis of the motor. (Fig

6521)

• Befestigungsschrauben (042)einsetzen und mit dem angegebe-nen Drehmoment anziehen. (sieheSchaubild Seite 38).

• Install and tighten the mounting screws (042) to the right torque.(see table page 38).

• Motor wieder einsetzen. • Install the motor.

6521

6520

042

6527

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POCLAIN HYDRAULICS

20 REPAR MS2-18 D/GB 800378128J

Auswechseln der Brems-backen

Replacing the brake shoes.

Vor der Demontage kann man dieAbnutzung der Bremsbeläge durch

die Inspektionsöffnungen kontrollie-ren.

Before disassembling it is possible to make a visual checking of the

brake pads wear via the inspection ports.


!

Das Auswechseln desBremsbacken und dasSchleifen der Trommelnmuß auf allen Motorender gleichen Achse vor-genommen werden.

• Befestigungsmuttern der Felgelösen.• Maschine auf der Höhe derauszubauenden Felge hochheben.• Rad abnehmen (Reifen).• Mechanische Bremse lösen.

!

The same repairs should be made on each motor of the same axle when replacing shoes and brake drums .

• Loosen the wheel rim retaining nuts.

• Raise the machine on the side of the wheel rim to be removed.

• Remove the wheel rim (tyre).

• Release the mechanical brake.

• Trommel (096) abziehen.

!

Reibfläche der Trommelüberprüfen, die weder tiefeRillen (tiefer als 0,2 mm)noch abnormale Abnut-zungserscheinungen auf-weisen darf, sonst mußsie geschliffen werden.(Ra 1,6 bis 3,2)

• Extract the drum (096).

!

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0,2 mm [0.0078 in]) nor abnormal wear. Otherwise, the brake drum should be replaced. (Ra 1.6 to 3.2)

2055

096

6528

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277008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 21

• Rückholfeder (154.a) abbauen. • Remove the return spring (154.a).

• Halterungsfedern (154.b) ab-bauen.

• Remove the retention springs (154.b).

• Bremsbacken aus der Betäti-gungsvorrichtung lösen.

• Release the brake shoes from the regulating mechanism.

• Rückholfedern (154.c) abbau-en.

• Remove the return springs (154.c).

154.a

154.b

1

2

154.c

6529

6530

6531

6532

6533

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POCLAIN HYDRAULICS

22 REPAR MS2-18 D/GB 800378128J

• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)

• Den mechanischen Bremshebelvom Bremsseil lösen und Brems-backe (154.2) entfernen

• Releasing the mechanical brake control lever from its cable, remove the brake shoe (154.2)

154.1

154.2

6535

6536

6534

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 23


!

Vorrichtung entstau-ben, sich vergewissern,daß der Radzylinder

dicht ist.

Reibfläche der Trommel überprü-fen, die weder tiefe Rillen (tiefer als0,2 mm) noch abnormale Abnut-zungserscheinungen aufweisendarf, sonst muß sie geschliffenwerden.

!

Remove all dust from the whole assembly. Make sure there are no leaks at

the wheel cylinder.

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0.2 mm) [0.0078in] nor abnormal wear.Otherwise, the brake drum should be replaced.

• Den Bremshebel am Bremsseil(098) befestigen und Bremsbacke(154.2) einbauen

• Attaching the control lever on the brake cable (098), install the brake shoe (154.2)

154.2

6535

6536

098

6549

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POCLAIN HYDRAULICS

24 REPAR MS2-18 D/GB 800378128J

• Rückholplatte an die Brems-backe (154.2) montieren.

• Mount the return plate on the brake shoe (154.2)

• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)

• Bremsbacken auf der Betäti-gungseinrichtung positionieren.

• Position the brake shoes on the regulating mechanism.

• Rückholfedern (154.c) einset-zen.

Install the return springs (154.c)

6537

6532

6533

154.c

6538

6539

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 25

• Bremsbacken in die Betäti-gungseinrichtung einbauen.

• Install the brake shoes in the regulating mechanism

• Halterungsfedern (154.b) ein-setzen.

• Install the retention springs (154.b).

• Rückholfedern (154.a) einset-zen.

• Install the return spring (154.a).

• Reibungsdurchmesser D derTrommel und der eingesetzten Ba-cken messen.

• Measure the brake drum friction diameter D and that of the brake shoes, which have been installed.

154.b

1

2

Durchmesser D diameter

6532

6531

6530154.a

6529

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POCLAIN HYDRAULICS

26 REPAR MS2-18 D/GB 800378128J

• Backendurchmesser anpassen,um bei Bremsen mit mechanischerEinstellvorrichtung mit Hilfe des ei-nen Zahnrads (156.1), oder beiBremsen mit automatischer Brem-sennachstellung mit Hilfe der zweiZahnräder (156.2 und 156.3), dasnötige Spiel zwischen Belag undTrommel zu erzielen. In diesemFall muß die Wirkung auf die Zahn-räder symmetrisch (a) sein. DenHebel (156.4) muss zu diesemZweck freigängig sein.

• Adjust the brake shoes diameter to obtain correct clearance between the brake padding and the drum using the adjusting wheel (156.1) for brakes equipped with mechanical adjustment system or two adjusting wheels (156.2 and 156.3) for brakes equipped with automatic clearance adjustment. In this case, the adjusting wheels should be adjusted symmetrically (a). Release the lever slightly (156.4) to enable this operation to take place.

Trommeldurchmesser (mm)Drum diameter [in] Bremsen

Brake nominal maximum

Total Spiel (mm)Total clearance [in]

250 x 60 250 [9.84] 252 [9.92 ] 0.55 [0.02]

270 x 60 270 [10.63] 272 [10.70 ] 0.80 [0.03]

325 x 80 325 [12.79 ] 327 [12.87] 0.80 [0.03]

350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]

• Trommel aufsetzen und über-prüfen, ob sie frei dreht.

• Install the drum, check that it can turn freely.

• Wenn nötig, den Radzylinderentlüften.• Felge montieren.Siehe Dokument INSTALLATIONMS D/GB (ref: 800078173V)

• Bleed the wheel cylinder, if necessary.

• Install the wheel rim.See documentation INSTALLATION MS F/GB (ref 677777844 K )

6540

6528

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 27

Auswechseln des Nocken-rings (026)

Demontage

Dazu die im Kapitel « Auswechselndes Lagerteils » unter « Demontage »beschriebenen Arbeiten ausführen,Seite 16

Replacement of the cam (026)

Disassembly

Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16

Wiedereinbau

Dazu die im Kapitel « Auswechselndes Lagerteils » unter " Wiederein-bau " beschriebenen Arbeiten ausfüh-ren, Seite 18.Allerdings muß bei Motoren mit 2Schluckvolumen mit einemSchluckvolumenverhältnis überoder unter 2 die Winkelposition be-

rücksichtigt werden.Beispiel: Motor MS18, Schluckvolu-men 1747-1049-698Kleines Schluckvolumen: 698 cm3

Buchstabe PMittleres Schluckvolumen: 1 049 cm3

Buchstabe MDie Buchstaben P oder M müssensich in der Achse befinden und inRichtung des Schiebers für dasWechseln des Schluckvolumenszeigen, auf der der Nockenring aufdem Lagerteil befestigt ist.

Reassembly

Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18.The angular position of the cam must be respected on dual displacement motors with a displacement ratio different from 2.

Example : Motor MS18 with displacement 1747-1049-698.Small displacement : 698 cm

3

[42.59 cu.in] letter P Medium displacement : 1049 cm

3

[64.01 cu.in] letter M.The letter P or M must be located in the axis and towards the displacement change spool, with the blind hole towards the fixing of the cam on the bearing support.

MS08MSE08

MS18MSE18

MS11MSE11

M P

2035

M

P

A R

P

M

A R

P

M

A

M

P

A R

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284 008 912 53

POCLAIN HYDRAULICS

28 REPAR MS2-18 D/GB 800378128J

Auswechseln des komplet-ten Zylinderblocks (010)

Demontage

Dazu die im Kapitel « Auswechselndes Lagerteils » unter « Demontage »beschriebenen Arbeiten ausführen,Seite 16

Replacement of the cylinders block assembly (010)

Disassembly

Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16

• Nach Demontage des Nocken-rings den Zylinderblock ausbauen.

• After removing the cam, remove the cylinders block.


• Neuen O-Ring (027) einsetzen. • Install a new O-ring (027).

• Kompletten Zylinderblock (010)einsetzen.

• Install the cylinders block assembly (010).

• Dazu die im Kapitel« Auswechseln des Lagerteils » unter"Wiedereinbau" beschriebenen Ar-beiten ausführen, Seite 18

• Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18

6541

6542

6541

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 29

Auswechseln des Verteilers(047).

Replacement of the valving (047).


•

Dazu die im Kapitel« Auswechseln des kompletten Zy-linderblocks (010)» unter« Demontage » beschriebenen Ar-beiten ausführen, Seite 28.

!

Position des Verteilers(047) in Bezug auf Ver-teilerdeckel (041) kenn-zeichnen. (Motor mit 2Hubvolumen).

•

Do operations described in chapter "replacement of the cylinders bloc assembly (010)" section "disassembly" page 28.

!

Mark location to the valving (047) in relation to the valving cover (041) (Dual displacement motor).

• Den Verteiler (047) durch An-heben an den Ausrichtungszapfenoder am Flansch vom Verteilerdek-kel (041) abmontieren.

• Separate the valving (047) fromthe cover (041) by levering at theindexing pins or at the flange.

!Den Verteiler vor Staubschützen.

• Federn (052) ausbauen.• Dichtungen und Gegendichtun-

gen (048) vom Verteilerdeckel(041) herausziehen und beseitigen.

Wiedereinbau

!

Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein.

!Protect the valving from dusts.

• Remove the springs (052).

• Remove and discard the seals

and back-up rings (048) from the cover (041).

Reassembly

!All traces of rust, mud,water must be removed .

• Neue Dichtungen und Gegen-dichtungen (048) ölen und einset-zen; dabei die Gegendichtungen sowenig wie möglich verformen.

• Lubricate and install new seals and back-up rings (048), ensuring the back up rings are twisted as lit- tle as possible.

• Die Federn (052) in ihr zuvormit Fett gefülltes Gehäuse einset-zen.

• Die Dichtungsauflageflächendes Verteilers (047) fetten.

• Den Verteiler(047) in den Ver-teilerdeckel (041) drücken

• Place the springs (052) in their housings, previously filled with grease.

• Lubricate the faces of the seals of the valving (047).

• Press the valving (047) into the cover (041).

2031

1135

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POCLAIN HYDRAULICS

30 REPAR MS2-18 D/GB 800378128J

!

Die Einbaurichtung desVerteilers (047) in bezugauf den Verteilerdeckel(041) beachten).

!

Den Einsatz des Vertei-lers (047) in den Vertei-lerdeckel (041) nichtforcieren.

!

Respect the assembly sense of the valving (047) in relation to the cover (041).

!Do not force when installing the valving (047) into the cover (041).

Montage der Verteileraus-führung 1C (konstanterHubvolumen).

Valving assembly type single displacement motor.

• Keine besondere Montagerich-tung.

• No particular assembly sense.

Montage der Verteilerausfüh-rung 2C (umschaltbarerHubvolumen).

• Den gewählten Buchstaben, derdie Drehrichtung anzeigt, gegen-über dem Steuerkolben (053) an-ordnen.

POSITIONIERUNG DES VERTEI-LERS

G/ L Links

Valving assembly type Dual displacement motor .

• Write the chosen letter indicate the rotation sense in front of the displacement change spool (053).

VALVING POSITIONING

G/L Left

2031041 047

053

6758

053

047

041

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 31

D/R Rechts D/R Right

• Falls kein Buchstabe vorhandenist, die Ausrichtung anhand der beimAusbau festgelegten Markierungenvornehmen.

• Dazu die im Kapitel« Auswechseln des kompletten Zy-linderblocks (010)» unter« Wiedereinbau » beschriebenen Ar-beiten ausführen, Seite 28.

Motoren SE02 und S05

• If there is no letter, do the indexing according to the marks made during disassembly.

• Do operations described in chapter "replacement of the cylinders block" section "reassembly" page 28 .

Situation of SE02 and S05 motors

SE02 Motor :SE02 motor :

S05 Motor :S05 motor

053

6757

041

047

6959

6948

G/L LinksG/L Left

D/R RechtsD/R Right

G/L LinksG/L Left

D/R RechtsD/R Right

053

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POCLAIN HYDRAULICS

32 REPAR MS2-18 D/GB 800378128J

Auswechseln der Deckel-dichtung (045)

Demontage

Replacement of the O-ring (045) of the end cover

Disassembly

• Motor auf Lagerteil stellen(Muttern sind zum Schutz der Ge-windebolzen aufgesetzt)

•

• Place the motor on the bearing support (fitted with nuts for studs protection)

• Schrauben (066) herausneh-men.

• Remove the screws (066)

• Verschlussplatte abnehmen. • Remove the end cover

• O-Ring (045) entfernen. • Discard the O-ring (045)

• Wenn Motor mit 2 Hubvolu-

men, O-Ring (057) entfernen

• Discard the O-ring (057) if the

motor has 2-displacement

6543

6544

6545

066

045057

6546

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 33


• Neuen O-Ring (045) einsetzen. Install a new O-ring (045).

• Wenn Motor mit 2 Hubvolu-men, neuen O-Ring (057) einset-zen, andernfalls zum nächstenSchritt übergehen

• Install a new O-ring (057) if the motor has 2-displacement. If not go to the next section

• Verschlussplatte montieren. • Install the end cover

• Schrauben (066) einsetzen undmit entsprechendem Drehmomentanziehen (siehe Schaubild Seite 38)

• Install and tighten the screws (066) to the right torque (see table page 38)

6547

6548

6544

6543

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290 008 912 53

POCLAIN HYDRAULICS

34 REPAR MS2-18 D/GB 800378128J

Auswechseln des Dreh-zahlsensors (Option)

Replacing the sensor (optional)


• Stecker (161.3) abziehen • Disconnect the connector (161.3)

• Schraube (165) aufschraubenund ausbauen

• Unscrew and remove the screw (165)

• Sensor (161) mit dem Träger(166) abziehen

• Extract the sensor (161) with its support (166)

161

166

6550

6551

6552

165

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 35


!

Der Dichtung (164) aufSauberkeit der Auflage-fläche dem Verteiler-deckel (041) prüfen. !

Make sure that the seal mounting surface (164) on the valving cover (041) is clean.

• Neuen Haltering (163) undneue Dichtung (164) auf den Sen-sor (161) mit seiner Distanzscheibe(167) schieben.

• Install the new brake washer (163) and the new seal (164) on the sensor (161) fitted with its adjusting sticker (167).

• Den Sensor in die Halterung(166) stecken, so daß die Dichtung(164) korrekt in ihrer Aufnahmesitzt.

• Push the sensor assembly into the support (166) until the seal (164) is in its housing.

• Sensor (041) in die Bohrungdes Verteilerdeckels bis zum Kon-takt mit dem Zylinderblock (011)schieben.

• Push the sensor into the valving cover (041) until it comes in contact with the cylinders block (011),

Die Kerbe im Steckeranschluss desSensors muss radial zur Mitte desMotors (Richtung Welle) zeigen.

the notch of the sensor should be oriented towards the center of the motor.

• Schrauben (165) einsetzen undmit entsprechendem Drehmomentanziehen (siehe Schaubild Seite38)

• Install and tighten the screw (165) to the right torque (see table page 38)

• Stecker (161.3) wieder an-schließen.

• Reconnect the connector (161.3).

6552

6551

6550

6558

2064

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292 008 912 53

POCLAIN HYDRAULICS

36 REPAR MS2-18 D/GB 800378128J

Werkzeug-Liste Tooling inventory

Standard Werkzeug Standard tools

• Innensechskant-SchlüsselHollow head

wrench 5 6 8 10 12 14

• Ring-/Maulschlüssel fürSechskantschraube

Hex head wrench 13 17 19 22 24

• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 bis 30 N.m [4.4 to 22.1 lbf.ft]

• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 bis 240 N.m [35 to 175 lbf.ft]

• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 bis 800 N.m [120 à 600 lbf.ft]

• KorrosionsschutzfettAuto-top 2000origine AGIP

Anti-oxidizing grease

Leuchtend grüne Farbe / fluores- cent green color

• Zange für Innenringe FACOM 499.32Internal snap ring

pliers

• Abzieher FACOM U 20 B Extractor

• Sechskantschlüssel fürInnensechskantschraube

Hex head wrench 13 17 19 22 24

• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]

• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]

• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]

6553

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293008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 37

Spezialwerkzeuge Special tools

• Montagewerkzeugzum Anheben derSchutzkappe oder zumKomprimieren der Tel-lerfeder.

• Mandrel for reassembling the brake cover or to compress the spring washer.

Ø A Ø B Ø C Ø D E F G

mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]

F02

F03110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]

F04

F05

F07

M12

125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]

50 [1.96] 10 [0.39] 20 [0.78]

F08

F09125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]

F11

F12 50 [1.96] 20 [0.78]

F18

F19

F21

M16

190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46]

70 [2.75]

10 [0.39]

30 [1.18]

• Rohr zum Festsetzendes Motors

Tube to immobi- lize the motor

• Werkzeuge zur me-chanischen Bremslö-sung.

Tools for mechanical brake release

0759

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294 008 912 53

POCLAIN HYDRAULICS

38 REPAR MS2-18 D/GB 800378128J

AnziehdrehmomenteNm ± 10%

(Gemäß Norm DIN 912)

Tightening torques in [lbf.ft] ± 10%

(According to the standard DIN 912)

Größe Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5

M8 25 35 41 18.4 26 30

M10 49 69 83 36 51 61

M12 86 120 145 63.4 88.4 107

M14 135 190 230 100 140 170

M16 210 295 355 155 218 262

M18 290 405 485 214 299 358

M20 410 580 690 302 428 509

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POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 39

ErsatzteileNummer Bezeichnung

010 Kompletter Zylinderblock012 Kompletter Kolben Cl. 0

013 Kompletter Kolben Cl. 1015 Reparatursatz

026 Kompletter Nockenring027 O-Ring

040 Komplettes Verteilerdeckel041 Verteilerdeckel042 Schraube043 Dichtungsring044 Schraube045 O-Ring047 Verteiler

048 Dichtungssatz050 Stopfen051 O-Ring052 Feder053 Umschaltkolben054 Scheibe055 Sicherungsring056 Feder057 O-Ring059 Stif t

065 Kompletter Verschlussplatte066 Schraube067 Dichtring

070 Komplettes Lagerteil071 Lagerteil072 Innerer Lippendichtring073 Rollenlager074 Rollenlager075 Scheibensatz076 Stützring077 Sicherungsring078 Äußerer Dichtring079 Abweiser

081 Dichtungsträger087 Passfeder090 Welle091 Radbolzensatz096 Bremstrommel097 Schraube098 Bremsseil099 Sicherungsring154 Komplette Bremsbacke155 Kompletter Radzylinder156 Gegenhalter

Spare parts list Item Description

010 Cylinders-block assembly 012 Piston Cl 0 assembly

013 Piston Cl 1 assembly 015 Repair kit

026 Cam assembly 027 O-ring

040 Valving cover assembly 041 Valving cover part 042 Screw 043 Seal washer

044 Screw 045 O-ring 047 Valving

048 Seal kit 050 Plug 051 O-ring 052 Spring

053 Valve spool 054 Washer 055 Snap ring 056 Spring 057 O-ring 059 Pin

065 End cover assembly 066 Screw 067 Sealing ring

070 Bearing support assembly 071 Bearing support part 072 Radial lip seal

073 Roller bearing 074 Roller bearing 075 Set of shims 076 Thrust ring 077 Snap ring 078 Lip seal 079 Deflector

081 Seal support 087 Key 090 Shaft 091 Set of studs 096 Drum brake 097 Screw

098 Brake cable 099 Snap ring 154 Brake shoe sub-assembly 155 Brake cylinder sub-assembly 156 Brake adjustment

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POCLAIN HYDRAULICS

40 REPAR MS2-18 D/GB 800378128J

Nummer Bezeichnung 100 Komplette Bremse

101 Bremsgehäuse102 Schraube106 O-Ring107 Kolben

108 Tellerfeder109 Sicherungsring110 Welle111 Dichtsatz Bremswelle112 Schraube113 Dichtungsring135 Satz Bremslamellen141 Schutzkappe142 Stopfen143 O-Ring

150 Drehzahlsensor-Vorbereitung152 Scheibe

153 Scheibe

160 Kompletter Sensor161 Sensor162 Mutter163 Scheibe164 Dichtung

Als Satz lieferbare Baugruppe

Item Description 100 Brake assembly

101 Brake body 102 Screw 106 O-ring 107 Brake piston 108 Spring washer 109 Snap ring 110 Brake shaft

111 Seal 112 Screw 113 Seal washer 135 Brake kit 141 Cover 142 Plug 143 O-ring

150 Speed sensor predisposition 152 Washer

153 Washer

160 Speed sensor assembly 161 Speed sensor part

162 Nut 163 Washer 164 Seal

Sub-assembly sold assembled

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297008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 41

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298 008 912 53

POCLAIN HYDRAULICS

42 REPAR MS2-18 D/GB 800378128J

Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.

0987

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299008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 43

0988

DichtungssatzSeal kit

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300 008 912 53

POCLAIN HYDRAULICS

44 REPAR MS2-18 D/GB 800378128J

Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.

0990

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301008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 45

0989

DichtungssatzSeal kit

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302 008 912 53

POCLAIN HYDRAULICS

46 REPAR MS2-18 D/GB 800378128J

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303008 912 53

POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 47

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304 008 912 53

China

POCLAIN HYDRAULICS BEIJING rep. officeUnit A0808, Hui Bin OfficiesNo.8 Beichendong St.BEIJING 100101CHINATel.: 86 10 6499 3988Fax: 86 10 6499 3979e-mail: [email protected]

España & Portugal

POCLAIN HYDRAULICS SPAIN S.L.

Gran Via Carlos III n

o

84 – 1

o

3

a

08028 BARCELONAESPAÑATel.: 349 3 409 54 54Fax: 349 3 490 21 79e-mail: [email protected]

POCLAIN HYDRAULICS SROKšírova 18661900 BRNO

Tel.: 420 5 43217830Fax: 420 5 43217818e-mail: [email protected]

France

POCLAIN HYDRAULICS France SASB.P. 10660411 VERBERIE CEDEXFRANCETel.: 33 3 44 40 77 77Fax: 33 3 44 40 77 91e-mail: [email protected]

Deutschland

POCLAIN HYDRAULICS GMBHBergstrasse 10664319 PFUNGSTADTDEUTSCHLANDTel.: 49 6157 9474 0Fax: 49 6157 9474 74e-mail: [email protected]

Japan

POCLAIN HYDRAULICS KK5-4-6 KugenumashinmeFUJISAWA 251JAPANTel: 81 466 50 4400Fax: 81 466 50 4422e-mail: [email protected]

Italia

POCLAIN HYDRAULICS SRLVia Svizzera 4/A41012 CARPI (MODENA)ITALIA

Tel.: 390 59 64 22 44Fax: 390 59 64 20 44e-mail: [email protected]

United Kingdom

POCLAIN HYDRAULICS LTDNene Valley Business ParkOundlePETERBOROUGH, Cambs PE8 4HNENGLANDTel.: 44 1832 273773Fax: 44 1832 274990e-mail: [email protected]

Nederland

POCLAIN HYDRAULICS BENELUX BVPenningweg 32C4879 AM ETTEN-LEURNEDERLAND

Tel.: 31 76 5021152Fax: 31 76 5012279e-mail: [email protected]

USA

POCLAIN HYDRAULICS INC.7900 Durand AvenueP.O. BOX 801STURTEVANT, WI 53177USATel.: 1 262 554 6739Fax: 1 262 554 4860e-mail: [email protected]

POCLAIN HYDRAULICS INDUSTRIE B.P. 106

60411 VERBERIE CEDEX - France Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 e-mail: [email protected]

www.poclain-hydraulics.com

S.A.S. au capital de 85 124 000 Francs Siège social: Route de Saint Sauveur VERBERIE (OISE) R.C.S. Senlis B 414 781 823 Siret 414 781 823 00011

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7.4 Vibration motor A2FM 32

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307008 912 53

Instructions for repair

A2FM32058 010 53

Vibration motor

008 196 03 01/1993

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308 008 912 53

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008 196 03 BOMAG 1

6.01 Repair survey vibration motor

6.02 Special tools

6.03 General notes for repairs

6.04 Sealing the vibration motor

6.05 Repairing the vibration motor drive

6.00Table of Contents

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310 008 912 53008 196 03BOMAG2

Fig. 1

1 Housing2 Connecting plate

3 Valve plate

4 Drive

5 Locking ring

6 Drive shaft


Installation weight:approx. 11 kg

Opening the motor will result in the lossof all warranty and policy adjustmentclaims!

The description of the repair procedures is in accordance with economical and technical aspects. We do not recommend any further

repairs.


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008 196 03 BOMAG 3

6.02 Special tools

1. Puller 079 944 02

Fig. 1

6.02Special tools

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312 008 912 53008 196 03BOMAG4


Please observe the following notes whencarrying out repairs on hydraulic compo-nents!

1. Close all openings on hydraulic components.

2. Replace all seals and gaskets.

3. Check all sealing and sliding surfaces for signsof wear.

4. Fill the hydraulic components with hydraulic oilbefore taking them into operation.

Fig. 1

Fig. 2

Fig. 3

Fig. 4


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008 196 03 BOMAG 5


1. Mark the position of the connecting plate to thehousing and unscrew the socket head capscrews (Fig. 1).

2. Swivel the connecting plate 1 (Fig. 2) aroundthe timing pin and lift it off.

3. Cover the drive shaft with adhesive tape toprevent the new radial seal from being damag-ed (Fig. 3).


Fig. 1

Fig. 2

Fig. 3

Fig. 4

6.04Sealing the vibration motor

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314 008 912 53008 196 03BOMAG6

5. Force the locking ring out (Fig. 5).

6. Remove the radial seal 1 (Fig. 6) and theO-ring (2).

7. Check the drive shaft for running grooves(Fig. 7).

8. If the running groove is very deep place anappropriate shim 1 (Fig. 8) in front of the radialseal.

Fig. 5

Fig. 6

Fig. 7

Fig. 8


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008 196 03 BOMAG 7

9. Press the new radial seal in dry by using asuitable sleeve (Fig. 9).

10. Insert the new O-ring 1 (Fig. 10) with somegrease and fill the new radial seal (2) withgrease.

11. Knock the locking ring in by tapping it lightlywith a hammer (Fig. 11).

12. Install the circlip (Fig. 12).

Fig. 9

Fig. 10

Fig. 11

Fig. 12


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316 008 912 53008 196 03BOMAG8

13. Make sure that the circlip is sitting correctly inthe groove (Fig. 13).

14. Insert new O-ring 1 (Fig. 14) with some grease.

15. Make sure that the timing pin 1 (Fig. 15) is inassembling position and attach the connectingplate.

16. Observe the marks and fasten the socket headcap screws crosswise with 25 Nm (Fig. 16).

Fig. 13

Fig. 14

Fig. 15

Fig. 16


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008 196 03 BOMAG 9

17. Unscrew the plug 1 (Fig. 17) and insert a newO-ring (2) with some grease.

Fig. 17


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Dismantling the drive

1. Mark the position of the connecting plate to thehousing and unscrew the socket head capscrews (Fig. 1).

2. Swivel the connecting plate 1 (Fig.2) aroundthe timing pin and lift it off.

3. Remove the O-ring 1 (Fig.3)

4. Remove the valve plate (2).


Fig. 1

Fig. 2

Fig. 3

Fig. 4


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008 196 03 BOMAG 11

6. Force the locking ring out (Fig. 5).

7. Remove the radial seal 1 (Fig. 6) and theO-ring (2).

8. Remove the shims 1 (Fig. 7).

9. Dismantle the drive by using the puller asshown in Fig. 8.

Guide the cylinder in by hand.

Fig. 5

Fig. 6

Fig. 7

Fig. 8

6.05Repairing the vibration motor drive

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10. Check the housing for signs of scoring (Fig. 9).

Assembling the drive

The drive 1 (Fig. 10) can only be renewed completely as the hydraulical and the mechanical parts are adjusted to each other.

1. Insert the spring cup 1 (Fig. 11) and the Belle-ville springs (2) into the cylinder (3) by using apiece of wire.

2. Slide all pistons into the cylinder by movingthem slightly from side to side (Fig. 12).

Fig. 9

Fig. 10

Fig. 11

Fig. 12


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3. Stand the new drive into a suitable bore andswash it to maximum displacement (Fig. 13).

4. Heat the housing up to a temperatur of approx.80 ˚C (Fig. 14).

5. Slide the warm housing onto the drive as far asit will go (Fig. 15).

Danger of injury!

Let the housing cool down, before furtherassembly to avoid damages to the O-ring.

6. Insert the shims 1 (Fig. 16).

Fig. 13

Fig. 14

Fig. 15

Fig. 16


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7. Press the new radial seal in dry by using asuitable sleeve (Fig. 17).

8. Insert the new O-ring 1 (Fig. 18) with somegrease and fill the new radial seal (2) withgrease.

9. Cover the drive shaft with adhesive tape toprevent the new radial seal from being damag-ed.

10. Knock the locking ring in by tapping it lightlywith a hammer (Fig. 19).

11. Install the circlip (Fig. 20).

Fig. 17

Fig. 18

Fig. 19

Fig. 20


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12. Make sure that the circlip is sitting correctly inthe groove (Fig. 21).

13. Pull the drive against the locking ring by usingthe puller (Fig. 22).

When the drive is touching, the locking ring is free of clearance.

14. Insert the O-ring (Fig. 23) with some greaseinto the the groove.

15. Stick the valve plate (2) onto the drive by usingoil.

16. Make sure that the timing pin 1 (Fig. 24) is inassembling position and put on the connectingplate.

Fig. 21

Fig. 22

Fig. 23

Fig. 24


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17. Observe the marks and tighten the sockethead cap screws crosswise with 25 Nm (Fig.25).

18. Screw the socket head cap screw into the driveshaft and check if the drive shaft can be turnedby using an Allen key (Fig. 26).

The vibration motor has to be bled andfilled with hydraulic oil before taking it intoservice.

Fig. 25

Fig. 26


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