Bomag Sanitary Landfill Compactor Bc 672 Rb Bc 772 Rb Service Repair Manual – PDF Download

Instructions for repair

BC 672 RB / BC 772 RB

Sanitary landfill compactor

Catalogue number

008 912 65

08/2002

Table of Contents

General

5 1.1 Foreword

6

1.2 Safety regulations

7

1.3 General repair instructions

11

1.5 Connection overview

12

1.6 Connection overview

14

1.7 Connection overview

16

Tests and adjustments

19 2.1 Technical data

20

2.2 Special tools

23

2.3 Pressure tests in the travel circuit

25

2.4 Checking high pressure relief valves and pressure override

26

2.5 Charge pump high pressure test

28

2.6 Travel pump high pressure test (individual test)

29

2.7 Checking charge pressure

31

2.8 Adjusting the DA-control valve

32

2.9 Checking the control chamber pressure

33

2.10 Checking the displacement setting of the travel motors

34

2.11 Checking the stand-by pressure of the steering/working pump

36

2.12 Checking the high pressure of steering/working pump

37

Trouble shooting

39 3.1 General

40

3.2 Trouble shooting diagram Oscillating articulated joint

41 57

4.1 Removing and installing live ring, oscillating articulated joint

58

4.2 Repairing the oscillating articulated joint

64

Repairing the brake in the final drive.

67

5.1 Repairing the brake in the final drive Suppliers documentation

008 912 65

9

1.4 Tightening torques

68 73

6.1 Travel pump A4VG 71 ... 180

75

6.2 Travel motor A6VM 28 ... 200

129

BOMAG

3

Table of Contents

4

BOMAG

008 912 65

1 General

008 912 65

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Introduction 1.1

Foreword

These repair instructions contain all necessary information for training and repair work.

Notes on maintenance, care and trouble shooting can be found in the operating and maintenance instructions.

1

General

2

Tests and adjustments

3

Flushing

4

Trouble shooting

5

Drum

6

Pivot steering

7

Components

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

The repair instructions describe the removal or dismantling and assembly of components and assembly groups.

The repair of disassembled assembly groups is described as far as this makes sense with respect to available tools and spare parts supply and as far as it can be understood by a skilled mechanic.

Danger Danger of injury

Please observe strictly the safety regulations in these operating instructions and the applicable accident prevention regulations.

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

You should only use genuine BOMAG spare parts.

These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional technical service bulletins.

In case of a new release all necessary changes will be included.

In the course of technical development we reserve the right for technical modifications without prior notification.

Information and illustrations in this repair manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.

BOMAG GmbH & Co. OHG Printed in Germany Copyright by BOMAG

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6DIHW\ UHJXODWLRQV Important notes 1.2

Safety regulations

These safety regulations must be read and applied by every person involved in the repair of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed.

Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. These repair instructions contain headers like „Note“, „Attention“, „Danger“ and „Environment“, which must be strictly complied with in order to avoid dangers for health and for the environment.

Danger Paragraphs marked like this highlight possible dangers for persons.

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine.

●

Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.

●

Use only safe and approved lifting gear of sifficient load bearing capacity to remove and install parts or components from and to the machine.

●

Be careful with cleansing agents. Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.

●

Cleaning or repair work on the fuel tank is very dangerous. Do not smoke or allow any ignitable sparks or open fire in the vicinity when cleaning or repairing a tank. .

●

When performing welding work strictly comply with the respective welding instructions.

Special safety regulations ●

Use only genuine BOMAG spare parts for repair purposes. Original parts and accessories have been specially designed for this machine.

●

We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

●

Unauthorized changes to the machine are prohibited for safety reasons.

●

If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine, danger of injury!

●

Do not perform cleaning work while the engine is running.

●

If tests must be performed with the engine running do not touch rotating parts of the engine, danger of injury.

●

Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting the engine in closed rooms.

●

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

●

Keep used filters in a separate waste container and dispose of environmentally.

●

Dispose of oils and fuel environmentally when performing repair or maintenance work.

●

Do not refuel in closed rooms.

●

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

●

Wipe off spilled oil and fuel.

L

Note

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

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Observe the regulations for the protection of the environment.

General ●

Before starting repair work stand the machine on level and solid ground.

●

Always secure the machine against unintended rolling.

●

Secure the engine reliably against unintentional starting.

●

Mark a machine that is defective or being repaired by attaching a clearly visible warning tag to the steering wheel.

●

On machines with articulated joint keep the articulated joint locked during work.

●

Use protective clothes like hard hat, safety boots and gloves.

●

Keep unauthorized persons away from the machine during repair work.

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●

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

●

Do not check the acid level of the battery with a naked flame, danger of explosion!

●

Old batteries contain lead and must be properly disposed of.

●

There is a danger of scalding when draining off engine or hydraulic oil at operating temperature.

●

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

●

Do not exceed the specified highest permissible tire pressure.

Hydraulics ●

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines.

●

Before applying pressure to the system make sure that all line connections and ports have been properly tightened and are in perfect condition.

●

Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.

●

Do not step in front of or behind the drums/wheels when performing adjustment work in the hydraulic system while the engine is running. Block drums and/or wheels with wedges.

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

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*HQHUDO UHSDLU LQVWUXFWLRQV General 1.3

●

●

General repair instructions

Before removing or disassembling and parts, hoses or components mark these parts for easier assembly.

Before assembly oil or grease all parts, as far as this is necessary.

●

Fill new hydraulic units with hydraulic oil before starting operation.

●

After changing a component thoroughly flush and bleed 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 speed of the exciter shaft.

●

The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. If the soil is too hard place the drums on old rubber tires. Do not activate the vibration on a hard, concreted base, danger of bearing damage.

●

After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized.

Hydraulic system Caution Do not open any hydraulic components if you have not been properly trained and without exact knowledge.

Please note Cleanliness is of utmost importance. Make sure that no dirt or other contaminating substances can enter into the system. ●

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

●

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

●

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

●

Do not run pumps and motors without oil.

●

When cleaning hydraulic components take care not to damage any fine machine surfaces.

●

Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not use such substances to clean seals and gaskets.

●

●

●

After changing a component clean the hydraulic oil tank thoroughly.

●

Fill the housings of hydraulic pumps and motors with hydraulic oil.

●

Use only hydraulic oils according to the specification in the maintenance instructions.

●

After changing a component clean the hydraulic system as described in the flushing instructions in order to prevent all other components from being damaged by abrasion and metal chips remaining in the system.

Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.

●

Change the hydraulic oil filter.

●

Bleed the hydraulic circuits.

Avoid the formation of rust on fine machined caused by hand sweat.

●

Start up the system without load.

●

Check the hydraulic oil level in the tank, fill up oil if necessary.

●

Grease must not used as a sliding agent for assembly work. Use hydraulic oil.

●

Do not start the engine after the hydraulic oil has been drained off.

●

●

Before commissioning

Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.

Clean ports and fittings before removal so that no dirt can enter into the hydraulic system.

●

Check the hydraulic oil level before and after the work.

●

Use only clean oil according to specification.

●

Check the hydraulic system for leaks, find and rectify the cause.

008 912 65

Commissioning

After commissioning ●

Check system pressures and speeds.

●

Check fittings and flanges for leaks.

●

After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic system, adjust if necessary.

●

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

Electrical system ●

Always disconnect the battery before starting work in the electrical system.

●

Ensure correct polarity when connecting the battery.

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●

Do not check voltage by tapping against ground.

●

When performing welding work always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location. Strictly disconnect the cables from the generator before starting work.

Seals and gaskets ●

Generally use new seals and gaskets when performing assembly work. The required seal kits are available as spare parts.

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7LJKWHQLQJ WRUTXHV Tightening torques 1.4

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.

Tightening torques for screws with metric unified thread Screw dimension M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Tightening torque Nm* (ft-lb) 8.8 3 (2) 6 (4) 10 (7) 25 (18) 50 (37) 88 (65) 137 (101) 211 (156) 290 (213) 412 (304) 560 (413) 711 (524) 1050 (774) 1420 (1047)

10.9 5 (4) 9 (7) 15 (11) 35 (26) 75 (55) 123 (91) 196 (145) 300 (221) 412 (303) 578 (426) 785 (559) 1000 (738) 1480 (1092) 2010 (1482)

12.9 5 (4) 10 (7) 18 (13) 45 (33) 83 (61) 147 (108) 235 (173) 358 (264) 490 (361) 696 (513) 942 (695) 1200 (885) 1774 (1308) 2400 (1770)

Tightening torques for screws with metric fine thread Screw dimension M8 x 1 M10 x 1.25 M12 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x2 M30 x 2 *

Tightening torques Nm* (ft-lb) 8.8 26 (19) 52 (38) 98 (72) 93 (69) 152 (112) 225 (166) 324 (239) 461 (340) 618 (456) 780 (575) 1147 (846) 1568 (1156)

10.9 37 (27) 76 (56) 137 (101) 127 (94) 216 (159) 318 (235) 466 (344) 628 (463) 863 (636) 1098 (808) 1578 (1164) 2254 (1662)

12.9 48 (35) 88 (65) 126 (119) 152 (112) 255 (188) 383 (282) 554 (409) 775 (572) 1058 (780) 1294 (1416) 1920 (1416) 2695 (1988)

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

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.

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Fig. 1 Travel pump

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Port A, high pressure reverse, front pump

15 Test port X2, pilot pressure forward

2

High pressure relief valve (460 bar), front pump

16 Port S, charge pressure from hydraulic oil filter

3

PS-line, pilot pressure supply

17 Plug b, solenoid valve reverse

4

Port A, high pressure reverse, rear pump

18 Charge pressure relief valve (28 bar), front pump

5

High pressure relief valve (460 bar), front pump

19 DA-control valve

6

Port B, high pressure forward, rear pump

20 Pressure override valve (410 bar), front pump

7

Plug T2, rear pump

21 Test port B, high pressure forward, front pump

8

Port B, high pressure forward, front pump

22 Charge pressure relief valve (28 bar), rear pump

9

Plug T2, front pump

23 Pressure override valve (410 bar), rear pump

10 Plug a, solenoid valve forward

24 Test port MB, high pressure forward, rear pump

11 Port T1, leak oil to return flow filter, front pump with magnetic plug

25 Port S1, charge pump suction port from tank

12 Test port X1, control chamber pressure reverse 13 Port T1, leak oil to return flow filter, rear pump with magnetic plug

26 Port P, pressure port on charge pump to hydraulic oil filter 27 Test port MA, high pressure reverse, rear pump 28 Test port MA, high pressure reverse, front pump

14 Test port G, charge pressure

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Fig. 1 Travel pump

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Port L, leak oil to return flow filter

29 Thermostat (55°C...70°C)

2

Port X, load signal to control valve block

30 Connection to tank

3

Setscrew for flow control valve (88 l/min)

4

Setscrew for pressure control valve (230 bar)

31 Connection from solenoid valve for brake/travel direction selector

5

Port S, suction line from tank

32 Test port for case pressure

6

Test port for stand-by pressure, 18 bar; high pressure 200 bar

33 Pressure switch (3 bar), normally open

7

Port B, high pressure

35 Magnetic plug, wheel motor, rear left

34 Contamination sensor

8

36 Magnetic plug, wheel motor, rear right

9

37 Leak oil connection from travel pump, rear right

10

38 Leak oil connection from travel pump, front right

11

39 Filter outlet, to solenoid valve

12 13

40 Pressure switch, filter contamination indicator (2.5 bar)

14

41 Pilot pressure connection, travel range selector

15 Active filter element

42 Plug, travel range selector

16 By-pass filter element

43 Plug, brake

17 Leak oil connection from travel pump, front left

44 Charge pressure switch (5 bar), right hand tandem pump, normally closed

18 Magnetic plug, wheel motor, rear right 19 Leak oil port, wheel motor, rear right 20 Leak oil port, wheel motor, rear left 21 Leak oil port, steering/working pump

45 Connection from left hand charge pump 46 Charge pressure switch (5 bar), left hand tandem pump, normally closed

22 Magnetic plug, steering/working pump

47 Filter outlet, to the charge oil supply port on left hand tandem pump

23 Leak oil port, wheel motor, front left

48 Port X, pilot pressure

24 Leak oil port, wheel motor, front right

49 Port G, synchronous control

25 Magnetic plug, wheel motor, front right

50 Port T, leak oil

26 Leak oil connection from travel pump, rear left

51 Port B, high pressure

27 Non-return valve (3 bar), to tank

52 Port A, high pressure

28 Connection to cooler

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Fig. 1 Valve block, working hydraulics

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Proportional solenoid, steering right 1a) Proportional solenoid, steering left

2

Switching solenoid, float position 2a) 2nd switching solenoid, float position

3

Proportional solenoid, blade down 3a) Proportional solenoid, blade up (on opposite side)

4

Pressure test port, pilot pressure steering left 4a) Pressure test port, pilot pressure steering right (on opposite side)

5

Pressure test port, pilot pressure blade up 5a) Pressure test port, pilot pressure blade down (on opposite side)

6

Pressure test port, tank pre-tensioning valve

7

Pressure test port, working pressure

8

LS-pressure limitation

9

Tank pre-tensioning valve

10 Pressure test port, steering left 11 Pressure test port, steering right 12 Pressure test port, blade down 13 Pressure test port, blade up

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2 Tests and adjustments

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2.1

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Technical data

Fig. 1

Dimensions in mm

A

BC 672/772 RB 3500

B

B2

B3

D

H

H2

H4

K

L

3800

3550

3775

1620

4100

3810

1950

580

8120

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Travel characteristics Travel speed (1) Travel speed (2) Max. gradability without/ with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 IFN Nominal speed Drive system Driven axles

BC 672 RB

BC 672 RB

kg

32100

32100

kg kg

15300 16800

15300 16800

km/h km/h %

0 ... 4,5 0 ... 12 100

0 ... 4,5 0 ... 12 100

kW

KHD BF6M1015CP Water 6 314

KHD BF6M1015CP Water 6 314

2100 hydrostatic 2

2100 hydrostatic 2

1 rpm

Electrical equipment 20

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Voltage supply Battery Generator Starter

V V/AH V/AH V/kW

BC 672 RB 12 12/180 Deutz 24/55 Deutz 24/6.6

BC 672 RB 12 12/180 Deutz 24/55 Deutz 24/6.6

cm3/rev. bar bar bar

4 Hydromatik A4VG 71 DA A4VG 71 DG Axial piston/ swash plate 71 430 +10/−20 480 −20 30 ±2

4 Hydromatik A4VG 71 DA A4VG 71 DG Axial piston/ swash plate 71 430 +10/−20 480 −20 30 ±2

bar

50 at 950 ±50 rpm

50 at 950 ±50 rpm

bar

1750 ±75/rpm

1750 ±75/rpm

cm3/rev. cm3/rev. bar bar

Hydromatik A6VM 160 HA 2T Axial piston – bent axle 160 50 280 380

Hydomatik A6VM 160 HA 2T Axial piston – bent axle 160 50 280 380

Travel pump Number of pumps Manufacturer Type front Type rear System Displacement Pressure override valve High pressure limitation Charge pressure limitation Travel pressure at control start Max. deviation travel pressure left/right Travel motor Manufacturer Type System Displacement stage 1 Displacement stage 2 Control start Control end Brakes Service brake Parking brake Brake releasing pressure Steering Type of steering Steering operation Oscillation angle Steering angle Steering/working pump Manufacturer Type System Displacement Dozer blade pressure Steering pressure Stand-by pressure LS-signal

hydrostatic hydrostatic Multi-disc, spring accumu- Multi-disc, spring accumulator lator bar 18...20 18...20

± ±

Oscill.-articul. hydrostatic 15 30

Oscill.-articul. hydrostatic 15 30

cm3/rev. bar bar bar bar

Brüninghaus A10VO 71 DFR Axial piston – swash plate 71 230 ±10 200 ±10 30 ±10 respective high pressure

Brüninghaus A10VO 71 DFR Axial piston – swash plate 71 230 ±10 200 ±10 30 ±10 respective high pressure

Rexroth

Rexroth

Working/steering valve Manufacturer

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Charge and return flow filter Charge circuit Return flow filter Wheel drive Manufacturer Type System Wheels Design Type per wheel side Diameter Number of teeth, front Number of teeth, rear Dozer blade Design Height adjustment above ground level Height adjustment below ground level Width across edge cutters Height Filling capacities Engine oil Fuel (diesel) Hydraulic oil Coolant Gear oil, transfer box Gear oil, wheel gear Grease lubrication *

22

BC 672 RB

BC 672 RB

12 80

12 80

Lohman + Stolterfoth GTF 110 R3 Planets

Lohman + Stolterfoth GTF 110 R3 Planets

Pakall Segment + tooth 1175 1620 50 40

Pakall Segment + tooth 1350 1660 60 50

mm

Pakall 1200

Pakall 1200

mm

200

200

mm mm

3884 1950

3884 1950

l l l l l l kg

approx. 38.0 500 350 approx. 44 4,5 6,5 2

approx. 38.0 500 350 approx. 44 4,5 6,5 2

micron micron

mm mm

The right for technical modifications remains reserved

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6SHFLDO WRROV 2.2 Special tools 1. RPM-meter for Deutz engine BOMAG part-no.: 059 711 12

Fig. 1

2. Vacuum pump to generate a vacuum in the hydraulic oil tank BOMAG part-no.: 007 610 04 (12V) BOMAG part-no.: 007 610 24 (24V)

Fig. 2

3. Hydraulic test case BOMAG part-no.: 007 610 03

Fig. 3

4. Pressure test hose 2.5 m long BOMAG part-no.: 079 930 03

Fig. 4

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6SHFLDO WRROV 5. Electrics test case BOMAG part-no.: 057 505 70

Fig. 5

6. Gear pump testing equipment BOMAG part-no.: 007 610 05

Fig. 6

7. Landfill site hygiene set BOMAG part-no.: 007 800 01

Fig. 7

24

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3UHVVXUH WHVWV LQ WKH WUDYHO FLUFXLW

2.3 Pressure tests in the travel circuit Danger Whenever performing tests make sure you direct visual contact with the driver.

1. Run the machine warm to operating temperature (approx. 40°C hydraulic oil temperature).

2. Connect the following pressure gauges (Fig. 1):

Fig. 1

1

High pressure, travel pump rear left, 600 bar.

2

High pressure, travel pump front left, 600 bar.

3

High pressure, travel pump front right, 600 bar.

4

High pressure, travel pump rear right, 600 bar.

5

Charge pressure, left hand tandem pump 60 bar.

6

Charge pressure, right hand tandem pump 60 bar.

7

Control chamber pressure, left hand tandem pump 60 bar.

8

Control chamber pressure, right hand tandem pump 60 bar.

Danger Make sure there are no persons in front of or behind the machine.

3. Input module (Fig. 2) enter PIN-CODE. 4. Start the engine, select 2nd speed range and switch to travel direction reverse.

L Note Do not actuate the emergency stop.

5. Accelerate the engine slowly up to full speed and watch the pressure gauges.

Nominal values: High pressures must increase evenly to 430 +10/ -20 bar. The charge pressures must not drop considerably (<28 bar). At least 28 bar at idle speed, increasing to 30 bar.

Fig. 2

Control chamber pressures must increase evenly to approx. 14 bar.

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&KHFNLQJ KLJK SUHVVXUH UHOLHI YDOYHV DQG SUHVVXUH RYHUULGH 2.4 Checking high pressure relief valves and pressure override 1. Run the machine up to operating temperature (40°C hydraulic oil temperature).

2. Input module (Fig. 1) enter PIN-CODE.

Fig. 1

3. Connect a 600 bar pressure gauge to both high pressure ports (Fig. 2) of a tandem pump.

Fig. 2

4. Pull the electric plugs A and B (Fig. 3) off the magnets on the other pump, since the machine might drive through the brake.

Fig. 3

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5. Turn the adjustment screw of the pressure override (Fig. 4) completely in (block).

Danger Make sure there are no persons in front of or behind the machine.

6. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction

L Note Do not actuate the emergency stop.

Fig. 4

Caution Perform the following test for max. 3 seconds, as otherwise the pump may be destroyed by overheating!

7. Accelerate for a moment (max. 3 seconds) to full speed and read the pressure gauges.

Nominal value: 480 -20 bar 8. If necessary adjust the high pressure relief valves (Fig. 5).

9. Repeat this test to the opposite travel direction.

10. Repeat these tests for the rear pump.

Fig. 5

11. Adjust the pressure override (Fig. 6) on the front pump to 430 bar (high pressure measurement on front pump!).

12. Adjust the pressure override on the rear pump to 430 bar (high pressure measurement on rear pump).

Caution If the pressure override is not correctly adjusted on one of the pumps (remains blocked) the high pressure in the respective circuit may increase up to the setting of the high pressure relief valves.

Fig. 6

13. Perform the same tests for the second tandem pump.

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&KDUJH SXPS KLJK SUHVVXUH WHVW 2.5 Charge pump high pressure test Special tools: Gear pump testing device, 600 bar pressure gauge.

1. Close the pump outlet port with a 200 bar pressure gauge (Fig. 1) fitted with a pressure gauge.

Hold the open end of the hose into a collecting vessel.

2. Crank the engine with the starter (pull the plug off the solenoid valve or keep the engine shut-down depressed).

3. Read the pressure gauge.

Nominal value: 200 bar

Fig. 1

28

4. If the nominal value is not reached, replace the charge pump.

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7UDYHO SXPS KLJK SUHVVXUH WHVW LQGLYLGXDO WHVW

2.6 Travel pump high pressure test (individual test) 1. Close the high pressure ports (Fig. 1) on one travel pump with plugs.

Fig. 1

2. Input module (Fig. 2) enter PIN-CODE.

Fig. 2

Danger Pull the electric plugs A and B (Fig. 3) off the magnets on the other pumps, because the machine might drive through the brake.

Fig. 3

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3. Connect a 600 bar pressure gauge to the high pressure test port of the pump (Fig. 4).

L Note Do not actuate the emergency stop.

4. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction 5. Raise the engine speed for a moment and read the pressure gauge.

Nominal value: 410 to 440 bar Fig. 4

30

6. If the nominal value is not reached, check pressure override and high pressure relief valves. If the valves are o.k., replace or repair the travel pump.

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&KHFNLQJ FKDUJH SUHVVXUH 2.7 Checking charge pressure

1. Run the machine until operating temperature is achieved, then shut down the engine.

2. Block the front charge pressure relief valve 1 (Fig. 1) on a tandem pump, turn the setscrew completely in to do so.

3. Connect a 60 bar pressure gauge to the charge pressure test port (3).

4. Start the engine and run it with half speed.

5. Set the rear charge pressure relief valve (2) to 30 bar.

6. Run the engine with maximum speed (the charge pressure increases).

Fig. 5

7. Loosen the blocked valve until the charge pressure of 30 bar is reached again.

8. Check the charge pressure again at idle speed.

Nominal value: min. 28 +/- 2 bar 9. Should the pressure of 28 bar not be reached, repeat the basic adjustment with a pressure higher than 30 bar, but on both valves identical.

10. Check and adjust the other tandem pump accordingly.

008 912 65

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31

$GMXVWLQJ WKH '$ FRQWURO YDOYH 2.8 Adjusting the DA-control valve 1. Warm the machine up to operating temperature.

2. Input module (Fig. 1) enter PIN-CODE. 3.

Select 2nd speed range.

Fig. 1

4. Connect 600 bar pressure gauges to the high pressure test ports (MA or MB) of both tandem pumps (1) / (2) and (3) / (4) (Fig. 2).

5. Start the engine and raise the engine speed to 950 +/- 50 rpm.

6. Select the travel direction in accordance with the chosen high pressure test port (in this illustration reverse) and read the pressure gauge.

L Note Do not operate foot brake and emergency stop.

Nominal value:

Fig. 2

High pressure 50 bar as mean value 7.

Raise the engine speed to 1700 rpm.

Nominal value: High pressure 400 bar

8. If deviations from the nominal value for control start are found the pressure must be adjusted on the corresponding DA-control valve (Fig. 3).

L Note Turn clockwise = control start at higher engine speed.

Turn anti-clockwise = control start at lower engine speed.

Both tandem pumps must be equalized, i.e. for a synchronous operation the adjustment values of right and left hand pumps should be almost identical.

Fig. 3

32

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&KHFNLQJ WKH FRQWURO FKDPEHU SUHVVXUH

2.9 Checking the control chamber pressure 1. Warm the machine up to operating temperature.

2. Input module (Fig. 1) enter PIN-CODE. 3. Select 2nd speed range.

Fig. 1

4. Connect one 60 bar pressure gauge each to the test ports (X1 and X2) (Fig. 2) for control chamber pressure.

5. Start the engine.

L Note Do not operate foot brake and emergency stop.

Nominal value: Engine speed 950 rpm: approx. 6 bar Engine speed 1700 rpm: approx. 12...14 bar Fig. 2

008 912 65

L Note The measurement of control start and control end under high pressure are much more meaningful than the control chamber pressure, because these measurements actually measure the effective pressure to the wheels.

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33

&KHFNLQJ WKH GLVSODFHPHQW VHWWLQJ RI WKH WUDYHO PRWRUV

Fig. 1

34

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&KHFNLQJ WKH GLVSODFHPHQW VHWWLQJ RI WKH WUDYHO PRWRUV 1

Pilot pressure port (pressure in swashing zylinder)

3

Electric plug, brake solenoid valve

2

High pressure port „G“

4

Setscrew, displacement adjustment

Special tools:

Once the pressure on pressure gauge (2) exceeds 280 bar, the pressure on pressure gauge (1) also starts to increase.

2 x 600 bar pressure gauges 2 pressure test hoses

L Note Always perform this test after replacing one or several motors.

If a new motor was installed, fill, bleed and, if necessary, flush the hydraulic system as described.

1. Run the machine warm in the first speed range, until the hydraulic oil has a reached a temperature of approx. 50 °C. 2. Connect a high pressure gauge 2 (Fig. 1) to port “G“ on the respective motor.

L

Note This pressure gauge shows the load dependent high pressure in travel operation.

When pressure gauge (2) reaches 330 bar, pressure gauge (1) must also reach 380 bar.

At pressure above 380 bar both pressure gauges (2 and 1) must have identical readings.

Evaluation of test: If the specified values are not reached adjust the pilot pressure on screw (4).

L Note If pressure gauge (2) shows 380 bar, while pressure gauge (1) shows less than 380 bar, turn the adjustment screw in anti-clockwise direction.

If pressure gauges (2) and (1) show identical pressure values before reaching 380 bar, turn the adjustment screw in clockwise direction.

6. Repeat this test on all other travel motors.

3. Connect a high pressure gauge (1) to the pilot pressure test port on the motor to be tested.

L

Note This pressure gauge shows the pressure in the swashing cylinder.

Danger Input module, enter PIN-CODE.

Secure all wheels with wedges.

L

Note The adjustments can be made in any travel direction.

4. Start the engine and let it run in idle speed, select second speed range and the respective travel direction.

Caution Do not actuate the emergency stop switch.

5. Slowly raise the engine speed, read both pressure gauges.

Nominal value: As the engine speed increases, the pressure on pressure gauge (2) port “G“ will increase.

The pressure on pressure gauge (2) increases from approx. 29 bar to 280 bar, while pressure gauge (1) does not indicate any pressure.

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&KHFNLQJ WKH VWDQG E\ SUHVVXUH RI WKH VWHHULQJ ZRUNLQJ SXPS 2.11 Checking the stand-by pressure of the steering/working pump 1. Connect a 60 bar pressure gauge to the high pressure test port (Fig. 1).

Caution Do not operate the steering and the dozer blade, since this would destroy the pressure gauge.

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

3. Read the pressure gauge.

Nominal value: 30 +/- 2 bar Fig. 1

36

4. If necessary correct the pressure on the flow control valve.

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&KHFNLQJ WKH KLJK SUHVVXUH RI VWHHULQJ ZRUNLQJ SXPS

2.12 Checking the high pressure of steering/working pump 1. Connect a 600 bar pressure gauge to the high pressure test port (Fig. 1).

2. Start the engine.

Danger Danger of squashing!

Make sure nobody is near the dozer blade.

3. Raise the blade and hold it against the stop or turn the steering wheel against an end stop.

4. Read the pressure gauge.

Nominal value:

Fig. 1

230 +10 bar 5. In case of deviations adjust the pressure regulator.

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38

&KHFNLQJ WKH KLJK SUHVVXUH RI VWHHULQJ ZRUNLQJ SXPS

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3 Trouble shooting

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*HQHUDO

General notes on trouble shooting in hydraulic systems

●

Check the hydraulic oil level before and after the work.

The following tests are performed for fault diagnostics and should enable you to encircle a fault in the hydraulic system.

●

Use only clean oil according to specification.

●

Check the hydraulic system for leaks, find and rectify the cause.

●

Ensure strict cleanliness, clean ports and fittings before disconnecting.

●

Fill new hydraulic units with hydraulic oil before starting operation.

●

After changing a component thoroughly flush and bleed the hydraulic system.

●

AS far as possible conduct all measurements at operating temperature 40 ... 50 °C.

●

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

3.1

General

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

In some cases these tests may also be conducted to identify faults on hydraulic components of the power transmission system.

On the basis of preliminary tests the individual measurements have the purpose to limit the cause of the fault first of all to a general area and then to determine exactly which oil circuit or hydraulic component is not working correctly.

Important points for trouble shooting and fault rectification

Hydraulic hoses Danger Danger of injury

Danger Danger of injury!

Hydraulic hoses must be visually inspected at regular intervals.

Do not touch rotating parts of the engine.

When working on the travel pump and performing tests in the travel circuit block the drums with suitable wheel chocks.

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. Before repressurizing the system make sure that all line connections and ports are in perfect condition.

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 with the genuine shape of the hydraulic hose

●

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

●

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.

When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.

Caution It is not recommended to open or repair hydraulic units and components without comprehensive knowledge.

Risk of damage to pressure gauges if incorrectly connected.

When performing trouble shooting it is assumed that the machine is correctly equipped and connected, that connections and hoses are free of faults and that setscrews have not been deadjusted without permission.

Progressive tests drawn up in the trouble shooting diagram lead to the detection of faults and their rectification by trained personnel. ●

Ensure strict cleanliness, clean ports and fittings before disconnecting.

●

Cover all openings and ports or close with plugs.

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3.2

Trouble shooting diagram

The machine drives with the travel lever in â&#x20AC;&#x17E;NEUTRALâ&#x20AC;&#x153;

Check the control current to the solenoids - Pull the plugs off the magnets of the control, one after the other

Machine stops?

Perform trouble shooting in electric system

yes

no

Check the zero position of the pump - Connect control chamber ports X3 and X4 on one pump with a hose - Start the engine - Repeat this test on all pumps

Machine stops?

no

yes

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7URXEOH VKRRWLQJ GLDJUDP

Adjust the mechanical 0-position - Connect control chamber ports X3 and X4 with a hose - Connect 600 bar pressure gauges to MA and MB. - Check which pump is delivering

- On this pump adjust the 0-position so that the pressure reading is below 60 bar - Repeat this test until the lowest pressure value is reached - Remove the connecting hose, repeat the pressure test Check the control unit - Remove the control unit - Check the smooth movement of the control piston

no Control unit OK?

Replace the control unit

yes Replace, repair the travel pump

42

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The machine does not drive Read fault code and proceed appropriately Check the emergency stop switch - Check whether the emergency stop switch was pressed Note: If necessary select the travel direction again after unlocking or operate the brake

Emergency stop switch OK?

no

Unlock the emergency stop switch, replace if necessary

yes

Check the electric control - Input module, enter PIN-CODE. - Switch the ignition on and select the desired travel direction - Check the voltage Nominal value: 24V

Voltage OK?

no

Perform trouble shooting in electric system

yes

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Check the solenoid - Pull the plug off the solenoid - Connect the adapter cable and measure the current draw Nominal value: approx. 2A

no Replace the solenoid

Current draw OK? yes

no Charge pressure OK?

Check the charge pump, search for cause of pressure drop

yes

Check the coupling on the engine - Loosen the charge pump from the travel pump and pull it off.

ATTENTION: Do not loosen the hoses!

- Loosen the charge pump from the travel pump and pull it off.

Nominal value: - The drive shaft must turn, otherwise the coupling is defective

44

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Machine travels to one direction only or to one travel direction with reduced power Read fault code and proceed appropriately Check the electric control - Input module, enter PIN-CODE. - Switch the ignition on and select the desired travel direction Check the voltage Nominal value: 24V

no

Voltage OK?

Perform trouble shooting in the electric system

yes Check the solenoid - Pull the plug off the solenoid - Connect the adapter cable and measure the current draw Nominal value: approx. 2A

Current draw OK?

no

Solenoid charge pump

yes

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7URXEOH VKRRWLQJ GLDJUDP

Check the high pressure relief valve - Interchange the high pressure relief valves

yes Travel direction changes

Replace the corresponding high pressure relief valve

no Check the swash time nozzles - Unscrew the nozzles from ports X1 and X2 and check for blockage

no Nozzles OK?

Clean/replace the nozzles

yes

46

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Replace the control

Travel direction changes? no

Replace/repair the travel pump

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7URXEOH VKRRWLQJ GLDJUDP

Hydraulic oil overheating

Check the engine cooling system - Check the hydraulic oil cooler for dirt - Check the engine cooling fan - Inspect the air intake box on the cabin roof for dirt

Radiator OK?

no

Clean a dirty radiator or repair the cooling system

yes

Check the high pressure limitation - Pull the plug off the brake solenoid valve - Start the engine - Actuate the travel lever - Select 2nd speed range - Run the engine with maximum speed .

- Check whether the high pressure relief valves heat up - Repeat this test to the opposite travel direction

Valve heating up?

no

Check the pressure setting of high pressure relief valves and pressure override, adjust or replace as necessary

yes Check the thermostat - Run the machine up to operating temperature (hydraulic oil temperature55°C).

- Check, whether the hose to the hydraulic oil cooler warms up at an hydraulic oil temperature of more than 70°C or becomes

Thermostat OK?

48

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no

Replace the thermostat

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Insufficient travel power, max speed is not reached

Pressure and speed test - Run the machine warm to operating temperature (approx. 50°C hydraulic oil temperature) - Input module, enter PIN-CODE.

- Connect 600 bar pressure gauges high pressure sides of the travel pumps (pos. 1 to 4) - Connect 60 bar pressure gauges for pilot pressure (Pos.7 and 8) - Connect 60 bar pressure gauges for charge pressure (Pos. 5 and 6) - Start the engine, select 2nd speed range and switch to the desired travel direction - Watch the pressure gauges and accelerate the engine slowly up to maximum speed Nominal values: Engine speed min. 2100 rpm; charge pressures must not drop, min. 25 bar Ă­n idle speed, increasing to 30 bar; control chamber pressures must increase evenly; high pressure must increase evenly up to approx. 430 bar.

no Rated speed OK?

Perform trouble shooting on engine

yes

Charge pressure in idle speed ok?

no

yes

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7URXEOH VKRRWLQJ GLDJUDP

Check the brake - Release the brake

- (only if pressure of left hand pump drops below 10 bar)

- Check charge pressure at idle

- Input module, enter PIN-CODE. yes* Charge pressure OK? no*

- * Inform the service department of BOMAG

Check the charge pump - Close the outlet port of the respective pump with a 200 bar pressure relief valve - Connect a 600 bar pressure gauge - Crank the engine with the starter (pull the plug off the engine shut-down solenoid) Nominal value: 200 bar

Pressure OK?

yes

Replace the charge pump

no*

50

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Check the individual components - Disconnect the high pressure hoses from one pump - Close the pump ports with plugs - Repeat the pressure test - Perform this test also on the other pump

yes Charge pressure

Replace/repair the corresponding travel motor

no

Replace/repair the corresponding travel pump

no Pilot pressure OK? yes

Check and adjust the DA-control valve - Unscrew and check the DA-control valve, replace it if necessary - Adjust the DA-control valve Nominal value: 1220 rpm engine speed 150 bar high pressure 1890 rpm engine speed 390 bar high pressure Pilot pressure evenly increasing

Pilot pressure OK? no

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7URXEOH VKRRWLQJ GLDJUDP

Checking the pressure override - Turn the adjustment screw completely in (block).

- Repeat the pressure test Attention: Relieve through the high pressure relief valves for max. 3 seconds!

Pilot pressure OK? no

Replace/repair the travel pump

High pressure OK?

no

yes - Mechanical damage in travel motors

Check the swash time nozzles - Unscrew the swash time nozzles from X1 and X2 and check them

- Engine power too low

52

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Nozzles OK?

no

Clean/replace the nozzles

yes Check the individual components - Disconnect the high pressure hoses from one pump - Close the pump ports with plugs - Repeat the pressure test - Perform this test also on the other pump

no High pressure OK?

Replace/repair the travel pump with the too low pressure

yes

Replace/repair the corresponding travel motor

008 912 65

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7URXEOH VKRRWLQJ GLDJUDP

No steering function / steering stiff, end stops are not reached

Read fault code and proceed appropriately Check the steering/dozer blade pump - Connect a 600 bar pressure gauge to the high pressure test port - Start the diesel engine and turn the steering wheel against an end stop - Read the pressure gauge Nominal value: 230 bar Stand-by: 30 bar

High pressure OK?

yes

Replace the flow booster

no

Check the load signal to the steering/dozer blade pump - Connect a 600 bar pressure gauge to pressure test port X on the pump - Operate the steering while the engine is running and read the pressure gauge. Depending on the load the pressure should increase up to.

LS-signal OK?

yes

Replace/repair the steering/dozer blade pump

no

Replace/repair the valve block

54

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7URXEOH VKRRWLQJ GLDJUDP

Central lubrication system not working (lubricant emerging from the relief valve)

Check the grease pump - Remove the lubrication hose - Connect a 600 bar pressure gauge - Close the lubrication hose with a plug - Switch the pump on and press the push button several times Nominal value: Raise the pressure to approx. 350 bar, grease emerging from the relief

no Pressure OK? yes

Check the pressure relief valve

no

Valve OK?

Replace the pressure relief valve

yes

Replace the lubrication pump

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7URXEOH VKRRWLQJ GLDJUDP

Check the main distributor

- Loosen the top and bottom lubrication hoses, one after the other

- Reconnect the lubrication hose - Connect a grease gun to the grease nipple and apply a pressure of 200 bar

- The hose from which grease comes flowing out indicates in which branch the blockage can be found - Reconnect the hoses

Changing/cleaning the main distributor

none Grease emerging

top

bottom

Replace, clean the respective sub-distributor

56

yes

no Grease emerging

Check the sub-divider in the front frame

Check the sub-distributor in the rear frame

- Generate a pressure of 200 bar with the grease gun and loosen the lubrication hoses one after the other. The hose from which grease comes flowing out indicates the block-

- Generate a pressure of 200 bar with the grease gun and loosen the lubrication hoses one after the other.

The hose from which grease comes flowing out indicates the

Repair the respective bearing location

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4 Oscillating articulated joint

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57

5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW 4.1 Removing and installing live ring, oscillating articulated joint Disassembling the live ring

Danger Safely support front and rear frames as well as oscillating articulated joint.

Danger of squashing!

1. Remove the front cover 1 (Fig. 1), remove the rear cover

Fig. 1

2. Disassemble the cover 1 (Fig. 2) from above the hoses.

Fig. 2

3. Remove cover 1 (Fig. 3) from the front frame.

Fig. 3

58

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5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW

4. Raise the dozer blade to end position and tie it to the front frame in this position (Fig. 4). Support the raised dozer blade with wooden blocks so that the front frame can be moved forward.

5. Release the brakes on both front final drives.

Danger Before releasing the multi-disc brake secure the machine against unintended rolling.

6. Remove the brake lines.

Fig. 4

7. Install measuring adapters 1 and 2 (Fig. 5) to the disconnected brake line and the free port on the final drive. Connect the installed measuring adapters with a pressure test hose (3).

8. Start the engine, the multi-disc brake will open automatically.

9. After releasing the brake shut down the engine.

Disconnect the pressure test hose from the measuring adapter fitted to the port on the final drive.

Danger Front drive without brake, secure the front frame against rolling.

Fig. 5

10. Connect a vacuum pump and generate a vacuum in the hydraulic oil tank.

11. Mark all hydraulic lines, hoses and electrical lines from the front to the rear frame, disconnect them from the connection points in the front frame, remove the hose clamps and lay the hoses down.

Close all connections immediately with plugs.

L Note Ensure correct routing of hoses and lines in the roller guide 1 (Fig. 6).

12. Drain or pump the fuel from the fuel tank.

Caution Fire hazard! Do not smoke, do not use open fire!

Fig. 6

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5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW 13. Safely support the rear end of the rear frame on both sides 1 (Fig. 7).

Danger Danger of squashing!

Fig. 7

14. Attach lifting tackle to the front frame.

15. Front lifting points 1 (Fig. 8).

Fig. 8

16. Rear lifting points 1 (Fig. 9).

Fig. 9

17. Front frame safely suspended by lifting gear (Fig. 10).

Danger Do not stand or step under loads being loaded.

Danger of squashing!

Fig. 10

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5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW

18. Place a plastic pad 1 (Fig. 11) under the steering cylinder rod.

19. Disconnect the lubrication hoses from connections (2).

20. Remove the bars and knock out the bolts (3).

L

Note Grease the parts.

Fig. 11

21. Unscrew all hexagon screws 1 (Fig. 12) from the console

L Note Cover the threads with copper paste.

Tightening torque: 418 Nm 22. Move the front frame carefully forward for approx.

2 m, until the oscillating articulated joint is free.

Danger Secure dozer blade or front frame against turning over.

Danger of squashing!

Do not step or work under suspended loads.

Danger of squashing!

Fig. 12

23. Support front frame and dozer blade in a safe manner.

24. Disassemble roller guide 1 (Fig. 13) from the tank 25. Attach the lifting tackle to the fuel tank.

Fig. 13

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5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW 26. Unscrew the rear hexagon screws from fuel tank 1 (Fig. 14).

Fig. 14

27. Remove the front bracket (Fig. 15) from the tank 28. Lift the fuel tank out of the front frame.

Fig. 15

29. Disconnect lubrication hoses 1 (Fig. 16) from the connections on the live ring. Unscrew socket (2).

30. Attach the lifting tackle to the oscillating articulated joint.

Danger Danger of squashing!

Fig. 16

31. Disconnect the top and bottom grease hoses 1 (Fig. 17) from the connections on the bearings from the inside.

Fig. 17

62

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5HPRYLQJ DQG LQVWDOOLQJ OLYH ULQJ RVFLOODWLQJ DUWLFXODWHG MRLQW

32. Unscrew the socket head cap screws 1 and 2 (Fig. 18) from the live ring.

33. Take the live ring off completely.

Fig. 18

L

Note Tighten the outer socket head cap screws 2 (Fig. 19) first, then lubricate the live ring. During the lubrication process keep turning the live ring and lubricate until the grease emerges from the sealing lip.

34. Align and fasten the live ring accordingly (Fig. 19).

G = position of lubrication bores B = position of filler plug Tightening torque: 419 Nm 35. Extract the oscillating articulated joint completely.

Fig. 19

36. Replace screws and sleeves 3 (Fig. 19).

37. Use a sleeve (Fig. 19) for each screw.

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63

5HSDLULQJ WKH RVFLOODWLQJ DUWLFXODWHG MRLQW

Fig. 1

64

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5HSDLULQJ WKH RVFLOODWLQJ DUWLFXODWHG MRLQW 1

Pivot bearing

9

Snap ring

2

Central block

10 Seal ring

3

Console

11 Bolt

4

Taper roller bearing

12 Sleeve

5

Dirt scraper

13 Cover

6

Hexagon screw

14 Flanged cover

7

Hexagon screw

15 Washer

8

Roll pin

1. Store the disassembled oscillating articulated joint safely.

Danger Danger of squashing!

2. Unscrew the hexagon screw 6 (Fig. 1).

3. Take off cover (13) and disc (15).

L Note Insert roll pin (6) into the bore of the disc.

4. Attach the lifting tackle to the console (3).

Danger Danger of squashing!

5. Drive bolt (11) with a mandrel.

L Note Grease the bolt.

6. Knock sleeves (12) out of the console.

7. Unscrew hexagon screws (6) from the flanged cover (14).

8. Take off the flanged cover (14).

9. Remove the dirt scraper (5).

L Note Assemble the new dirt scraper with grease.

10. Take out the snap ring (9)..

11. Knock out the taper roller bearing (4), take out the inner dirt scrapers (5).

L

Note Assemble the new dirt scraper with grease.

Use new taper roller bearings.

12. Check the pivot bearings (1) for the steering cylinders, if necessary assemble new ones.

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66

5HSDLULQJ WKH RVFLOODWLQJ DUWLFXODWHG MRLQW

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5 Repairing the brake in the final drive.

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67

5HSDLULQJ WKH EUDNH LQ WKH ILQDO GULYH 5.1 Repairing the brake in the final drive Special tools: Clamping device Widening mandrel Manual hydraulic press Caution Opening the gearbox causes the loss of warranty and policy adjustment claims.

Disassembling the brake 13. Clamp shim 1 (Fig. 1) with the clamping device until the circlip (2) is unloaded.

14. Unclip the circlip from the groove, relieve and remove the clamping device.

Fig. 1

15. Remove circlip 2 (Fig. 2) and shim (1).

Fig. 2

16. Insert the widening mandrel (Fig. 3) into the driver and clamp it.

Fig. 3

68

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5HSDLULQJ WKH EUDNH LQ WKH ILQDO GULYH 17. Pull brake 1 (Fig. 4) out of the gearbox.

18. Remove one outer disc (2) and shim (3) from the gearbox.

Fig. 4

19. Pull the grooved ball bearing (Fig. 5) from the driver.

20. Clean all parts and check for wear.

21. Replace damaged parts.

Fig. 5

Assembling the brake 1. Assemble the grooved ball bearing 1 (Fig. 6).

2. Insert the shim (2).

Fig. 6

3. Assemble the brake discs (Fig. 7).

L Note The disc pack consists of 10 outer (1) and 9 inner discs (2), which are alternately assembled.

Caution The start and end discs are both outer discs!

Fig. 7

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69

5HSDLULQJ WKH EUDNH LQ WKH ILQDO GULYH 4. Guide driver 1 (Fig. 8) through the brake discs and press the shaft into the grooved ball bearing underneath.

Fig. 8

5. Insert the oiled seal pack 1 (Fig. 9) into the bearing axle and press it again the end stop.

Caution Ensure correct positioning (3) of the seal ring.

The last outer disc (2) must still be freely moveable!

Fig. 9

6. Insert the oiled piston 1 (Fig. 10) into the bearing axle and press it again the end stop.

7. Insert the pressure springs (2 and 3) into the bores in the piston.

8. Attach shim (5).

Fig. 10

9. Insert circlip 2 (Fig. 11).

Fig. 11

70

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5HSDLULQJ WKH EUDNH LQ WKH ILQDO GULYH

10. Press shim 1 (Fig. 12) down with the clamping device until circlip (2) can be installed.

Caution Make sure that the circlip is correctly mounted.

11. Remove the clamping device, vent the brake several times with the manual hydraulic press (pmax = 50 bar) and check for leaks (pressure drop).

Fig. 12

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71

72

5HSDLULQJ WKH EUDNH LQ WKH ILQDO GULYH

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6 Suppliers documentation

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73

74

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6.1

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Travel pump A4VG 71 ... 180

%20$*

75

76

7UDYHO SXPS $ 9*

%20$*

008 912 65

7UDYHO SXPS $ 9*

RDE 92003-02-R/05.99 ersetzt / replaces RDE 92003-02-R/06.98

Reparaturanleitung Repair instructions

008 912 65

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A4VG 71 - 180 / Baureihe 32 A4VG 71 - 180 / Series 32

77

78

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008 912 65

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7UDYHO SXPS $ 9*

Schnittbild

Reparaturanleitung A4VG Repair Instructions A4VG

Sectional view

HW/D

HD/D

EP/D

Brueninghaus Hydromatik

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Schnittbild

Sectional view

Repair Instructions A4VG

DA/D

4

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Reparaturanleitung A4VG

Turcon-Glyd-Ring Dichtung

Repair Instructions A4VG

Turcon-Glyd-ring seal

Deckel

Stelldruck

FĂźhrungsbuchse Stellzylinder

Turcon-Glyd-Ring LeckÜl Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung der Verstellung auf Turcon-Dichtungen.

Die Stßckliste der kompletten Einheit erhält dabei eine neue Ident.- Nummer.

TypenschlĂźssel, Typnummer und AuĂ&#x;enabmeĂ&#x;ungen bleiben dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich vom Stellkolben. Stellkolben ändert sich in eine angefaste AusfĂźhrung).

Alten Stellkolben nicht bei Turcon-Dichtung verwenden (scharfkantig - Dichtungen werden beschädigt).

Pumpengehäuse / Pump housing mit Lagerbuchse / with bush ALT / OLD

At present the change of the control into Turcon seal is made for A4VG. The parts list of the complete unit will receive a new identification number.

Type reference and outside dimensions remain unchanged (pump housing will change at the area of the positioning piston. Positioning piston will change into chamfering design).

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

Pumpengehäuse / Pump housing mit Turcon-Dichtung / with Turcon seal *

NEU / NEW *

Die Umstellung der Verstellung auf TurconDichtung ist im allgemeinen mit einer Funktionsverbesserung verbunden (DA-Verhalten, geringerer TemperatureinfluĂ&#x; auf Stellzeiten).

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

Bei gleicher Dßsenbestßckung kÜnnen sich die Stellzeiten geringfßgig verändern.

The control times will slightly change with the same throttle sections. Therefore our customers have to be informed about this change.

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Allgemeine Reparaturhinweise General repair instructions

Repair Instructions A4VG

Achtung!

Nachfolgend Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten!

Attention!

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

Alle Ă&#x2013;ffnungen der Hydraulikaggregate verschlieĂ&#x;en.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur original HYDROMATIK-Ersatzteile verwenden.

Replace all seals.

Use only original HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf VerschleiĂ&#x; prĂźfen.

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

Check all seal and sliding surfaces for wear.

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

Hydraulikaggregate vor Inbetriebnahme mit Betriebsmedium befĂźllen.

Fill up hydraulic aggregates with medium before start- up.

6

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008 912 65

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Dichtsätze und Baugruppen

Reparaturanleitung A4VG

Seal kits and sub assembly groups

Repair Instructions A4VG

1

Dichtsatz fĂźr Triebwelle.

Seal kit for drive shaft.

2

Ă&#x201E;uĂ&#x;erer Dichtsatz.

External seal kit.

3

Triebwerk komplett.

Complete rotary group.

4

Stellkolben Positioning piston

5

AnschluĂ&#x;platte Valve plate

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Baugruppen

Repair Instructions A4VG

Sub assemblies

6

Ansteuergeräte HW, HD, EP Hinweis: NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HW, HD, EP Note: Size 71 control device as size 40 - 56 with flat seal.

7

Ansteuergerät DA Hinweis: NG 71 wie NG 40 - 56 mit Flachdichtung.

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

8

Hilfspumpe Boost pump

9

Regelventil Control valve

10

HD - Ventil High pressure valve

8

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Reparaturanleitung A4VG

Sub assemblies

Repair Instructions A4VG

11

ND - Ventil Low pressure valve

12

Druckabschneidung Pressure cut-off

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Triebwelle abdichten

Repair Instructions A4VG

Sealing of the drive shaft

13 14

Triebwelle abkleben.

Sicherungsring ausbauen.

Protecting the drive shaft.

Remove retaining ring.

15

Blechschraube in die mit Gummi gefĂźllten LĂścher eindrehen.

Mit Zange WDR herausziehen.

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

Pull out shaft seal with pliers.

16

Wellendichtring mit Buchse auf Anschlag einpressen.

Sicherungsring einbauen.

Press-in shaft seal with bush to stop.

Assemble retaining ring.

10

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Reparaturanleitung A4VG

Sealing of the boost pump

Repair Instructions A4VG

Achtung! * Angefaste "Seite" zum Deckel montieren.

Note! * Mount chamfered side facing cover.

17 18

Lage kennzeichnen, Befestigungsschrauben ausbauen.

Mark position, remove fixing screws.

19

Deckel abdrĂźcken.

Pry-off cover.

20

Kontrolle: O-Ring, Nut, Lauffläche, AnschluĂ&#x;platte.

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

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Stellkolbendeckel abdichten

Repair Instructions A4VG

Sealing of the control piston cover

Achtung!

Korrekt mechanische 0-Lageneinstellung ĂźberprĂźfen Attention!

Check correct mechanical 0-position.

21 22

Lage kennzeichnen.

Mark position.

23

Deckel verdrehen und mit leichten Hammerschlägen lÜsen.

Rotate cover and release by tapping gently with hammer.

12

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RDE 92003-02-R/05.99

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Reparaturanleitung A4VG

Sealing of the control piston cover

Repair Instructions A4VG

24

Deckel kennzeichnen. MaĂ&#x; festhalten, Kontermutter lĂśsen, Stellschraube gegenhalten.

Mark cover. Must be fixed, loosen counter nut, hold adjustment screw.

25

Deckel demontieren.

Remove cover.

26

Deckel von Stellschraube "abschrauben".

Lift off by turning the setting screw.

27

Kontrolle!

O-Ring (1), Nut (2), Gehäuse (3).

Check!

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

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Speisedruckventil abdichten Sealing of the boost pressure valve

Repair Instructions A4VG

28 29

Ventil komplett ausbauen.

Hinweis: Einstellschraube nicht verändern.

Achtung!

Nach Einbau Ventileinstellung ĂźberprĂźfen!

Remove valve completely: Note: Do not change adjustment screw.

Attention!

Check valve setting after installation.

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Reparaturanleitung A4VG

Sealing of the pressure relief valve HD

Repair Instructions A4VG

Druckbegrenzungsventil abdichten

30 31

Ventil komplett ausbauen.

Kontrolle: O-Ring, Gehäuse.

Wechsel der Dichtmutter - EinstellmaĂ&#x; (*) festhalten.

Achtung!

Nach Einbau "Ventileinstellung" ĂźberprĂźfen.

Remove valve completely.

Control: O-ring, housing.

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

Attention!

After assembly check "valve setting".

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Sealing of the pressure cut-off

Repair Instructions A4VG

32 33

Einstellteil komplett ausschrauben.

Kontrolle: O-Ring, Gehäuse.

Wechsel der Dichtmutter - EinstellmaĂ&#x; (*) festhalten.

Achtung!

Nach Einbau "Ventileinstellung" ĂźberprĂźfen.

Unscrew setting cartridge completely.

Control: O-ring, housing.

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

Attention!

After assembly check "valve setting".

16

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7UDYHO SXPS $ 9* Ansteuergerät abdichten

Reparaturanleitung A4VG

Sealing of the control device

Repair Instructions A4VG

DA

HD

HW

EP

NG 71 ... 125 DA

NG 180

Ansteuergerät abbauen.

Remove control device.

Hinweis: NG 71: Abdichtung der Ansteuergeräte wie NG 40 - 56 mit Flachdichtung.

Achtung!

Korrekte hydraulische Nullageneinstellung ĂźberprĂźfen.

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

Attention!

Check correct hydraulic 0-position.

34 Brueninghaus Hydromatik

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Ansteuergerät HW

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Control device HW

Repair Instructions A4VG

35

Kontrolle: O-Ringe und Dichtung.

Check: O-rings, gasket.

36 18

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Ansteuergerät HD

Reparaturanleitung A4VG

Control device HD

Repair Instructions A4VG

Kontrolle: O-Ringe Check: O-rings

37

38 Brueninghaus Hydromatik

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Ansteuergerät EP

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Control device EP

Repair Instructions A4VG

Kontrolle: O-Ringe und Dichtung.

Check: O-rings, gasket.

39

40 20

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Ansteuergerät DA

Reparaturanleitung A4VG

Control device DA

Repair Instructions A4VG

Kontrolle: O-Ringe Check: O-rings

41

Ablaufdrossel

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Regelventil abdichten/ĂźberprĂźfen

Repair Instructions A4VG

Sealing of the regulator valve

43 44

Blende ĂźberprĂźfen.

Keine Beschädigung.

Inspect orifice.

No damage.

45

Gewinde abkleben.

O-Ring einsetzen.

Cover threads.

Insert O-ring.

22

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Reparaturanleitung A4VG

Removing of the pump

Repair Instructions A4VG

VerschluĂ&#x;schraube / Stift Locking screw / pin

Verdrillschraube Timing adjustment screw

46 47

Ansteuergerät abbauen.

Remove control device.

48

Hilfspumpe ausbauen.

Hinweis: Einbaulage kennzeichnen.

Remove auxiliary pump.

Note: Mark assembly position previously.

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Pumpe demontieren

Repair Instructions A4VG

Pump disassembly

49

Lage der Verdrillschraube markieren (1).

EinstellmaĂ&#x; festhalten.

Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).

Record setting measure.

Set the indexing screw to disassembly position (2).

50

Lage der Hilfspumpe und AnschluĂ&#x;platte markieren.

AnschluĂ&#x;plattenbefestigung lĂśsen.

Mark position of the connection plate.

Loosen connection plate fixation.

51

AnschluĂ&#x;platte und Steuerplatte abheben.

Lift off port plate and control plate.

52

1. Zylinder nach unten drĂźcken.

2. Verdrillschraube herausdrehen.

1. Press the cylinder to the bottom.

2. Remove fixing indexing screw.

53

Zylinder komplett mit Kolben und RĂźckzugeinrichtung ausbauen.

Push off hydraulic section of rotary group.

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Reparaturanleitung A4VG

Pumpe demontieren

Repair Instructions A4VG

Pump disassembly

54

Seegerring / WDR ausbauen.

Remove retaining ring and radial seal ring.

55

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slide hammer strokes.

56

Schwenkwiege / Lager komplett ausbauen.

Remove swash plate / bearing cups.

Gelenkstift ausbauen.

Remove joint pin.

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Verstellung demontieren

Repair Instructions A4VG

Dismantling of the control

58

59

Lage vom Deckel markieren, MaĂ&#x; "Nullage" festhalten, Mutter lĂśsen.

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

Loosen nut.

60

Deckel abdrehen.

Remove cover.

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Reparaturanleitung A4VG

Verstellung demontieren

Repair Instructions A4VG

Dismantling of the control

61

Lage des Deckels markieren.

Befestigungsschrauben lรถsen, abbauen.

Mark position of the cover.

Loosen locking screw, remove cover.

62

Stellzylinder ausbauen.

Remove positioning ring.

63 64

Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.

Fit tool device and preload spring.

Remove take-off ring.

65

Ringe ausbauen.

Sicherungsring ausbauen.

Achtung: Teile stehen unter Federvorspannung.

Remove rings.

Remove safety ring.

Attention: Parts are under spring load.

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Zylinder demontieren

Repair Instructions A4VG

Dismantling of the cylinder

66

Kolben mit RĂźckzugeinrichtung ausbauen.

Tragkugel mit Tellerfedersäule abheben.

Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.

67 68

Sicherungsring ausbauen.

Remove safety ring.

69

Scheibe 1, 2 Disc 1, 2

1 28

2

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Reparaturanleitung A4VG

Inspection notes

Lager Bearing

Repair Instructions A4VG

Lagerschalen Bearing cup

70

Kontrolle!

Käfig-Paar (1), Lagerschalenpaar (2).

Check!

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

71

Kontrolle!

Lagerbahnen (1) Check!

Bearing surfaces (1)

72

Kontrolle!

Gleitfläche riefenfrei.

Check!

Sliding surface free from scoring.

73

Kontrolle!

RĂźckzugeinrichtung riefenfrei.

Check!

Check that return device is free of scoring.

74

Kontrolle!

1. Verzahnung "ausgeschlagen", Passungsrost.

2. Laufflächen.

3. Lauffläche - Wellendichtring.

Check!

1. Splines for damage or fretting.

2. Running surfaces.

3. Groove cut by shaft seal.

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Ă&#x153;berprĂźfungshinweise Inspection notes

Repair Instructions A4VG

75

Kontrolle!

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

Check!

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

76

Kontrolle!

Zylinderbohrungen (1), Verzahnungen (2).

Check!

Cylinder bores (1), splines (2).

77

Kontrolle!

Zylindergleitfläche (1) riefenfrei.

Steuerplatte (2) nicht riefig.

Check!

Cylinder surface (1) free of scoring.

Control plate (2) without scoring.

78

Kontrolle!

Stellkolben - Schwenkwiegenverbindung Gleitstein (1), Nut im Stellkolben (2), Stellkolben.

Check!

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

Positioning piston.

30

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Reparaturanleitung A4VG

Positioning piston, rotary group assembly

Repair Instructions A4VG

79

Stellkolben montieren.

Hinweis: Auf korrekten Sitz der geteilten Ringe "achten".

Assemble positioning piston.

Instruction: Observe correct fit of the divided rings.

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring Hilfswerkzeuge / Auxiliary tools:

FĂźhrungsdorn / Guide thorn: A4VG28 A4VG40 A4VG56 A4VG71 A4VG90 A4VG125 A4VG180 A4VG250

Montagezange / Assembly pliers: B+S x M22

Montage / Assembly A4VG

I: 277 4 347 I: 277 4 049 I: 277 4 050 I: 277 4 051 I: 277 4 052 I: 277 4 053 I: 277 4 054 I: 277 4 072

1 2 3 3 2 Pos. / Item 1

1

Pos. / Item 2 / 3

Pos. / Item 2 / 3

Pos. / Item 1

Pos. / Item 1: StangenfĂźhrungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

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Stellkolben, Triebwerk montieren Positioning piston, rotary group assembly

Repair Instructions A4VG

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

Dichtring (Pos. 2) in die Montagezange einlegen.

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

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

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

Dichtring ins Gehäuse einfßhren und in der Aufnahmenut plazieren. Dann Spannung lÜsen und Montagezange heraus ziehen. Lage des Dichtringes prßfen - eventuell mit dem Finger egalisieren.

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

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

FĂźhrungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

FĂźhrungsdorn leicht einfetten.

Stellkolben mit FĂźhrungsdorn einbauen.

Grease slightly guide thorn.

Install positioning piston with guide thorn.

32

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Reparaturanleitung A4VG

Positioning piston, rotary group assembly

Repair Instructions A4VG

80

Stellkolben ins Gehäuse einsetzen.

Hinweis: Stellkolben vor Einbau einĂślen.

Insert positioning piston into the housing.

Instruction: Oil positioning piston before assembly.

81

Lagerschalenpaar einsetzen.

Insert bearing cup set.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett Assemble bearing, wire, gliding stone and articulating pin.

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

82 83

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

Repair Instructions A4VG

Installation of the rotary group

Kontrolle:

Sitz der Schwenklager in der Lagerbahn.

Schwenkwiege mit Stellkolben verschwenken "Leichtgängig".

Mittig stellen mit MeĂ&#x;vorrichtung (Uhr oder TiefenmaĂ&#x;) Punkt 1 und 2 kontrollieren - gleiches MaĂ&#x;.

Check:

Location of the swivel-bearing in the bearing.

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

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

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

84 85

Gelenkstift montieren.

Fit joint pin.

34

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

Haltevorrichtung montieren.

Mit Gewindestift Schwenkwiege festhalten.

Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.

Do not use force.

86

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

Teil/Part 4

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â&#x2C6;&#x2026;

â&#x2C6;&#x2026;

â&#x2C6;&#x2026;

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3, 4, 5

Teil/Part 5 â&#x2C6;&#x2026;

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

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

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

Brueninghaus Hydromatik

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Triebwerk einbauen

Repair Instructions A4VG

Installation of the rotary group

87

Neue Montageposition!

Triebwelle mit Lager und Wellendichtring einbauen.

Assemble drive shaft with bearings and radial seal rings.

88

89

Scheibe 1, 2 Disc 1, 2

1

87

2 90

Kolben mit RĂźckzugeinrichtung montieren.

Hinweis: Kolben, Gleitschuhe einĂślen.

Assemble piston with retaining plate.

Note: Oil piston and piston pad.

36

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

91

Vorrichtung ausbauen.

Zylinder mit Kolben und RĂźckzugeinrichtung einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

92

Montagehilfe: Mit O-Ring Kolben festhalten.

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

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Pumpe montieren Assembly of the pump

Repair Instructions A4VG

93

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung!

Geräuschkerben sind drehrichtungsbezogen eingeschliffen.

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

Note!

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

94

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 direction of rotation.

95

Grundeinstellung - Verdrillschraube A4VG...71 * = 28 Âą 0,75 mm A4VG...90 * = 29 Âą 0,75 mm A4VG...125 * = 20 Âą 0,75 mm A4VG...180 * = 22 Âą 0,75 mm.

Basic setting - indexing screw A4VG...71 * = 28 Âą 0,75 mm A4VG...125 * = 20 Âą 0,75 mm

96

A4VG...90 * = 29 Âą 0,75 mm A4VG...180 * = 22 Âą 0,75 mm.

Zylinder nach unten drĂźcken (1).

Verdrillschraube einbauen (2).

Kerbe in Montageposition.

Press the cylinder to the bottom (1).

Screw in the indexing screw (2).

Groove in mounting position.

97

Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

38

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Pumpe montieren

Repair Instructions A4VG

Assembly of the pump

98

Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise rotation.

99

100

AnschluĂ&#x;platte aufbauen.

Achtung! Federvorspannung!

Mit zwei Befestigungsschrauben Ăźberkreuz AnschluĂ&#x;platte in GehäusefĂźhrung einsetzen - Fertigmontage!

Assemble connection plate.

Attention! Spring preloaded!

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

101

Verdrillschraube - Nach Markierung ausrichten.

Locking screw - Observe adjusting measure.

102

1. Deckel montieren.

2. Nullage nach MaĂ&#x; einstellen.

1. Assemble cover 2. Adjust zero position according to measure.

Brueninghaus Hydromatik

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39

Anziehdrehmomente

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9*

Reparaturanleitung A4VG

Tightening torques

Repair Instructions A4VG

Anziehdrehmomente fĂźr Schaftschrauben (Metrisches ISO-Regelgewinde)

Tightening torques for shaft bolts (Metric ISO Standard Thread) Strength Classes

Festigkeitsklassen Die nebenstehenden Werte fĂźr Anziehdrehmomente gelten nur fĂźr Schaftschrauben mit metrischem ISO-

Gewinde grĂśĂ&#x;e

8.8

10.9

12.9

Anziehdrehmoment(Nm)

10.9 2,0

3,1

4,5

5,3

DIN 931 and DIN 933. These values are

M5

6,1

8,9

10,4

also valid only for light or unoiled,

M6

10,4

15,5

18.0

untreated surface as well as for use only

M8

25

37

43

with torque-indicating

M10

51

75

87

wrenches and force limiting tools.

M12

87

130

150

240

M14

140

205

240

370

M16

215

310

370

430

510

M18

300

430

510

430

620

720

M 20

430

620

720

M 22

580

830

970

M 22

580

830

970

M 24

740

1060

1240

M 24

740

1060

1240

M 27

1100

1550

1850

M 27

1100

1550

1850

M 30

1500

2100

2500

M 30

1500

2100

2500

2,3

M4

3,1

4,5

5,3

M5

6,1

8,9

10,4

leicht oder nicht geĂślte, unbehandelte

M6

10,4

15,5

18.0

Oberflächen, sowie nur bei Verwen-

M8

25

37

43

dung von Drehmoment- und Kraftbe-

M10

51

75

87

grenzungsschlĂźsseln.

M12

87

130

150

M14

140

205

M16

215

310

M18

300

M 20

threads and head support surface dimensions in accordance with DIN 912,

GewindegrĂśĂ&#x;e

Bezeichnung

Thread size

Designation

M8x1

VSTI 8 x 1

-ED/SA

=5

M8x1

VSTI 8 x 1

-ED/SA

=4

M 10 x 1

VSTI 10 x1

-ED

= 10

M 10 x 1

VSTI 10 x1

-ED

=7

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 20

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 15

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 30

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 22

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 30

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

= 40

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

= 50

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 37

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 60

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 44

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 70

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 51

M 27 x 2

VSTI 27 x 2

-ED

= 90

M 27 x 2

VSTI 27 x 2

-ED

= 66

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 100

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 74

M 33 x 2

VSTI 33 x 2

-ED/SA

= 120

M 33 x 2

VSTI 33 x 2

-ED/SA

= 88

Anziehdrehmoment(Nm)

Tightening torques (lb.ft)

M 42 x 2

VSTI 42 x 2

-ED/SA

= 200

M 42 x 2

VSTI 42 x 2

-ED/SA

= 147

M 48 x 2

VSTI 48 x 2

-ED

= 300

M 48 x 2

VSTI 48 x 2

-ED

= 220

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

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

Festigkeitsklassen Gewinde

8.8

Strength classes

10.9

12.9

The values for tightening torques shown

Thread

8.8

ziehdrehmomente gelten nur fĂźr Seal-

grĂśĂ&#x;e

Anziehdrehmoment (Nm)

in the table are valid only for seal-lock

Lock Bundmuttern der Festigkeits-

M6

10

nuts of the strength class 8.8 and with

M6

7,4

klasse 8.8 mit metrischem ISO-Regel-

M8

22

metric ISO-standard thread.

M8

16,2

M 10

40

M 10

29,5

M 12

69

M 12

50,9

M 14

110

M 14

81,1

M 16

170

M 16

125,3

gewinde.

Anziehdrehmomente fĂźr Linsenschrauben mit Kreuzschlitz DIN 7985 (Metrisches ISO-Regelgewinde)

size

ziehdrehmomente gelten nur fĂźr Linsenschrauben mit Kreuzschlitz DIN 7985 der Festigkeitsklasse 8.8 mit metrischem ISO-Regelgewinde

Gewinde

8.8

10.9

10.9

12.9

Tightening torque (lb.ft)

Tightening torques for cross-slotted lens head screws DIN 7985 (Metric ISO- Standard Thread)

Festigkeitsklassen Die nebenstehenden Werte fĂźr An-

2,3

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

Anziehdrehmomente fĂźr VerschluĂ&#x;schrauben VSTI (Metrisches Feingewinde)

Die nebenstehenden Werte fĂźr An-

12.9

Tightening Torque(lb.ft) 1,3

2,0

AuĂ&#x;erdem gelten diese Werte nur fĂźr

shaft bolts with metric ISO- standard

size

8.8

M4

1,3

nach DIN 912, DIN 931 und DIN 933.

shown in the table are valid only for

Thread M3

M3

Regelgewinde und KopfauflagemaĂ&#x;en

The values for tightening torques

Strength classes 12.9

grĂśĂ&#x;e

Anziehdrehmoment(Nm)

M3

1,1

M4

2,9

M5

The values for tightening torques shown in the table are valid only for crossslotted lens head screws DIN 7985 of the

Thread size

8.8

M3

0,8

M4

2,1

6

M5

4,4

M6

10

M6

7,4

M8

25

M8

18,4

M10

49

M10

36,1

strength class 8.8 and with metric ISOstandard thread.

10.9

12.9

Tightening torques (lb.ft)

Brueninghaus Hydromatik

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Reparaturanleitung A4VG

Tightening torques

Repair Instructions A4VG

Anziehdrehmomente fĂźr Schaftschrauben (Metrisches ISO-Regelgewinde)

Tightening torques for shaft bolts (Metric ISO Standard Thread) Strength Classes

Festigkeitsklassen Die nebenstehenden Werte fĂźr Anziehdrehmomente gelten nur fĂźr Schaftschrauben mit metrischem ISO-

Gewinde grĂśĂ&#x;e

8.8

10.9

12.9

Anziehdrehmoment(Nm)

10.9 2,0

3,1

4,5

5,3

DIN 931 and DIN 933. These values are

M5

6,1

8,9

10,4

also valid only for light or unoiled,

M6

10,4

15,5

18.0

untreated surface as well as for use only

M8

25

37

43

with torque-indicating

M10

51

75

87

wrenches and force limiting tools.

M12

87

130

150

240

M14

140

205

240

370

M16

215

310

370

430

510

M18

300

430

510

430

620

720

M 20

430

620

720

M 22

580

830

970

M 22

580

830

970

M 24

740

1060

1240

M 24

740

1060

1240

M 27

1100

1550

1850

M 27

1100

1550

1850

M 30

1500

2100

2500

M 30

1500

2100

2500

2,3

M4

3,1

4,5

5,3

M5

6,1

8,9

10,4

leicht oder nicht geĂślte, unbehandelte

M6

10,4

15,5

18.0

Oberflächen, sowie nur bei Verwen-

M8

25

37

43

dung von Drehmoment- und Kraftbe-

M10

51

75

87

grenzungsschlĂźsseln.

M12

87

130

150

M14

140

205

M16

215

310

M18

300

M 20

threads and head support surface dimensions in accordance with DIN 912,

GewindegrĂśĂ&#x;e

Bezeichnung

Thread size

Designation

M8x1

VSTI 8 x 1

-ED/SA

=5

M8x1

VSTI 8 x 1

-ED/SA

=4

M 10 x 1

VSTI 10 x1

-ED

= 10

M 10 x 1

VSTI 10 x1

-ED

=7

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 20

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 15

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 30

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 22

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 30

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

= 40

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

= 50

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 37

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 60

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 44

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 70

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 51

M 27 x 2

VSTI 27 x 2

-ED

= 90

M 27 x 2

VSTI 27 x 2

-ED

= 66

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 100

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 74

M 33 x 2

VSTI 33 x 2

-ED/SA

= 120

M 33 x 2

VSTI 33 x 2

-ED/SA

= 88

Anziehdrehmoment(Nm)

Tightening torques (lb.ft)

M 42 x 2

VSTI 42 x 2

-ED/SA

= 200

M 42 x 2

VSTI 42 x 2

-ED/SA

= 147

M 48 x 2

VSTI 48 x 2

-ED

= 300

M 48 x 2

VSTI 48 x 2

-ED

= 220

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

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

Festigkeitsklassen Gewinde

8.8

10.9

Strength classes 12.9

The values for tightening torques shown

Thread

8.8

ziehdrehmomente gelten nur fĂźr Seal-

grĂśĂ&#x;e

Anziehdrehmoment (Nm)

in the table are valid only for seal-lock

Lock Bundmuttern der Festigkeits-

M6

10

nuts of the strength class 8.8 and with

M6

7,4

klasse 8.8 mit metrischem ISO-Regel-

M8

22

metric ISO-standard thread.

M8

16,2

M 10

40

M 10

29,5

M 12

69

M 12

50,9

M 14

110

M 14

81,1

M 16

170

M 16

125,3

gewinde.

Anziehdrehmomente fĂźr Linsenschrauben mit Kreuzschlitz DIN 7985 (Metrisches ISO-Regelgewinde)

size

ziehdrehmomente gelten nur fĂźr Linsenschrauben mit Kreuzschlitz DIN 7985 der Festigkeitsklasse 8.8 mit metrischem ISO-Regelgewinde

Gewinde

8.8

10.9

10.9

12.9

Tightening torque (lb.ft)

Tightening torques for cross-slotted lens head screws DIN 7985 (Metric ISO- Standard Thread)

Festigkeitsklassen Die nebenstehenden Werte fĂźr An-

2,3

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

Anziehdrehmomente fĂźr VerschluĂ&#x;schrauben VSTI (Metrisches Feingewinde)

Die nebenstehenden Werte fĂźr An-

12.9

Tightening Torque(lb.ft) 1,3

2,0

AuĂ&#x;erdem gelten diese Werte nur fĂźr

shaft bolts with metric ISO- standard

size

8.8

M4

1,3

nach DIN 912, DIN 931 und DIN 933.

shown in the table are valid only for

Thread M3

M3

Regelgewinde und KopfauflagemaĂ&#x;en

The values for tightening torques

Strength classes 12.9

grĂśĂ&#x;e

Anziehdrehmoment(Nm)

M3

1,1

M4

2,9

M5

The values for tightening torques shown in the table are valid only for crossslotted lens head screws DIN 7985 of the

Thread size

8.8

M3

0,8

M4

2,1

6

M5

4,4

M6

10

M6

7,4

M8

25

M8

18,4

M10

49

M10

36,1

strength class 8.8 and with metric ISOstandard thread.

10.9

12.9

Tightening torques (lb.ft)

Brueninghaus Hydromatik

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Sicherheitsbestimmungen

Repair Instructions A4VG

Safety regulations

Allgemein

General advice

¡ Machen Sie sich mit der Ausstattung der Maschine vertraut. ¡ Fahren Sie die Maschine nur, wenn Sie sich vÜllig mit den Bedien- und Steuerelementen sowie der Arbeitsweise der Maschine vertraut gemacht haben. ¡ Benutzen Sie Ihre Schutzausrßstung wie Schutzhelm, Sicherheitsschuhe und GehÜrschutz. ¡ Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ¡ Benutzen Sie die Maschine nur fßr den ihr zugedachten Zweck.

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

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

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

Vor dem Start

Before starting

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

¡ Observe the operating instructions before starting. ¡ Check the machine for obvious faults. ¡ Do not operate the machine with defective instruments, warning lights or control elements. ¡ All safety devices must be in a secure position. ¡ Do not carry with you movable objects or secure them to the machine. ¡ Keep oily and inflammable material away from the machine. ¡ Before entering thc driverâ&#x20AC;&#x2122;s cabin, check if persons or obstacles are beside or beneath the machine. ¡ Be careful when entering the driverâ&#x20AC;&#x2122;s cabin, use stairs and handles. ¡ Adjust your seat before starting.

42

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Sicherheitsbestimmungen

Reparaturanleitung A4VG Repair Instructions A4VG

Safety regulations Starten ¡ Beim Starten mĂźssen alle Bedienhebel in â&#x20AC;&#x153;Neutralstellungâ&#x20AC;? stehen. ¡ Die Maschine nur vom Fahrersitz aus Starten. ¡ PrĂźfen Sie die Anzeigeinstrumente nach dem Start, um sicher zu gehen, daĂ&#x; alles ordnungsgemäĂ&#x; funktioniert. ¡ Lassen Sie die Maschine nicht unbewacht, während der Motor läuft. ¡ Beim Start mit Batterieverbindungskabeln verbinden Sie Plus mit Plus und Minus mit Minus. Massekabel (Minus) immer zuletzt anschliesen und zuerst abtrennen.

Start ¡ When starting all operating levers must be in â&#x20AC;&#x153;neutral positionâ&#x20AC;?. ¡ Only start the machine from the driverâ&#x20AC;&#x2122;s seat ¡ Check the indicating instruments after start to assure that all functions are in order. ¡ Do not leave the machine unobserved when the motor is running. ¡ When starting with battery connection cables connect plus with plus and minus with minus.

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

Vorsicht ¡ Auspuffgase sind lebensgefährlich. Bei Start in geschlossenen Räumen fßr ausreichende Luftzufuhr sorgen!

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

Hydraulikanlage 1. Hydraulikanlage steht unter hohem Druck!

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

Unter hohem Druck austretende Hochdruck-

2.

3.

4.

5.

6.

7.

High pressure fluids (fuel, hydraulic oil) which

FlĂźssigkeiten (Kraftstoff, HydraulikĂśl) kĂśnnen die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen Arzt aufsuchen, da anderenfalls schwere Infektionen entstehen kĂśnnen!

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

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

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

Beim AnschlieĂ&#x;en von Hydraulikzylindern und -motoren ist auf vorgeschriebenen AnschluĂ&#x; der Hydraulikschläuche zu achten!

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

Hydraulikschlauchleitungen regelmäĂ&#x;ig kontrollieren und bei Beschädigung und Alterung austauschen! Die Austauschschlauchleitungen mĂźssen den technischen Anforderungen des Geräteherstellers entsprechen!

2.

3.

4.

5.

6.

7.

escape under high pressure can penetrate the skin and cause heavy injuries.

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

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

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

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

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

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

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!

Ă&#x2013;le, Kraftstoffe und Filter ordnungsgemäĂ&#x; entsorgen!

Brueninghaus Hydromatik

008 912 65

%20$*

119

43

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Einstellhinweise - Mechanische "Nullage"

Repair Instructions A4VG

Adjustment instructions - Mechanical "zero position"

HW

HD

EP

DA

106

Achtung!

Sicherheitsbestimmungen beachten!

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

Manometer an MA und MB anschlieĂ&#x;en.

Nullage so einstellen, daĂ&#x; bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Totband der Nullage - vermitteln.

Attention!

Observe safety regulations!

Connect both control chambers with hose NW6. Avoidance of rest signal from hydraulic zero position.

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

Note: Adjust death line of zero position.

107

44

Brueninghaus Hydromatik

120

%20$*

008 912 65

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9*

Einstellhinweise - Hydraulische "Nullage"

Reparaturanleitung A4VG Repair Instructions A4VG

Adjustment instructions - Hydraulic "zero position"

HW

HD

EP Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

108

Manometer an X1 und X2 anschlieĂ&#x;en.

Nullage so einstellen, daĂ&#x; bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Excenterjustierung - nicht ßber ¹90° verdrehen.

Connect manometer to X1 and X2.

Adjust zero position so that at blocked drive both manometer indicate the same pressure value.

Note: Eccentric adjusting - Do not turn over ¹90°.

109

Brueninghaus Hydromatik

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121

45

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Einstellhinweise - ND-Ventil (Speisedruck)

Repair Instructions A4VG

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung!

Sicherheitsbestimmungen beachten!

Hinweis: Nachjustierung nur bei Betriebstemperatur.

Manometer an "G" anschlieĂ&#x;en.

Achtung! * Speisedruckeinstellung!

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

Hinweis: Einstelldaten nach Werksauftrag. * bei DA-AusfĂźhrung

*

Attention!

Observe safety regulations!

Note: Readjusting only at operating temperature.

Connect manometer to "G".

"G" Attention! * Boost pressure setting!

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

Note: Adjusting data according to order.

110

46

Brueninghaus Hydromatik

122

%20$*

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RDE 92003-02-R/05.99

7UDYHO SXPS $ 9*

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

Reparaturanleitung A4VG Repair Instructions A4VG

Achtung!

Sicherheitsbestimmungen beachten!

Druckabschneidung Pressure cut-off

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

Bei Veränderung eines Einsteilwertes immer beide kontrollieren.

2. Nachjustierung nur bei Betriebstemperatur Manometer an MA und MB anschlieĂ&#x;en.

Druckabschneidung: MaĂ&#x; X Einstellschrauben notieren!

Einstellschraube auf Block drehen.

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

(Nur kurzzeitig "Temperaturâ&#x20AC;&#x153;.)

Drucklos "Einstellwertâ&#x20AC;&#x153; verändern - Kontrolle Druckabschneidung: Einstellschraube auf MaĂ&#x; (*) zurĂźckdrehen.

Druckwert kontrollieren bzw. nachjustieren.

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

Hinweis: Einstelldaten nach Werksauftrag.

111

Attention!

Observe safety regulations.

HP valve without bypass-function HD- Ventile HP- valves

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

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

2. Readjusting only at operating temperature.

Connect manometer MA and MB. Pressure cut-off: Note measure X setting screw! Turn setting screw on block.

HP valves: Operate valves with small pump flow volume.

Check setting value. ("temperatureâ&#x20AC;&#x153; only for a short time).

Change "setting valueâ&#x20AC;&#x153; - check.

112

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!

Brueninghaus Hydromatik

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RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Einstellhinweise - Bypassventil

Repair Instructions A4VG

Adjustment instructions - Bypass valve A4VG 71 - 90

Pos.1 ca. 2 Umdrehungen

10 Nm Pos.1

Anziehdrehmoment / Tightening torque

20 Nm

150 Nm 100 Nm

Pos.1

Neu / New

Alt / Old

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

Vehicle with hydrostatic transmission and gear shift without idling setting position (free wheeling).

Hydrostatischer Antrieb / BypaĂ&#x;-Schaltung

Hydrostatic transmission / Bypass-switching

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. Zu diesem Zweck haben die in der Verstellpumpe integrierten Hochdruckbegrenzungsventile eine sogenannte BypaĂ&#x;-Funktion.

D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird der Ventil-Einsatz so entspannt, daĂ&#x; ein freier Ă&#x2013;l-Umlauf mĂśglich ist.

In this case the travel transmission is switched on to free wheeling.For this purpose the variable displacement pump has incorporated high pressure relief valves with bypass function.

The screw (item 1) is unscrewed to such an extent, that the valve cartridge is released and free oil circulation is possible.

A4VG 125 - 250 Pos.1

48

Bypass-Schaltung ca. 2 Umdrehungen 200 Âą10 Nm

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124

%20$*

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RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Einstellhinweise - DA- Regelung

Reparaturanleitung A4VG

Adjustment instructions - DA control

Repair Instructions A4VG

Achtung!

Sicherheitsbestimmungen beachten! Ă&#x153;berprĂźfung der Einstelldaten Betriebstemperatur soll während des Ă&#x153;berprĂźfungsvorgangs weitgehend konstant gehalten werden.

Antriebsmotor starten, Leerlaufdrehzahl Blockzustand Fahrtrichtungsschalter "0â&#x20AC;&#x153; Motordrehzahl langsam steigern bis zur max.

Motordrehzahl, dabei MeĂ&#x;geräte beobachten.

Speisedruck: Leerlaufdrehzahl Psp = ca. 15-20 bar max. Motordrehzahl Psp = . . . . . . . . bar* Blockzustand Fahrtrichtungsschalter - vorwärts (StraĂ&#x;engang und Festgebremst)

Verdrillung Regelbeginn

114

Einstelldaten Pumpe A4V/DA ĂźberprĂźfen Regelbeginn HD 40 - 50 bar Motordrehzahl . min.1 * Psp . . . . . bar* HD . . . . . . bar Nachjustierung - Regelbeginnschraube Regelende HD . . . . . bar* Motordrehzahl . . . . . min.1 * Psp . . . . . bar* Nachjustierung - Verdrillschraube Hinweis: Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

115

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125

49

RDE 92003-02-R/05.99

7UDYHO SXPS $ 9* Reparaturanleitung A4VG

Einstellhinweise - DA- Regelung

Repair Instructions A4VG

Adjustment instructions - DA control

Attention!

Observe safety regulations!

Check setting data.

Operating temperature should be kept largely constant during the check procedure.

Start prime mover, idle speed.

Block position Drive direction switch - "0â&#x20AC;&#x153;.

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

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

Timing adjustment screw Begin of control

116

Check setting data pump A4VIDA Begin of control: HD 40 - 50 bar Motor speed . . . . . rpm* Psp . . . . . . . bar* HD . . . . . . . bar* Readjusting - control start screw End of control HD . . . . . . . . bar Motor speed . . . . . . rpm* Psp . . . . . . . bar* Readjusting timing adjustment screw Note: Eccentric adjusting - observe direction of rotation * Setting data according to order!

117

Brueninghaus Hydromatik GmbH, Werk Elchingen, GlockeraustraĂ&#x;e 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

50

Brueninghaus Hydromatik

126

%20$*

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008 912 65

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128

7UDYHO SXPS $ 9*

%20$*

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6.2

008 912 65

Travel motor A6VM 28 ... 200

%20$*

129

130

7UDYHO PRWRU $ 90

%20$*

008 912 65

7UDYHO PRWRU $ 90

Reparaturanleitung / Repair instructions A6VM 28...200 / 63

RDE 91604-01-R/08.01 ersetzt / replaces RDE 91604-01-R/08.99

Mobile Hydraulics

008 912 65

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131

7UDYHO PRWRU $ 90 Reparaturanleitung A6VM

Type code

Repair Instructions A6VM

RDE 91604-01-R/08.01

TypschlĂźssel

Typschlßssel A6V M Axialkolbenmaschine Schrägachsenbauart, verstellbar

A6V

Betriebsart Motor (Einschubmotor A6VE siehe RD 91606) NenngrĂśĂ&#x;e â&#x2030;&#x2026; Schluckvolumen Vg max (cm3)

/ 6 3 W

M 28 55 80 107 140 160 200

N G 28...200: Fertigung Werk Elchingen

Regel- und Verstelleinrichtung Hydraulische Verstellung Steuerdruckanstieg steuerdruckabhängig

10 bar HD1 25 bar HD2 35 bar HD3 Hydraulische Zweipunktverstellung HZ HZ1 HZ3 Elektrische Verstellung, Steuerspannung 12 V EP1 mit Proportionalmagnet 24 V EP2 Elektrische Steuerspannung 12 V EZ1 Zweipunktverstellung, 24 V EZ2 mit Schaltmagnet 12 V EZ3 24 V EZ4 Automatische Verstellung, ohne Druckanstieg HA1 hochdruckabhängig mit Druckanstieg â&#x2C6;&#x2020;p = 100 bar HA2 Hydraulische Verstellung, drehzahlabhängig DA pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 elektrisches Fahrtrichtungsventil 12 V DA2 + elektrische Vg max-Schaltung 24 V DA3 pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 elektrisches Fahrtrichtungsventil 12 V DA5 + elektrische Vg max-Schaltung 24 V DA6

Druckregelung (nur fĂźr HD, EP) ohne Druckregelung (kein Zeichen) Druckregelung, direktgesteuert direktgesteuert, mit 2. Druckeinstellung fernsteuerbar

28 55 80 107 140 160 200

â&#x20AC;&#x201C; â&#x20AC;&#x201C;

â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C;

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* * * . * * * * *

* * * * * * * * *

28 55 80 107 140 160 200

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Ă&#x153;bersteuerung der HA-Verstellung (nur fĂźr HA1, HA2) ohne Ă&#x153;bersteuerung (kein Zeichen) hydraulische Ă&#x153;bersteuerung elektrische Ă&#x153;bersteuerung Steuerspannung 12 V 24 V elektrische Ă&#x153;bersteuerung Steuerspannung 12 V + elektrisches Fahrtrichtungsventil 24 V

D E G

T U1 U2 R1 R2

* Differentialkolben

2

HD1 HD2 HD3 HZ HZ1 HZ3 EP1 EP2 EZ1 EZ2 EZ3 EZ4 HA1 HA2 DA DA1 DA2 DA3 DA4 DA5 DA6

Gleichgangkolben

Brueninghaus Hydromatik

132

%20$*

008 912 65

RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90

Reparaturanleitung A6VM

TypschlĂźssel

Repair Instructions A6VM

Type code Type code Axial piston unit Bent axis design, variable displacement

/ 6 3 W

A6V

Mode of operation Motor (plug-in motor A6VE see RE 91606) Size â&#x2030;&#x2026; Displacement Vg max (cm3)

A6V M

M 28

5 5 8 0 107140 160200

Sizes 28...200: production plant Elchingen

Control device Hydraulic control pilot pressure increase pilot pressure related

28 55 80 107 140 160 200

10 bar HD1 25 bar HD2 35 bar HD3 Hydraulic two-position control HZ HZ1 HZ3 Electrical control, control voltage 12 V EP1 with proportional solenoid 24 V EP2 Electrical control voltage 12 V EZ1 two-position control, 24 V EZ2 with switching solenoid 12 V EZ3 24 V EZ4 Automatic control, without pressure increase HA1 high pressure related with pressure increase â&#x2C6;&#x2020;p = 100 bar HA2 Hydraulic control, speed related DA pSt/pHD = 5/100, hydraulic valve for travel direction DA1 electrical valve for travel direction 12 V DA2 + electrical Vg max-switch 24 V DA3 pSt/pHD = 8/100, hydraulic valve for travel direction DA4 electrical valve for travel direction 12 V DA5 + electrical Vg max-switch 24 V DA6

Pressure control (only for HD, EP) without pressure control (no code) Pressure control, direct control direct control, with 2nd pressure setting remote control Override of HA-control (only for HA1, HA2) without override (no code) Hydraulic override Electrical override control voltage Electrical override + el. valve for travel direction

control voltage

â&#x20AC;&#x201C; â&#x20AC;&#x201C;

â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C;

â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C;

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HD1 HD2 HD3 HZ HZ1 HZ3 EP1 EP2 EZ1 EZ2 EZ3 EZ4 HA1 HA2 DA DA1 DA2 DA3 DA4 DA5 DA6

* * * . * * * * *

* * * * * * * * *

28 55 80 107 140 160 200

â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

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â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

D E G

T U1 U2 R1 R2

12 V 24 V 12 V 24 V

* Differential piston

Synchronizing piston

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3

134

7UDYHO PRWRU $ 90

%20$*

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Schnittbild

Reparaturanleitung A6VM

Sectional drawing

Repair Instructions A6VM

A6 VM 55-107 HZ3 Baureihe / Series 63 Verstellmotor Variable motor

A6 VM 55-107 EZ3 Baureihe / Series 63 Verstellmotor Variable motor

A6 VM 55-107 HA3 Baureihe / Series 63 Verstellmotor Variable motor

A6 VM 55-107 HA3U Baureihe / Series 63 Verstellmotor Variable motor

Brueninghaus Hydromatik

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5

RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Reparaturanleitung A6VM

Schnittbild

Sectional drawing

Repair Instructions A6VM

A6 VM 28-200 HD Baureihe / Series 63 Verstellmotor Variable motor

A6 VM 28-200 HD Baureihe / Series 63 Verstellmotor mit SpĂźlventil Variable motor with flushing valve

A6 VM 28-200 HD1D Baureihe / Series 63 Verstellmotor mit Druckregelventil Variable motor with pressure control valve

6

Brueninghaus Hydromatik

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90

Reparaturanleitung A6VM

Schnittbild

Repair Instructions A6VM

Sectional drawing

A6 VM 28-200 EP Baureihe / Series 63 Verstellmotor Variable motor

A

B

min

max

G M1

T(T1)

A6 VM 28-200 EP./..A Baureihe / Series 63 Verstellmotor Variable motor

A

B

max

min

G T(T1)

M1

Brueninghaus Hydromatik

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Reparaturanleitung A6VM

Schnittbild

Repair Instructions A6VM

Sectional drawing A6 VM ... DA1 Baureihe / Series 63 Verstellmotor Variable motor

A6 VM ... DA3 Baureihe / Series 63 Verstellmotor Variable motor

8

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140

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Dichtsätze und Baugruppen Seal kits and sub assembly groups

Repair Instructions A6VM

Schaltmagnet / Proportionalmagnet Solenoid

Deckel mit * Drosselstift. * Drosselstift "Auftragsbezogen".

*

Cover with * throttle pin. * Throttle pin "as to order requirement".

* *

* * * Deckel mit SpĂźl- und Speisedruckventil und * Drosselstift * Drosselstift "Auftragsbezogen".

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

12

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Reparaturanleitung A6VM

Baugruppen / Steuerteile

Repair Instructions A6VM

Component groups / Control components

z. B. HA EP

Auftragsbezogen

HA2

* DA

"as to order requirement".

HD

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RDE 91604-01-R/08.01

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Baugruppen / Steuerteile

Repair Instructions A6VM

Component groups / Control components z. B. HZ3 / EZ3

HA3 / HA3U

14

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Triebwerk montieren / siehe Serviceinformation

Reparaturanleitung A6VM

Rotary group assembly / see service information

Repair Instructions A6VM

Triebwelle: mechanischer Teil Rotary group: mechanical part 1

*

2

Abstimmung MaĂ&#x; * und Lagerdrehmomente siehe Serviceinfo.

Adjustment dimension * and bearing torque see service infoprmation.

Lager aufpressen.

Beim Aufpressen Lagerdrehmoment nicht Ăźberschreiten.

Press on bearing.

Do not exeed bearing torque during press-on.

BOJH GG DRTT GHE

000 000 BOJH GG DRTT GHE

Lager mit MontagehĂźlse vorspannen und laufende Drehmomentenkontrolle.

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

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RDE 91604-01-R/08.01

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Triebwerk montieren

Repair Instructions A6VM

Rotary group assembly

*

Sicherungsring montieren.

MaĂ&#x; * fĂźr Abstimmscheibe mit EndmaĂ&#x;en ermitteln (Ăźberkreuz).

Assemble safety ring.

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

Abstimmscheibe einbauen.

Sicherungsring montieren.

Triebwelle einbaufertig.

Install adjustment disc.

Assemble safety ring.

Drive shaft ready for assembly.

32

Brueninghaus Hydromatik

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7UDYHO PRWRU $ 90

008 912 65

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Reparaturanleitung A6VM

Triebwerk montieren Rotary group assembly

Repair Instructions A6VM

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready for assembly.

MontagehĂźlse montieren.

Place assembly sleeve.

o

Gehäuse auf 80 C erwärmen. o

Warm up housing to 80 C.

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Brueninghaus Hydromatik

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008 912 65

RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Triebwerk montieren

Reparaturanleitung A6VM

Rotary group assembly

Repair Instructions A6VM

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

2

1 2

Zylinder in Nullposition ausrichten.

1. Zylinderbefestigungsschraube demontieren.

2. O-Ring einsetzen.

Fix zero position of cylinder with Qmax-screw.

1. Disassemble cylinder fixing screw.

2. Insert O-ring.

Brueninghaus Hydromatik

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165

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166

7UDYHO PRWRU $ 90

%20$*

008 912 65

7UDYHO PRWRU $ 90

008 912 65

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167

168

7UDYHO PRWRU $ 90

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169

170

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008 912 65

7UDYHO PRWRU $ 90

008 912 65

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171

172

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Montageanweisung fĂźr Anziehdrehmomente

Reparaturanleitung A6VM

Assembly guidelines for tightening torques

Repair Instructions A6VM

A6 V - Stellkolben / positioning piston fĂźr / for A6V / A7V / A7F / A8V)

1

2

Anziehdrehmoment MA fĂźr Gewindestift (1) / Tightening torque MA for threaded pin (1) (Verbindung: Stellkolben und Stellzapfen / Connection: Positioning piston and positioning trunnion M6 M8 M10 M12

: 8,5 Nm : 14,0 Nm : 30,0 Nm : 52,0 Nm

Anziehdrehmoment MA fĂźr Schraube (2) / Tightening torque MA for shaft bolts (2) (Verbindung: Stellkolben und Stellzapfen fĂźr A6V Connection: Positioning piston and piston for A6V M14 x 1,5

:

120 Nm

Brueninghaus Hydromatik

008 912 65

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173

43

174

7UDYHO PRWRU $ 90

%20$*

008 912 65

7UDYHO PRWRU $ 90

008 912 65

%20$*

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RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Reparaturanleitung A6VM

Inbetriebnahme Operating instruction

Repair Instructions A6VM

EinstellĂźberprĂźfung

Setting test

(Regelbeginn von Vg max - Vg min )

(Begin of regulation of Vg max - Vg min )

z.Beispiel HD

e.g HD X - 10 bar Einstellschraube - Regelbeginn / Set screw - begin of control

P

Vg min G

X

Betriebsdruck / Operating pressure

~ P/2 1:2 M1 Stelldruck / Control pressure

Sicherheitsbestimmungen beachten!

Einstelldaten nach Werksauftrag!

Blockzustand (StraĂ&#x;engang und festgebremst).

Observe safety regulations!

Setting data as to production order Blocked condition (travel mode and manual brake).

A6 VM - HD

A6 VM - HD

Vg max - Vg min

Vg max - Vg min

Manometer "G" = 600 bar

Pressure gauge "G" = 600 bar

Manometer "M1" = 600 bar

Pressure gauge "M1" = 600 bar

Manometer "X" = 60 bar

Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Beispiel: 10 bar Steuerdruck an X

Begin of regulation / Setting Example: 10 bar pilot pressure at X

Manometer an M1 beachten!

Druckwert an X erhĂśhen bis an M1 die Hälfte des Druckes an G ansteht â&#x2122;Ś Regelbeginn

Observe pressure gauge at M1!

Increase pressure value at X till half the pressure is generated at G â&#x2122;Ś Begin of regulaation

Einstellschraube im Uhrzeigersinn â&#x2122;Ś Regelbeginn frĂźher

Setscrew turned clockwise â&#x2122;Ś Begin of regulaation earlier

Einstellschraube gegen Uhrzeigersinn â&#x2122;Ś Regelbeginn später

Setscrew turned anti-clockwise â&#x2122;Ś Begin of regulaation later

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008 912 65

RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90 Inbetriebnahme

Reparaturanleitung A6VM

Operating instruction

Repair Instructions A6VM

EinstellĂźberprĂźfung

Setting test

(Regelbeginn von Vg max - Vg min )

(Begin of regulation of Vg max - Vg min )

z.Beispiel EP

e.g EP Einstellschraube - Regelbeginn / Set screw - Begin of control P Vg min G Betriebsdruck / Operating pressure

~ P/2 1:2 M1 Stelldruck / Control pressure

Sicherheitsbestimmungen beachten!

Einstelldaten nach Werksauftrag!

Blockzustand (StraĂ&#x;engang und festgebremst).

Observe safety regulations!

Setting data as to production order Blocked condition (travel mode and manual brake).

A6 VM - EP

A6 VM - HD

Vg max - Vg min

Vg max - Vg min

Manometer "G" = 600 bar

Pressure gauge "G" = 600 bar

Manometer "M1" = 600 bar

Pressure gauge "M1" = 600 bar

Magnet = Multimessgerät

Solenoid = multi measuring device

Regelbeginn / Einstellung

Begin of regulation / Setting Example: 200/400 mA

Beispiel: 200/400 mA Manometer an M1 beachten!

Druckwert an X erhĂśhen bis an M1 die Hälfte des Druckes an G ansteht â&#x2122;Ś Regelbeginn

Observe pressure gauge at M1!

Increase pressure value at X till half the pressure is generated at G â&#x2122;Ś Begin of regulaation

Einstellschraube im Uhrzeigersinn â&#x2122;Ś Regelbeginn frĂźher

Setscrew turned clockwise â&#x2122;Ś Begin of regulaation earlier

Einstellschraube gegen Uhrzeigersinn â&#x2122;Ś Regelbeginn später

Setscrew turned anti-clockwise â&#x2122;Ś Begin of regulaation later

Brueninghaus Hydromatik

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7UDYHO PRWRU $ 90

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008 912 65

7UDYHO PRWRU $ 90

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179

180

7UDYHO PRWRU $ 90

%20$*

008 912 65

RDE 91604-01-R/08.01

7UDYHO PRWRU $ 90

Reparaturanleitung A6VM Repair Instructions A6VM

Brueninghaus Hydromatik

008 912 65

%20$*

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RDE 91604-01-R/08.01

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Brueninghaus Hydromatik GmbH, Werk Elchingen, GlockeraustraĂ&#x;e 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: service.elchingen@bru-hyd.com Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen14, D-72160 Horb,Tel. (07451) 920, Fax (07451) 8221, E-Mail: serv ice.horb@bru-hyd.com

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