Hidrostatico Sandvik

Drill Carrier TC 6; Maintenance and lubrication manual
Drill Carrier TC 6
MAINTENANCE
AND
LUBRICATION MANUAL
B 00500--4 en 0409 / AR 1 (74)

2 (74) B 00500--4 en 0409 / AR

CONTENTS
1. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. CARRIER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1. Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1. Engine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2. Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1. Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1. Lubrication oils / fluids and volumes for DD320 . . . . . . . . . . . . . . . . 43
5.2. Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6. FRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1. Greasing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7. SAFETY DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 65
7.1. Servicing safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2. Hydraulic system safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3. Maintenance safety precautions for the boom . . . . . . . . . . . . . . . . . . 68
7.4. Troubleshooting guide for the hydraulics . . . . . . . . . . . . . . . . . . . . . . 69
7.5. Troubleshooting guide for the engine . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.6. Troubleshooting guide for the axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
B 00500--4 en 0409 / AR 3 (74)

4 (74) B 00500--4 en 0409 / AR

1. SAFETY
Always follow safety instructions and be careful in your work.
Servicing, adjusting, or repairing the rig is only allowed to persons with
special service training for the rig in question. Read the instructions
carefully before servicing, adjusting, or repairing the rig.
ATTENTION
Pressurized hydraulic hoses must no be touched by hand. The hoses

may have unnoticeable hairline cracks that let out high-- pressure oil
sprays that may penetrate the skin.
WARNING
Watch out for rotating parts of the rig. Service or repair the rig only with
the engine stopped. Make sure that the rig cannot be started without
cause during the service.
WARNING
Do not stay under a rig that has not been supported properly. Do not
disconnect hydraulic hoses or valves before having supported the rig.
Before service, support the rig mechanically or by running a cylinder into
WARNING its extreme position.
OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND

REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylinder has
been removed, the hydraulic circuit must be vented and flushed. This is
ATTENTION
done to prevent dirt and air in the cylinder from causing functional
disturbances.
B 00500--4 en 0409 / AR 5 (74)

2. CARRIER FRAME
2.1. Main components
2 3
4
4
5
1. Engine
2. Hydrostatic transmission
3. Driving controls
4. Frame (rear and front)
5. Axles
6 (74) B 00500--4 en 0409 / AR

1. Diesel engine
1. Dipstick of engine
6 2 oil level
5 2. Radiator
3. Oil filter
4. Fuel filters
5. Contamination indi-
cator for intake air
filter.
6. Air filter (dry)
1 3
4
1. Diesel engine (alternative)
5 2 1. Dipstick of engine
oil level
2. Radiator
3. Oil filter
4. Fuel filters
5. Air filter (oil bath)
1 3
4
2. Transmission
1. Motor
2. Gear box
2
B 00500--4 en 0409 / AR 7 (74)

3. Driving controls
1. Steering wheel
2. Service brake ped-
1
al
3. Accelerator pedal
4
4. Drive selector ST1
Forward / back-
ward drive selector
switch (carrier pan-
el).
5. Engine stop / on /
glow / start key
3
2 5 switch.
6 6. Emergency stop
button.
4. Frame (rear and front)
1 1. Hinge pins
5. Axles
1. Planetary gear
3 units
2. Brakes cylinders
3. Brakes
1
1
8 (74) B 00500--4 en 0409 / AR

3. LOCATION OF COMPONENTS
4 2
3 6 7 7 option
5 4
2 8
1
3 1
1. Fuel receiver
2. Hydraulic oil receiver
3. Engine cooler
4. Engine air filter
5. Hydraulic pump for hydrostatic transmission
6. Hydraulic oil receiver for transmission
7. Main switchgear
8. Hydraulic motor for transmission
B 00500--4 en 0409 / AR 9 (74)

4. ENGINE
4.1. Engine components
Refer to your engine operation and maintenance manual to get the detailed instructions.
10 12
6
11
2 3 4
1
7
1.Fuel filters 7. Pump (transmission)
2.Oil drain plug 8. Cooler
3.Engine oil filter 9. Expansion vessel (cooler)
4.Motor oil filling cap 10. Air filter
5.Dipstick 11. V--belts
6.Contamination indicator for air filter (not 12. Hydraulic throttle cylinder
with oil bath air filter)
10 (74) B 00500--4 en 0409 / AR

4.2. Engine maintenance

Daily or once in shift (10 hours)
1. Clean the air filter.
2. Check the engine oil level
3. Check the coolant level (additive concentration)
4. Check the fuel level
5. Check engine monitoring system, warning system
6. Check the V--belts tension
Remark:
For a new vehicle, after first week (50 hours)
D Change the engine oil filter.
D Check the engine mounts.
D Check the tightness of air intake and exhaust manifolds.
Every 125 hours
7. Clean the engine and cooler cooling fins.
Every 250 hours
8. Check the V--belts.
Every 500 hours
9. Change the engine oil filter.
10. Check the valve clearance.
11. Check the engine mounts.
12. Clean the air filter.
13. Clean the catalytic exhaust gas purifier.
Every 1000 hours
14. Clean the fuel precleaner.
15. Change the fuel filter.
16. Check the tightness of air intake and exhaust manifolds.
Workshop Maintenance
Every 1500 hours Alternator
Starter motor
Every 3000 hours Injectors
B 00500--4 en 0409 / AR 11 (74)

! DANGER When servicing or repairing the equipment, shut down the

engine unless it is required to be running for adjustment
purposes.
DAILY OR ONCE IN SHIFT (10 HOURS)

Dry type air filter
The life of the expendable paper cartridges in dry--type air cleaners depends on dust
collector (2) being emptied in good time. Failing this, the cartridge will clog up fast. Be sure,
therefore, to empty the collector not later than when filled halfway. Where the air is very
dust--laden, this may require daily servicing.
Emptying the dust collector:
D Stop the engine.
D Release clip (1) and remove dust collector (2) along with cover (3).
D Take off cover (3) and empty collector.
D Refit assembly, making sure that recess on cover mates with lug on collector.
D When cleaner is installed in horizontal position, check that the ”Top” mark is
actually at top.
Fig 1. Cleaning the air filter
12 (74) B 00500--4 en 0409 / AR

Dust discharge valve
1
1
Fig 2. Dust discharge valve
D Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated
by arrows.
D Clean discharge slot from time to time.
D Remove any caked dirt by pressing together the upper section of the valve.
Filter cartridge
5 2
1 4 3
Fig 3. Clean cartridge
D Undo clip fasteners 1.

D Take off hood 2 and remove cartridge 3.
D Clean cartridge (replace at least once a year).
D Clean cartridge 3.
-- Using dry compressed air (max. 5 bar), blow out from inside outwards, or
-- Tap out (in emergencies only). Do not damage the cartridge, or
-- Wash out according to manufacture‘s specifications.
D Check paper filter (light showing through) and gaskets for damage. Replace if
necessary.
D After five filter services or after two years at the latest, replace safety cartridge 4
(never clean!).
B 00500--4 en 0409 / AR 13 (74)

To do so:
-- Undo hex nut 5 and remove cartridge 4.
-- Insert new cartridge, re--install hex nut and tighten.
D Install cartridge 3, replace hood 2 and do up clip fasteners 1.
!
Never clean filter cartridge with gasoline or hot fluids!
!
Never clean filter with gasoline. Dispose of old oil in accordance with
environmental regulations!
Cleaning intervals
Fig 4. Service indicator

D The amount of dirt in the combustion air filter depends on the amount of dust in the
air and the size of the air filter used. If a high level of dust is anticipated, a
cyclone--type pre--cleaner can be fitted in front of the combustion air filter.
D Cleaning intervals must therefore be determined from case to case.
D If dry type air filters are used, cleaning should only be carried out according to the
service indicator or service switch.
D Filter servicing is needed when:
-- Service indicator the red signal 1 is fully visible when the engine is off.
-- Service switch the yellow pilot light comes on when the engine is running.
D After carrying out service work, press the reset button on the service indicator. The
service indicator is now ready for operation again.
14 (74) B 00500--4 en 0409 / AR

Check the engine oil level
1. Engine oil dipstick

D Ensure that the engine or vehicle is in a level position.
D Engine warm:
-- Shut engine off, wait for 5 minutes and check oil level.
D Engine cold
-- Check oil level
D Remove the oil dipstick.
D Wipe the dipstick with a non--fibrous, clean cloth.
D Insert it to the stop and remove again.
D Check the oil level, and if necessary, top up to the “MAX” mark.
-- If the oil level is only just above the “MIN“ mark, more oil must be added.
!
The oil level must not fall below the “MIN” mark.
B 00500--4 en 0409 / AR 15 (74)

Check the cooling system / level
! DANGER Always stop the engine before cleaning.

Never attempt to clean a hot engine.
D The amount of contamination in the cooling system depends on the engine

application.
D Oil and fuel residues on the engine increase the risk of contamination. Therefore
pay special attention to leaks if the engine is used in dusty environments.
D Serious contamination can occur, for example:
-- on construction sites where there is a high level of air--borne dust.
-- in harvesting application where there are high concentrations of chaff and chopped
straw in the vicinity of the machine.
D Because applications vary, cleaning intervals have to be determined from case to
case. The cleaning interval given above can be used as a guide.
Clean cooling system
D External cooling system: Clean according to cooling system manufactures
specifications.
Compressed Air
-- Blow out heat exchanger with compressed air. Be careful not to damage the
cooling fins.
-- Wash out loosened dirt with a hose.
Cold Cleansing Agent
-- Spray the heat exchanger with a commercial cold cleansing agent and let stand
for about 10 minutes.
-- Hose clean with a strong jet of water (do not spray water directly onto the alternator,
wiring or electronic components).
D Refit service flap.
D Run the engine up to normal operating temperature to evaporate any remaining
water.
16 (74) B 00500--4 en 0409 / AR

4.2.1. Engine cooling system

Expansion vessel (1) is located upper of the cooler.
Always use antifreeze solution or cooling system conditioner to protect the cooling system
from corrosion. Check the proper concentration from engine instruction booklet.
Check the amount of cooling liquid daily when the engine is cold. The amount of cooling
liquid is correct when the liquid level reaches the bottom of the expansion vessel filling
pipe.
Engine revolution speed drops first to idle and stops after a delay if the amount of cooling
liquid drops too low. At the same time an indicator light goes on in the operating panel.
Hot fluid and steam can cause severe injuries. Never open the radiator
cap when the engine is hot or running.
WARNING
B 00500--4 en 0409 / AR 17 (74)

DANGER Never add cold coolant to hot engine as this may

!
damage the cylinder
DANGER Engine is equipped with a suction fan. Blow the

!
radiator clean from the fan side.
Change antifreeze solution every 2--years. Drain both engine and radiator. Mix the
antifreeze solution and refill cooling system slowly to avoid air pockets. Start the engine
with expansion vessel cap off and let the coolant level stabilize. Add coolant if necessary.
Check the cooling system for leaks at the same time.
18 (74) B 00500--4 en 0409 / AR

Check the fuel level
1 2
Fig 5. Check the fuel level
1. Filler cap
2. Fuel level. The indicator light and display blinks if level is too low.
D Use only clean commercial--grade diesel fuel.

D If necessary, insert a fuel pre--filter.
D If in doubt, ask the nearest service representative.
D Use summer or winter--grade fuel, depending on the ambient temperature
!
Never fill the fuel tank while the engine is running. Ensure cleanliness.
Do not spill fuel!
Winter operation
D Use winter grade diesel fuel operation below 0qC.
B 00500--4 en 0409 / AR 19 (74)

Check the engine monitoring system, warning system
2
3
5
4
1.Display Upper default display is fuel level, when carrier key switch S2 is turned
on.
Upper default display become diesel rpm reading when diesel is running.
Lower default display is diesel hours, when carrier key switch S2 is
turned on.
2--3. Upper When you push top line button you have on upper display that reading.
buttons When you push top line button over 2 seconds there is again diesel rpm
reading.
Alarm came always on top and also button indicator light is then on.
4--5. Lower When you push lower line button you have on lower display that reading.
buttons Alarm came always on top and also button indicator light is then on.
2--5. All All button indicator light have indicator light test.
button When carrier key switch S2 is turned on all button indicator light flash.
2. Engine coolant temperature. 4. Engine oil pressure. Normal

The temperature should be un- pressure is over 1 bar. Indicator
der under 100qC. Indicator light light and display blinks and
and display blinks and buzzer is buzzer is on if pressure is below
on if temperature is over113qC. 0,7 bar.
3. Fuel level. The indicator light 5. Voltmeter. The indicator light
and display blinks if level is too and display blinks and buzzer is
low. on if voltage is under 20VDC.
20 (74) B 00500--4 en 0409 / AR

Indicator lights
1 9
2 5
3 6
4
7
1. Service brake. The indica- 6. Air filter indicator light is on

tor light is on if front or rear if filter is clogged (optional).
brake pressure is below 145
bar.
H21 H23
2. Park brake. 7. Low engine coolant level.

Indicator light is on if brake Indicator light is on if coolant
pressure is below 5 bar. level is too low.
H150 H7
3. Pre--heating indicator. 8. Blinker (option). Indicator

The engine can be started light blink if left or right blinker
when the indicator lights up. If is on.
the engine is already warm,
H19 preheating is not necessary.
4. Charging. 9. Water in fuel indicator (op-

The indicator lights up if the tion).
alternator is not operational.
Switch off the engine and look
H4 for the cause.
5. Transmission oil tank level.
Indicator light is on if oil tank
level is too low.
H18
B 00500--4 en 0409 / AR 21 (74)

Indicator lights (ABA-- alternative)
8
H91
1 9
2 5
10
3 6
4
7
1. ABA--brake. 6. Air filter indicator light is on

Indicator light is on if brake if filter is clogged (optional).
pressure is below 110 bar in
front or rear service brake cir-
cuit. When the pressure drops
below 75 bar in front or rear
H21 service brake circuit the H23
brakes are automatically put
on and they cannot be by-
passed.
2. Park brake. 7. Low engine coolant level.
Indicator light is on if brake Indicator light is on if coolant
pressure is below 5 bar. level is too low.
H150 H7
3. Pre--heating indicator. 8. Blinker (option). Indicator
The engine can be started light blink if left or right blinker
when the indicator lights up. If is on.
the engine is already warm,
H19 preheating is not necessary.
4. Charging. 9. Water in fuel indicator (op-
The indicator lights up if the tion).
alternator is not operational.
Switch off the engine and look
H4 for the cause.
5. Transmission oil tank level. 10. Hydraulic transmission
Indicator light is on if oil tank charge pressure. Indicator
level is too low. light is lit if the pressure drops
H91
H18 under 15 bar.
22 (74) B 00500--4 en 0409 / AR

Check the V-- belts retention

Check the engine V--belts
Fig 6. Checking V--belts

D Visually inspect the entire V--belt for damage.
D Replace damaged V--belts.
D After installing new belts, run engine for 15 minutes, then check belt tension.
5 4 3 2
Fig 7. Tension gauge

D To check the tension of the V--belt, use a tension gauge
-- Place indicator arm (1) into gauge.
-- Position gauge on V--belt (2), midway between the pulleys, with flange (3) on
bottom of gauge against the edge of belt
-- Push slowly on the black pad (4) at right angles to belt (2) until the spring is heard
or felt to trigger.
-- Carefully raise the gauge without changing the position of indicator arm (1).
-- Read off value where the indicator arm (1) intersects scale (5) (arrow) and read
indicator arm (1) off.
B 00500--4 en 0409 / AR 23 (74)

-- If necessary, retension belt and measure again.
!
Check, tension and change belts only with the engine off.
Coolant / fuel pump V--belt tension
D Loosen screws (1) and (2).
1 D Press fuel pump (3) in direction of arrow

until the correct V--belt tension has been
achieved.
D Tighten screws (1) and (2).
3
2
Fig 8. Tensioning / changing coolant / fuel pump belt
Changing coolant / fuel pump V--belts
D Loosen screws (1) and (2).
1 D Press fuel pump (3) in direction of

arrow.
D Remove V--belt and position new belt.
3 D Press fuel pump counter to direction of
2
arrow until the correct V--belt tension has
been achieved.
D Tighten screws (1) and (2).
Fig 9. Changing coolant / fuel pump V--belts
24 (74) B 00500--4 en 0409 / AR

Tensioning alternator V--belt
3 4 D Loosen screws (1), (2) and (4).

D Adjust alternator (5) in direction of arrow
5 by turning screw (3) until correct V--belt
1 tension id achieved.
D Retighten screws (1), (2) and (4).
Fig 10. Tensioning alternator V--belt
Changing alternator V--belt
3 4 D Loosen fuel pump V--belt.

D Loosen screws (1), (2) and (4).
5
D Adjust screw (3) until V--belt can be
1 removed.
D Position new belt.
D Adjust screw (3) until the correct V--belt
tension has been achieved.
2 D Retighten screws (1), (2) and (4).
D Tension fuel pump V--belt.
Fig 11. Changing alternator V--belt
B 00500--4 en 0409 / AR 25 (74)


Change the engine oil filter
! DANGER Beware of burns from hot oil.
D With attached locking piston:

-- undo tensioning screws and remove tensioning clamps downwards.
D Undo the lube oil filter cartridge using a commercial tool and spin off.
D Catch any escaping oil.
D Clean any dirt from the filter carrier sealing surface.
D Lightly oil the rubber gasket of the new lube oil filter cartridge.
D Manually screw in the new cartridge until the gasket is flush.
D Tighten the lube oil filter cartridge with another half--turn.
D If locking piston is available:
-- Position tensioning clamps and tighten with tensioning screws.
D Check oil level.
D Check oil pressure.
D Check lube oil filter cartridge seal for leaks.
1. Used filter cartridge.
2. New filter cartridge.
2
1
Fig 12. Engine oil filter
26 (74) B 00500--4 en 0409 / AR

Check the engine mounts
Fig 13. Check the engine mounts.
Installation location Total (Nm) Remarks

Cylinder head screw 8,5
Rocker arm adjustment 21
screw
Foot on flywheel side 187
Foot on fan side 187 M16 x 40 8.8 A4C
Intake manifold 8,5 M16 x 40 8.8 A4C
Exhaust manifold 21
Oil drain screw 50
Injection valve attach- 16 Torx
ment
Injection line attachment 30 M14 x 1,5
Oil pan (cast) 29
Oil pan (sheet metal) 21
B 00500--4 en 0409 / AR 27 (74)

Check the tightness of air intake and exhaust manifolds
Fig 14. Air intake and exhaust manifolds

The connections of intake-- and exhaust manifolds to the cylinder heads should be
checked for tightness, and retightened where necessary. The connections of fuel piping
should be checked too.
28 (74) B 00500--4 en 0409 / AR

EVERY 125 HOURS

Cooling fins
Clean the cooling fins every 125 hours for impurities. Always inspect/clean the cooling fins
with the engine stopped.
Fig 15. Engine and cooler cooling fins
! DANGER Always stop the engine before cleaning.

Never attempt to clean a hot engine.
D The amount of contamination in the cooling system depends on the engine

application.
D Oil and fuel residues on the engine increase the risk of contamination. Therefore
pay special attention to leaks if the engine is used in dusty environments.
D Serious contamination can occur, for example:
-- on construction sites where there is a high level of air--borne dust.
-- in harvesting application where there are high concentrations of chaff and chopped
straw in the vicinity of the machine.
D Because applications vary, cleaning intervals have to be determined from case to
case. The cleaning interval given above can be used as a guide.
B 00500--4 en 0409 / AR 29 (74)

Clean cooling system

D External cooling system: Clean according to cooling system manufactures
specifications.
Compressed Air
-- Blow out heat exchanger with compressed air. Be careful not to damage the
cooling fins. Do not use a higher air pressure than 4 bar.
-- Wash out loosened dirt with a hose.
Cold Cleansing Agent
-- Spray the heat exchanger with a commercial cold cleansing agent and let stand
for about 10 minutes.
-- Hose clean with a strong jet of water (do not spray water directly onto the alternator,
wiring or electronic components).
D Refit service flap.
D Run the engine up to normal operating temperature to evaporate any remaining
water.
30 (74) B 00500--4 en 0409 / AR

EVERY 250 HOURS

Check the V-- belts
Check the engine V--belts
Fig 16. Checking V--belts

D Visually inspect entire V--belt for damage.
D Replace damaged V--belts.
D After installing new belts, run engine for 15 minutes, then check belt tension.
5 4 3 2
Fig 17. Tension gauge

D To check the tension of the V--belt, use a tension gauge
-- Place indicator arm (1) into gauge.
-- Position gauge on V--belt (2), midway between the pulleys, with flange (3) on
bottom of gauge against the edge of belt
-- Push slowly on the black pad (4) at right angles to belt (2) until the spring is heard
or felt to trigger.
-- Carefully raise the gauge without changing the position of indicator arm (1).
B 00500--4 en 0409 / AR 31 (74)

-- Read off value where the indicator arm (1) intersects scale (5) (arrow) and read
indicator arm (1) off.
-- If necessary, retension belt and measure again.
!
Check, tension and change belts only with the engine off.
EVERY 500 HOURS

Change the engine oil filter
Change the engine oil filter cartridge.
! DANGER Beware of burns from hot oil.
D With attached locking piston:

-- undo tensioning screws and remove tensioning clamps downwards.
D Undo the lube oil filter cartridge using a commercial tool and spin off.
D Catch any escaping oil.
D Lightly oil the rubber gasket of the new lube oil filter cartridge.
D Tighten the lube oil filter cartridge with another half--turn.
D If locking piston is available:
-- Position tensioning clamps and tighten with tensioning screws.
D Check oil level.
D Check oil pressure.
D Check lube oil filter cartridge seal for leaks.
1. Used filter cartridge.
2. New filter cartridge.
2
1
Fig 18. Changing the engine oil filter
32 (74) B 00500--4 en 0409 / AR

Check the valve clearance

D Loosen ventilation valve and swing to the side.
D Remove the cylinder head cover.
D Position crankshaft as per schematic, see “Crankshaft position 1 and 2”.
D Before adjusting valve clearance, allow engine to cool down for at least 30 minutes.
The oil temperature should be below 80q C.
D Check valve clearance (1) between rocker arm / tappet contact face (2) and (3) with
feeler gauge (6) (there should be only slight resistance when feeler blade is
inserted). Valve clearance with cold engine: Inlet valve 0.3+0.1 mm / exhaust valve
0.5+0.1 mm.
5
1
4
Fig 1. Adjust valve clearance

D Adjust valve clearance if necessary:
-- release locknut (4)
-- use (7) to turn setscrew (5) so that the correct valve clearance 1 is attained after
locknut (4) has been tightened.
D Check and adjust valve clearance on all cylinders.
D Reinstall cylinder head cover (with new gasket if necessary).
D Swing ventilation valve into position and fasten.
Fig 2. Check valve clearance
B 00500--4 en 0409 / AR 33 (74)

Crankshaft Position 1
Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet
valve about open). Adjust valve clearance according to schematic (marked in black).
Mark respective rocker arm with chalk to show that adjustment has been carried out.
1 2 3 4
BF4M2012
Crankshaft Position 2
Turn crankshaft one full revolution (360q). Adjust valve clearance according to schematic
(marked in black).
1 2 3 4
BF4M2012
wrong right
34 (74) B 00500--4 en 0409 / AR

Check the engine mounts
Fig 3. Check the engine mounts.
Installation location Total (Nm) Remarks

Cylinder head screw 8,5
Rocker arm adjustment 21
screw
Foot on flywheel side 187
Foot on fan side 187 M16 x 40 8.8 A4C
Intake manifold 8,5 M16 x 40 8.8 A4C
Exhaust manifold 21
Oil drain screw 50
Injection valve attach- 16 Torx
ment
Injection line attachment 30 M14 x 1,5
Oil pan (cast) 29
Oil pan (sheet metal) 21
B 00500--4 en 0409 / AR 35 (74)

Clean the air filter

Emptying the dust collector:
D Stop the engine.
D Release clip (1) and remove dust collector (2) along with cover (3).
D Take off cover (3) and empty collector.
D Refit assembly, making sure that recess on cover mates with lug on collector.
D When cleaner is installed in horizontal position, check that the ”Top” mark is
actually at top.
Fig 4. Cleaning the air filter

Dust discharge valve
1
1
Fig 5. Dust discharge valve
D Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated
by arrows.
D Clean discharge slot from time to time.
D Remove any caked dirt by pressing together the upper section of the valve.
36 (74) B 00500--4 en 0409 / AR

Filter cartridge
5 2
1 4 3
Fig 6. Clean cartridge
D Undo clip fasteners 1.

D Take off hood 2 and remove cartridge 3.
D Clean cartridge (replace at least once a year).
D Clean cartridge 3.
-- Using dry compressed air (max. 5 bar), blow out from inside outwards, or
-- Tap out (in emergencies only). Do not damage the cartridge, or
-- Wash out according to manufacture‘s specifications.
D Check paper filter (light showing through) and gaskets for damage. Replace if
necessary.
D After five filter services or after two years at the latest, replace safety cartridge 4
(never clean!).
To do so:
-- Undo hex nut 5 and remove cartridge 4.
-- Insert new cartridge, re--install hex nut and tighten.
D Install cartridge 3, replace hood 2 and do up clip fasteners 1.
!
Never clean filter cartridge with gasoline or hot fluids!
!
Never clean filter with gasoline. Dispose of old oil in accordance with
environmental regulations!
B 00500--4 en 0409 / AR 37 (74)

Cleaning intervals
Fig 7. Service indicator

D The amount of dirt in the combustion air filter depends on the amount of dust in the
air and the size of the air filter used. If a high level of dust is anticipated, a
cyclone--type pre--cleaner can be fitted in front of the combustion air filter.
D Cleaning intervals must therefore be determined from case to case.
D If dry type air filters are used, cleaning should only be carried out according to the
service indicator or service switch.
D Filter servicing is needed when:
-- Service indicator the red signal 1 is fully visible when the engine is off.
-- Service switch the yellow pilot light comes on when the engine is running.
D After carrying out service work, press the reset button on the service indicator. The
service indicator is now ready for operation again.
38 (74) B 00500--4 en 0409 / AR

Clean the catalytic exhaust gas purifier
! CAUTION Use cleaning solution in accordance with manufacturers

recommendations and in a properly ventilated area.
The condition of exhaust, amount of wet or heavy particulates, determines the cleaning
cycle.
1. Remove the purifier from the exhaust system. If quick--release clamp design is
installed, remove the centerbody only.
2. Immerse the purifier in diesel fuel. Allow soak for 1 hour.
3. Using steam or high pressure water (not greater than 100 psi), wash the purifier
through both the inlet and outlet ends keeping the tip of the nozzle at least 2 inches
away from the purifier face. Do not use detergents.
4. Dry the purifier thoroughly with compressed air (not greater than 100 psi) keeping
the tip of the nozzle at least 2 inches away from the purifier face.
5. Place the converter back into the exhaust system being sure to tighten all clamps
and fittings and replacing gaskets where necessary.
Fig 8. Cleaning the catalytic exhaust gas purifier
B 00500--4 en 0409 / AR 39 (74)

EVERY 1000 HOURS

Clean the fuel precleaner
1
5
Clean - Drain / Replace

D Shut engine off.
D Close fuel shut--off valve or infeed.
D Place fuel collection container beneath the fuel pre--filter.
D Open bleeder screw 1.
D Gently open drain screw 2, drain fuel and any particles of dirt.
D Clean filter element 3 in the event of a decrease in power, but replace annually.
Clean / replace
D Loosen the filter cover.
D Replace filter element.
D Clean filter housing.
D lid with new gasket, and tighten the cup.
D Tighten the drain screw 2.
D Close bleeder screw 1.
D Check fuel inlet 4 and fuel outlet 5 threaded connection for leaks.
D Bleed fuel system.
D Open fuel shut off valve.
D Check for leaks after starting the engine.
40 (74) B 00500--4 en 0409 / AR

Change fuel filters

D Close fuel shut--off valve
D Undo fuel filter cartridge (1) with commercial tool and spin off.
D Catch any escaping fuel.
D Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
D Tighten the fuel filter cartridge with a final half--turn.
D Open the shut off valve
D Check for leaks.
!
The fuel system does not need to be bled after changing fuel filter.
!
Keep naked flames away when working on the fuel system. Do not
smoke.
Fig 9. Fuel filters
B 00500--4 en 0409 / AR 41 (74)

Check tightness of piping and exhaust and inlet manifolds.

The connections of intake-- and exhaust manifolds to the cylinder heads should be
checked for tightness, and retightened where necessary. The connections of fuel piping
should be checked too.
Fig 10. Inspecting air intake and exhaust manifolds
42 (74) B 00500--4 en 0409 / AR

5. MAINTENANCE
5.1. Lubrication oils / fluids and volumes for DD320

CLASSIFICATION FIRST FILLING
TARGET VOLUME NOTE !
RECOMMENDATION OIL / FLUID
CF, CF--4,CG--4, ACEA E3, Shell
Diesel engine 10 l First filling
MB228.4, Caterpillar ECF--1 Rimula R3 X 15W--40
CF, CF--4,CG--4, ACEA E3, Shell
Diesel engine 9,5 l With oil filter
MB228.4, Caterpillar ECF--1 Rimula R3 X 15W--40
Hydraulic oil A SUFFIX A

Shell Donax TM
receiver of or
50 l
hydrostatic DIN 51524 part 2 (HLP),
transmission Shell Tellus Oil S 68
ISO 6743--4 (HM)
Gear box of SAE 75 W/ 90 API GL5
2,4 l SAE 90 API GL3
transmission SAE 80 W/ 90 API GL5
Front / rear axle 28 l API GL--4 Ambra Multi G Wet brake
Viscosity class
Hydraulic oil
DIN 51524 part 2 (HLP), Shell Tellus Oil S 68 is choosen ac-
receiver of 250 l
ISO 6743--4 (HM) or 100 cording to oper-
drilling
ating conditions
Gear box of SAE 75W / 90 API GL5
water reel 1,7 l Esso GX 85W--140
SAE 80W / 90 API GL5
Gear box of SAE 75W / 90 API GL5
cable reel 2,2 l Esso GX 85W--140
SAE 80W / 90 API GL5
Compressor
5l API CE / CF Shell AEON 3000
CT 10
Shank
lubrication 10 l Sandvik Shell Torcula Oil 100
KVL10
Air conditioner 1800 --
Sandvik R--134a TC 6
Refrigerant 1900 g
Refer to the
separate air
Air conditioner ISO--100 (high--viscosity) or Sanden
conditioner
Oil ISO--46 (low--viscosity) PAG SP--20 or SP--10
instructions
(B85630).
Fuel of diesel Thermoshell Winter
150 l EN 590
engine 1202
Cooling of diesel BS 6580, AFNOR, ASTM D GlycoShell consen-
engine 3306 trate (50/50)
B 00500--4 en 0409 / AR 43 (74)

5.2. Maintenance table

Daily
D Check the hydraulic transmission oil level.
D Check the hydraulic oil level
As required maintenance
D Check the pressures.
Weekly (50 hours)
D Check the tire conditions and pressure.
Remark
D Change the transmission oil.
D Change the transmission hydraulic oil filter..
D Change the hydraulic oil.
Remark
For a new vehicle, after first 100 hours
D Change differential planetary reduction gear oil
Every 200 hours
D Check the planetary reduction gear oil levels.
Every 250 hours
D Check the brakes
D Bleed the brake system
NOTE:
The brake system must always be bled after repair
Every 500 hours
D Change hydraulic oil.
D Change the hydraulic oil filter..
D Change transmission hydraulic oil
D Change the transmission oil filter.
D Change the transmission pump oil filter
Every 1000 hours
D Check the frame joint and axle oscillation.
D Change the planetary reduction gear oils.
. According to the periodic lubrication instructions for the drilling equipment.
44 (74) B 00500--4 en 0409 / AR

DAILY
Check the hydraulic transmission oil level
3 2
1. Sight glass
2. Breather
3. Electrical oil level switch
Fig 11. Checking the oil level / changing the oil
The level of the oil should be checked daily. In case of loss of oil, the leak must be fixed.
Use only recommended fluids. It is not permissible to mix.
Observe strict cleanliness when filling oil. Contaminated oil is a major cause of premature
component failure.
B 00500--4 en 0409 / AR 45 (74)

Check the hydraulic oil level
3 MAX
2
MIN 1
1. Sight glass (MIN)

2. Sight glass (MAX)
3. Return filter
4. Breather
Fig 12. Hydraulic oil level checking
Check hydraulic reservoir sight glass and add fluid as needed. Fluid level should not be
above the top sight glass (2) or below the bottom sight glass (1).
! CAUTION Cleanliness is of extreme importance. Before changing oil,

the exterior or the tank must be thoroughly cleaned to
prevent the possibility of dirt and foreign matter entering the
system.
As required maintenance
Check the pressures
see manual “Hydrostatic transmission” B 16150
46 (74) B 00500--4 en 0409 / AR

WEEKLY
Check the tire conditions and pressure.
Early detection of cuts and other damage may easily be repaired and thereby prolong tire
life or prevent a possible tire change in a rough working environment. Maximum tire
pressure is 8,0 bar.
Make sure the valve stem protective caps are reinstalled on all wheels when checks and
inflating procedures are completed.
! WARNING Make sure the tires and rims are undamaged and correctly
assembled. Use safety cables or other safety devices when
inflating the tires. Failure to observe appropriate safety
precautions can result in serious personal injuries.
! WARNING Do not stand at the front of the tyre when inflating procedures
are completed. Stand at the side of the tyre.
Fig 13. Safety precaution
B 00500--4 en 0409 / AR 47 (74)

REMARK:
Change the transmission oil
3 2
1. Sight glass
2. Breather
component failure.
48 (74) B 00500--4 en 0409 / AR

Change the transmission oil filter.

Renew the filter during an oil change and additionally when the mechanical filter indicator
shows a blocked filter by projecting a red peg. Indication pressure over the filter element
is 2,5 bar.
Unscrew the filter. Prior to fitting a new filter into place make sure that the filter housing
is clean.
!
Observe strict cleanliness when replenishing filter. Contaminated oil
is a major cause of premature component failure.
2
Fig 15. Changing the transmission oil filter
1. Return oil filter

2. Oil filter contamination indicator
B 00500--4 en 0409 / AR 49 (74)

Change the hydraulic oil

Remove the reservoir fill cap and empty the hydraulic reservoir by removing the drain plug.
Change the oil while it is warm. Fill the tank with fresh oil using the hand pump. Use oils
as specified in oil recommendation. Check hydraulic reservoir sight gauges and add fluid
as needed. Fluid level should not be above the top sight glass (2) or below the bottom sight
glass (1).
3 MAX
2
MIN 1
Fig 16. Change the hydraulic oil

3. Return filter
4. Breather
50 (74) B 00500--4 en 0409 / AR

REMARK:
Change differential planetary reduction gear oil
Change the oil while it is warm, and any foreign particles still suspended in the oil. Remove
the drain plug and drain the oil into the container. Refill the gear box via check hole. The
oil level should be flush with bottom of check hole. Use recommended oil only. Inspect the
breather and clean it if necessary.
vent
oil drain plug
oil fill/check plug
Fig 17. Change differential planetary reduction gear oil
B 00500--4 en 0409 / AR 51 (74)

EVERY 200 HOURS

Check the planetary reduction gear oil level
Check the oil level when the vehicle is parked on level and after a few minutes so that the
oil level has had time to settle.
oil fill/check plug
Fig 18. Checking oil level
52 (74) B 00500--4 en 0409 / AR

EVERY 250 HOURS

Check and adjust the brakes
Bleeding the brakes
Internal Heat -- Cause, Effect, Solution
It is possible for heat to come from within the system itself as in the case of heat generated
by the friction of lining to drum when braking. This heat cause the fluid to expand. If the
fluids is then held captive, subsequent cooling and contracting can cause a pressure drop.
MICO Hydraulic Locking Devices that include a pressure accumulator are designed to
dampen these fluctuations of pressure and to absorb the increase in pressure within its
operating range.
D C
E
1
A B
F
D
Fig 19. MICO brake cylinder
1. Service brake bleed screw

2. Safety brake bleed screw
A. Spring
B. Piston
C. Port (Safety brake)
D. Port (Service brake)
E. Piston
F. Collar
B 00500--4 en 0409 / AR 53 (74)

Importance of bleeding
The hydraulic brake system must be bled whenever any lines has been disconnected. Air
trapped in the system can cause spongy and inadequate brakes. There are two methods
of bleeding hydraulic systems, pressure bleeding and manual bleeding. Both methods are
acceptable and adequate but pressure bleeding is recommended if the equipment is
available. Follow bleeding instructions as specified by vehicle manufacturer.
To properly bleed the system...
1. Be certain all fittings are tight to avoid leaking.
2. Depress pedal and open up bleeder screws to allow air to escape. Air will always
seek the highest level.
3. Retighten bleeder screws and allow pedal to return.
4. Repeat cycle until pedal is firm.
5. Make several static brake applications and then repeat cycle once more.
Leak in the system
Even the smallest leak in a brake system will adversely affect the system. A leak may
eventually deplete the reverse supply and reduce braking pressure. To help prevent
leaking...
1. Check connections during bleeding and static brake processes to be sure they are
tight.
2. Always reinstall new hoses, lines and fittings if they look the least bit questionable.
3. Brake hoses, brake lines, MICO locking device, brake components, cylinders, and
all fittings must be routinely inspected for leaks, damage or wear. Adequate fluid
levels must be maintained. In the event of any loss of fluid, the brake system must
be carefully inspected for leaks.
54 (74) B 00500--4 en 0409 / AR

D63 Axle adjustment
1. Start up diesel and lift the rig onto the jacks so that the wheels are off the ground.
2. Turn off diesel.
3. Carefully remove the plug screw (1) from the cover of each brake cylinder (4 pcs)
and remove the spring (2) and lock nut (3) behind the plug screw.
4. Start up diesel and release the parking brake.
5. Tighten the adjusting screw (4) approximately 1.7 Nm so that the brake is locked.
6. Loosen the adjusting screw 1 1/3 turns.
7. Repeat the steps to the axle’s other brake cylinder.
8. Place the lock nuts (3) back to the axle brake cylinders and check that the wheel
rotates freely.
9. Place the springs (2) and plug screws (1) back to the brake cylinders of the axle
in question.
10. Repeat steps 5--9 to the brake cylinder of the other axle.
11. Engage the parking brake and retract the jacks.
12. Select a safe driving direction and slow driving speed.
13. Slowly increase the diesel revolutions to the 1500 rpm --> the rig must not move
(if it moves, re--adjust the axle).
14. Decrease the diesel revolutions to idling and turn the driving direction selection
switch to the middle position.
15. Turn off diesel.
4 3
2
B 00500--4 en 0409 / AR 55 (74)

EVERY 500 HOURS

Change the hydraulic oil
Remove the reservoir fill cap and empty the hydraulic reservoir by removing the drain plug.
Change the oil while it is warm. Fill the tank with fresh oil using the hand pump. Use oils
as specified in oil recommendation. Check hydraulic reservoir sight gauges and add fluid
as needed. Fluid level should not be above the top sight gauge or below the bottom sight
gauge.
3 MAX
2
MIN 1
Fig 20. Change the hydraulic oil

3. Return filter
4. Breather
56 (74) B 00500--4 en 0409 / AR

Change the hydraulic oil filter.

Renew the filter according to the periodic maintenance instructions for the drilling
equipments.
Renew the filter (1) during an oil change and additionally when the indicator light shows
a blocked filter by on the indicator panel.
! CAUTION Cleanliness is of extreme importance. Before changing the

filter, the exterior or the tank must be thoroughly cleaned to
prevent the possibility of dirt and foreign matter entering the
system.
Fig 21. Changing the hydraulic oil filter
B 00500--4 en 0409 / AR 57 (74)

Change transmission hydraulic oil
3 2
1. Sight glass
2. Breather
component failure.
58 (74) B 00500--4 en 0409 / AR

Change the transmission oil filter.

Renew the filter during an oil change and additionally when the mechanical filter indicator
shows a blocked filter by projecting a red peg. Indication pressure over the filter element
is 2,5 bar.
Unscrew the filter. Prior to fitting a new filter into place make sure that the filter housing
is clean.
!
Observe strict cleanliness when replenishing filter. Contaminated oil
is a major cause of premature component failure.
2
Fig 23. Changing the transmission oil filter

B 00500--4 en 0409 / AR 59 (74)

Change transmission pump oil filter.
1
2
Fig 24. Changing the transmission pump filter
1. Oil filter
If the hydraulic pressure reaches over 5 bar in filter element housing, the mechanical
indicator activated and shows that filter is blocked. Replace with new filter.
1. Stop the engine.

2. Place oil collection container beneath the hydraulic transmission oil filter.
3. Open filter housing (1).
4. Change new filter.
5. Lubricate new gasket and replaced it.
6. Check for leaks after starting the engine
60 (74) B 00500--4 en 0409 / AR

6. FRAME MAINTENANCE
EVERY 200 hours
Check the all bolts and nuts tightening
EVERY 1000 hours
Check the oscillation axle bushings and frame joint bearings.
Check the oscillation axle bushings by lifting up the engine end axle wheel. With small
movements check the play that possibly has developed in the oscillation bearings. If any
play appears, replace the bearings according work shop manual instructions.
Fig 25. Oscillation axle bushings and frame joint bearings
1. Oscillation axle
B 00500--4 en 0409 / AR 61 (74)

Check the frame joint.
DANGER When the engine is running, no one should be allowed

!
near the hinge area.
.
Check the centre pivot by turning the steering to and from with small movements. Check
the play that possibly has developed in the centre hinge bearings. If any play appears,
replace the hinge bearings.
Fig 26. Checking the frame joint
62 (74) B 00500--4 en 0409 / AR

Change differential planetary reduction gear oil

Change the oil while it is warm, and any foreign particles still suspended in the oil. Remove
the drain plug and drain the oil into the container. Refill the gear box via check hole. The
oil level should be flush with bottom of check hole. Use recommended oil only. Inspect the
breather and clean it if necessary.
vent
oil drain plug
oil fill/check plug
Fig 27. Change differential planetary reduction gear oil
B 00500--4 en 0409 / AR 63 (74)

6.1. Greasing points

Weekly:
Use a grease gun with recommendated grease.
! WARNING Accumulated grease or oil on the carrier is a fire hazard. Remove

debris any time a significant quantity oil is spilled on the carrier.
Lubricate the propeller shaft fittings. All drive line sections are furnished with grease
nipples on universal joints and telescopic sections. Lubrication must be done carefully to
avoid damage of the seals.
abcd
b
All drive line sections are fitted with grease nipples on universal joints and telescopic
sections. Lubrication must be done carefully to avoid damage of the seals.
Lubricate:
a. Oscillation axle pins.
b. Hinge pins
c. Steering cylinder pins.
d. Propeller shaft support bearing.
64 (74) B 00500--4 en 0409 / AR

7. SAFETY DURING MAINTENANCE OPERATIONS

7.1. Servicing safety precautions
! DANGER 1. When servicing or repairing the vehicle, shut down the

engine unless it is required to be running for adjustment
purposes.
! DANGER 2. Keep your head, hands, feet and loose clothing away
from power-- driven parts.
! DANGER 3. Do not grab the steering wheel when mounting the

vehicle.
! DANGER 4. Ensure that all tyre and rim parts are undamaged and
correctly assembled before inflating the tyre.
! DANGER 5. Always inflate the tyres with the correctly designed

inflation device. Don’t exceed the tire manufacturer’s
recommended maximum pressure.
B 00500--4 en 0409 / AR 65 (74)

! WARNING 6. Use caution when draining hot fluids from the vehicle,
splashing hot fluid can cause serious burns.
! WARNING 7. Accumulated grease or oil on the vehicle is a fire hazard.

Remove debris any time a significant quantity oil is
spilled on the vehicle.
! CAUTION 8. Do not arc weld on this vehicle without first

disconnecting the alternator.
! WARNING 9. Before performing maintenance or repair work on any

equipment, consult the manufacturer’s instruction
manual and follow the recommended procedures.
10. Inspect equipment daily for signs of failure or beginning of failure.

11. Perform all recommended checks.
12. Report all defects.
13. Use the proper tools for service.
14. Never attempt to clean, lubricate all or adjust the vehicle while it is in motion.
15. Always comply with your company’s regulations and practices for the safe
servicing of this vehicle.
66 (74) B 00500--4 en 0409 / AR

7.2. Hydraulic system safety precautions
! DANGER 1. When troubleshooting a hydraulic system for leaks, use

a piece of cardboard or other material as detector rather
than your hand. Pressurized hydraulic fluid escaping
from a fault component can penetrate the skin and
cause serious injury.
! DANGER 2. Never attempt the do work on the hydraulic system

before you are sure that there is no pressure. Before
disconnecting lines:
D Release pressure from the system.
D Release pressure from the accumulators.
! DANGER 3. Before performing service or maintenance work under

the raised boom (equipments) perform the following
operations:
D Empty the boom.
D Place adequate support under the boom.
D Shut down the engine.
D Release pressure from the accumulators.
! CAUTION 4. Use caution when draining hot fluids from the machine
splashing hot fluid can cause serious burns.
! CAUTION 5. When washing parts, do not use corrodents.
B 00500--4 en 0409 / AR 67 (74)

6. Do not change the pressure setting of any hydraulic valves unless

authorized instruction has been obtained.
7. Clean the area around the component to be repaired before starting work.
If possible, change the complete component.
8. Hydraulic components and hoses should be stored with all connections
well plugged. Do not remove the plugs until the components are mounted
on the rig.
9. Hydraulic pumps and motors are heavy. Before detachment you must have
equipments to lift them up safely.
7.3. Maintenance safety precautions for the boom
1. Before performing service or maintenance work under a raised boom

perform the following operations:
D Place an adequate support under the boom.
D Shut down the vehicle.
2. Repairs and alternations which can be assumed to effect the operating
safety must not be made without manufacturer’s permission.
3. When servicing or repairing the boom shut down the engine unless required
for adjustment purposes.
4. Do not change the pressure settings of any valves unless authorized
instructions has been obtained.
5. Before disconnecting hydraulic lines release pressure from the system.
68 (74) B 00500--4 en 0409 / AR

7.4. Troubleshooting guide for the hydraulics
Trouble Location Probable Remedy

cause(s)
Steering Steering The relief valve Check and adjust the
is very hydraulics is damaged or pressure. Change a new
stiff the adjustment relief valve when neces-
has altered. sary.
Hydraulic Change a new pump.
pump has
damaged.
The steering The cylinder leakage can
cylinder seals be ascertained by operat-
are leaking. ing the steering several
times to see whether the
cylinder heats up in ab-
normal way. Change the
cylinder seals.
Steering valve Change a new steering
damage unit. Maintain strict clean-
ness.
Steering Steering Air in the Carry out bleeding be
is sticking steering sys- driving the steering to ex-
and un- tem. treme positions a few
steady times. Check the inlet
side of the pump.
Steering valve Change the steering
worn. valve.
Steering col- Change the bearing.
umn bearing
worn.
B 00500--4 en 0409 / AR 69 (74)

Trouble Location Probable Remedy

cause(s)
Service Service Internal leak in Change the cylinder
brake brake the brake seals.
does not system cylinders.
h ld
hold Too low brake Check and adjust the
pressure. pressure in the hydraulic
system
Air in the brake Bleed the system.
system.
Brake plates Check the brake plates,
are worn out. and change if necessary.
Safety Safety Brake plates Renew the brake plates.
brake brake are worn out.
d
does nott system
t Lack of power Renew the springs.
hold of safety brake
cylinder
springs.
Oil leak in the Change the brake valve.
safety brake
valve, thus
pressure in the
spring brake.
Safety Safety Air in the Bleed the system.
brake brake system.
d
does nott system
t Releasing Check the pressure, ad-
release pressure too just according to the
(open) low. workshop manual.
Oil leak in the Change the seals.
brake cylinder.
70 (74) B 00500--4 en 0409 / AR

7.5. Troubleshooting guide for the engine

Operating troubles are often due to improper operation or maintenance of
the engine. In the event of trouble, always check whether the operating
instructions have been strictly followed.
Trouble Location Probable cause(s) Remedy

Engine Operation Not declutched (where pos- Check
fails (or sible).
diffi lt) to
difficult) t Below start limit temperature. Check
start
start.
Engine shut--down lever still in Check
stop position.
Op. Media Wrong SAE--grade of engine Renew
oil or oil quality.
Fuel quality grade not as spe- Renew
cified in lubrication manual.
Electrics Battery defective or flat Check
Connections of starter Check
circuit loose or oxidized.
Starter faulty or pinion does Check
not engage.
Engine Valve clearance incorrect. Adjust
Injector defective. Check
Renew
Engine Engine Flame type heater plug sys- Check
fails (or tem / Heating tube defective.
diffi lt) to
difficult) t Air in fuel system. Check
start
start.
Fuel filter, fuel strainer / Check
screen contaminated. Renew
Clean
Engine Op. Media Fuel quality grade not as spe- Renew
starts, but cified in lubrication manual.
runs un- Engine Valve clearance incorrect. Adjust
evenly or
stalls. Injection line leaky. Check
Renew
Air in fuel system. Check
Clean
B 00500--4 en 0409 / AR 71 (74)


Engine Op. Media Oil level too low. Top up
b
becomes Oil level too high. Lower lev-
too hot, el
tempera-
moni- Combus-
ture moni Air cleaner contaminated. Renew
tor gives tion
ti Ai
Air Air cleaner service switch / Renew
warning. service indicator defective.
Cooling Cooling fins soiled. Clean
System
Engine Cooling Cooling blower faulty, V--belt Check
becomes System broken or slack. Renew
t h
too hot,
t Cooling air temperature rise / Check
tempera- Hor air recirculation.
ture moni-
tor gives Oil cooler soiled. Check
warning. Clean
Engine Injector defective. Check
Renew
Engine Operation Engine shut--down lever still in Check
gives poor stop position.
perfor-
f Oil level too high. Lower lev-
mance. el
Op. Media Fuel quality grade not as spe- Renew
Combus- Air cleaner contaminated. Renew
ti Air
tion Ai Air cleaner service switch / Renew
service indicator
defective.
Injection line leaky. Check
Renew
Air in fuel system. Check
Clean
72 (74) B 00500--4 en 0409 / AR


Engine Engine Injection line leaky. Check
nott work-
k Injector defective. Check
ing on all Renew
cylinders
cylinders.
Clean
Engine Operation Oil level too low. Top up
h little
has littl Excessive inclination of en- Check
or no oil gine.
pressure
pressure.
oil or oil quality.
Engine oil Operation Oil level too high. Lower lev-
consump- el
ti ex-
tion Excessive inclination of en- Check
cessive. gine.
oil or oil quality.
Engine Operation Oil level too high. Lower lev-
smokes el
bl
blue. Excessive inclination of en- Check
gine.
Engine Operation Below start limit Check
smokes temperature.
white.
hit Op. Media Fuel quality grade not as spe- Renew
Renew
Flame type heater plug sys- Check
tem / Heating tube defective.
Engine Combus- Air cleaner contaminated. Renew
smokes
k ti Air
tion Ai Air cleaner service switch / Renew
black. service indicator defective.
Renew
B 00500--4 en 0409 / AR 73 (74)

7.6. Troubleshooting guide for the axle

Operating troubles are often due to improper operation or maintenance of the axle.
In the event of trouble, always check whether the operating instructions have been strictly
followed.
Trouble Probable cause(s) Remedy
Insufficient Incorrect adjust- Inspect disc thickness
braking. ment. and if discs are usable re-
adjust brakes.
Brake discs worn Inspect disc thickness
out. and replace if necessary.
Soft brake ped- Air in the brake Bleed the brakes.
al. circuit.
Ineffective Incorrect Adjust.
safety brake. adjustment.
Brake disc worn out. Renew the brake discs.
Overheating. Too small of a brake Readjust the brakes.
gap.
Parking brake Unlock the brake and ad-
dragging. just the correct gap.
Restriction in brake Inspect for and replace
lines. damage lines.
For more information, see the workshop manual for the vehicle.
74 (74) B 00500--4 en 0409 / AR

HYDROSTATIC TRANSMISSION
This manual is a guide to the proper and safe operation of the vehicle. With respect to
operation, the equipment used with the vehicle requires additional modifications, which
must be considered separately. The information contained in this manual is current as of
the date of publication. Continued product improvement, and different versions of the
equipment, could result in changes to the vehicle that are not reflected herein.
B 16151--5 en 1108 / AR 1 (79)

CONTENTS
1. GENERAL DESCRIPTION OF THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . 4

2. TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. TRANSMISSION DIAGRAM (ABA-- SYSTEM) (OPTION) . . . . . . . . . . . . . . . . . 14
3.1. ABA-- system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2. Transmission pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3. Tramming motor (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4. Accumulator charging valve (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5. Brake pedal (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6. Accelerator pedal (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7. Throttle cylinder (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8. Sequence valve (21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.9. Safety brake operating valve (22.1 / 22.2) . . . . . . . . . . . . . . . . . . . . . . . . 23
3.10. Priority valve (29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.11. Steering valve (30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.12. Air and oil cooler (25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.13. Return oil filter (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.14. Transmission oil receiver (27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.15. Pressure relief valve (12 and 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.16. Brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4. GENERAL DESCRIPTION OF THE HYDROSTATIC TRANSMISSION
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1. Charge pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2. Charge pressure filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. CONTROL PRESSURE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1.1. DA--control (1.2) of the pump (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1.2. HD--control (1.1) of the pump (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6. HIGH PRESSURE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7. FLUSHING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1. Operation of safety and service brake circuits . . . . . . . . . . . . . . . . . . . 37
7.1.1. Switching on the safety brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.2. Switching off the safety brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2. Service brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.2.1. Hydromechanical braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.2. Hydrostatic braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.3. Testing the brakes (carrier 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2.4. Testing the brakes (carrier 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3. Operation of the control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4. Operation of the transmission circuit in different situations . . . . . . 46
7.4.1. Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 (79) B 16151--5 en 1108 / AR

7.5. Tramming forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.5.1. Tramming forwards (low speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5.2. Tramming forwards (high speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.6. Tramming backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.7. Tramming down a ramp (low speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.8. Tramming down a ramp (high speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1. Tramming pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2. Measuring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3. Initial start-- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4. Throttle cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.5. Pressure switches (S150.1, S150.2, S56, S57) . . . . . . . . . . . . . . . . . . . . 70
8.6. Pressure switches (S57B, S56B, S200, S201) . . . . . . . . . . . . . . . . . . . . 70
8.7. Adjusting the pressure relief valves (12 and 32) . . . . . . . . . . . . . . . . . 71
8.8. Adjusting the sequence valve (21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.1. Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3. Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
B 16151--5 en 1108 / AR 3 (79)

1. GENERAL DESCRIPTION OF THE HYDRAULIC SYSTEM

Closed circuit
In its most compact form, the closed hydraulic circuit consists of the hydraulic pump,
hydraulic motor, pressure lines connecting the pump and motor, and high and low
pressure lines. The system features a high-- and a low--pressure side; which is which
depends on the direction of the load. The system is protected with pressure relief valves
installed between pressure lines.
In a closed hydraulic circuit, the return oil from the actuator flows in the low--pressure line
to the intake side of the hydraulic pump without passing the receiver. However, the system
oil changes gradually, as a result of leaks in the pump and motor. A separate charge pump
constantly charges the low--pressure side of the closed circuit, replacing the oil that flows
to the receiver because of leaks.
The charge pump operates in an open circuit and pumps oil from the receiver to the closed
circuit. The remainder of the volume flow, which is not needed in the circuit, returns to the
receiver through the charge pressure relief valve. The charge pressure relief valve setting
determines the charge pressure. The charge pressure is also used as control pressure
for the pump and motor.
B max.
B min.
max.
0 0
B
1 max. 2
1. Hydraulic pump
2. Hydraulic motor
3. Pressure line
A simple closed system is used; this includes a variable displacement pump and motor.
The pump runs in one direction, but its angle can be adjusted steplessly over the zero
angle; i.e., the volume flow direction can be changed. The angle of the motor running in
both directions can also be adjusted steplessly, but in one direction only.
4 (79) B 16151--5 en 1108 / AR

4
1 2
5
6
1. Hydraulic pump
2. Hydraulic motor
3. Pressure line
4. Pressure relief valves as overload protectors
5. Drain line
6. Oil receiver
Pump and motor drainage oil is delivered to a receiver.
4
1 2
1. Hydraulic pump
2. Hydraulic motor
3. Pressure line
The system is protected against overpressure with pressure relief valves. The system
requires two pressure relief valves, one for each direction.
B 16151--5 en 1108 / AR 5 (79)

3
7
11 4
10
4
1 2
11
5
1. Hydraulic pump
2. Hydraulic motor
3. Pressure line
5. Drain line
6. Oil receiver
7. Oil required for controlling the closed circuit.
8. Charge pump
9. Auxiliary devices, filter, radiator, etc.
10. Charge pressure relief valve
11. Non--return valve
The charge pump output is used to replace the drainage oil and control the closed circuit
pump and motor. The charge pressure fills the low--pressure side of the closed circuit
through the non--return valve. The charge pressure relief valve limits the charge pressure
according to the requirements of the pump and motor control. The drainage oil flows
through the cooler to the receiver. The system’s filter is installed in conjunction with the
charge pump.
6 (79) B 16151--5 en 1108 / AR

2. TRANSMISSION DIAGRAM
50 5 1
210
D
D
D
RELEASE
R6
1.17
42
41
40
23.1
S 1 5 0 .1
22.1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
38
23.2
39
Fig. 1.Transmission circuit hydraulic diagram
B 16151--5 en 1108 / AR 7 (79)

ITEM FUNCTION
1. Transmission pump Delivers the required amount of oil to the transmission
circuit.
1.1 HD control Directs the oil flow to the pump (1) control cylinder (1.3).
1.2 DA control Adjusts the control pressure to the pump (1) HD control
(1.1) according to the diesel engine’s speed.
1.3 Control cylinder Adjusts the angle of the inclined plate of the pump (1)
according to the control pressure from the HD control
(1.1).
1.4 Pressure cut--off valve Limits the maximum pressure in the high--pressure sys-
tem of the pump (1).
1.5 Charge pump Delivers oil to the high--pressure system of the pump (1)
according to the diesel engine’s speed.
1.6 Measuring orifice Serves as a measuring orifice for the pump (1) DA con-
trol (1.2).
1.7 Orifice Limits the flow of oil from DA control (1.2) to pump (1)
control circuit.
1.8 Shuttle valve Directs the flow of oil from the pump’s (1) high--pressure
circuit to the pressure cut--off valve (1.4) on the basis of
the higher pressure.
1.9 Pressure relief valve Limits the increase in pressure caused by external fac-
tors in the pump’s (1) high pressure circuit (line A).
Also operates as an intake valve in the high pressure
circuit (line A).
1.10 Pressure relief valve Limits the increase in pressure caused by external fac-
tors in the pump’s (1) high pressure circuit (port B).
Also operates as an intake valve in the high pressure
circuit (line B).
1.11 Filter Filters the oil delivered by the charge pump (1.5) of the
pump (1).
1.12 Pressure relief valve Limits the maximum pressure of the charge pump (1.5)
of the pump (1).
1.13 Pressure difference Circulates the oil delivered by the charge pump (1.5) of
valve the pump (1) back to the charge pump’s (1.5) intake
side.
1.14 Orifice Adjusts the operation speed of the control cylinder (1.3).
1.17 Visual contamination in- Indicates the contamination of filter (1.11).
dicator
8 (79) B 16151--5 en 1108 / AR

2. Transmission motor Converts the hydraulic energy delivered from the trans-
mission pump (1) to mechanical energy.
2.1 Selector valve Depending on the tramming direction the oil flow is di-
rected to the proportional regulating valve (2.3) and the
control cylinder (2.2) of the motor (2).
2.2 Control cylinder Controls the angle of the inclined plate of the motor (2)
with the control pressure from the selector valve (2.1)
and proportional regulating valve (2.3).
2.3 Proportional regulating Controls the oil flow to the control cylinder (2.2) of the
valve transmission motor (2) with the control pressure from the
selector valve (2.1).
2.4 Flushing valve Removes a certain amount of oil from the low--pressure
side of the high--pressure line of the transmission circuit
to the cooling circuit.
2.5 Selector valve Depending on the tramming direction, opens the low--
pressure side of the high--pressure circuit to the cooling
circuit.
2.6 Orifice Limits the amount of oil flowing from the high--pressure
circuit to the cooling circuit.
2.7 Pressure relief valve Limits the suction pressure of the transmission pump (1).
2.8 One--way restrictor Stabilizes the operation of the control cylinder (2.2) of
the transmission motor (2).
2.9 Non--return valve Prevents the transmission motor (2) control circuit pres-
sure from discharging to the low--pressure side of the
transmission’s high--pressure circuit.
2.10 Non--return valve Prevents the motor (2) control circuit pressure from dis-
charging to the low--pressure side of the transmission’s
high--pressure circuit.
3. Hydraulic accelerator pedal Adjusts the hydraulic control pressure proportional to the
angle of the accelerator pedal (3) to the throttle cylinder
(4).
4.Throttle cylinder Adjusts the diesel engine’s (5) speed according to the
control pressure from the accelerator pedal (3).
5. Diesel engine Produces the required mechanical energy for the trans-
mission and carrier hydraulics.
6. Control block for tramming Includes tramming direction and speed selector valves
direction and speed
6.1 Tramming direction selec- Directs the oil flow from the pressure--reducing valve
tor valve (14.1) to pilot line (Y2) or (Y1) of the HD control (1.1) of
the transmission pump (1).
6.2 Tramming speed selector Controls the flow of oil from the HD control (1.1) of the
valve transmission pump (1) to control line X1 of the transmis-
sion motor (2).
B 16151--5 en 1108 / AR 9 (79)

6.3 Tramming speed selector Controls the flow of oil from the HD control (1.1) of the
valve transmission pump (1) to control line X2 of the transmis-
sion motor (2).
7. Non--return valve Ensures sufficient oil circulation from the transmission
pump (1) to the cooling circuit.
8. Orifice Stabilizes the operation of the HD control (1.1) of the
transmission pump (1).
9. Orifice Stabilizes the operation of the HD control (1.1) of the
transmission pump (1).
10. Orifice Limits the amount of oil flowing from the transmission
pump (1) to the safety brake circuit.
11. Gear pump of the service Charges the required amount of oil to the service brake
brake circuit circuit.
12. Pressure relief valve Limits the maximum pressure of the service brake cir-
cuit.
13.Accumulator charging Distributes the oil from the service brake circuit pump
valve (11) to the service brake circuit or return oil circuit as re-
quired.
13.1 Control valve Directs the oil flow delivered to the accumulator charging
valve (13) to either the service brake circuit or the return
oil circuit as dictated by the control valve (13.2).
13.2 Control valve Controls the operation of the control valve (13.1) on the
basis of the pressure in the service brake circuit. When
the pressure level in the service brake circuit increases
to 190 bar, the control valve (13.2) changes its position
and directs the pilot oil from the control valve (13.1) to
the receiver. Then, at the same time, the control valve
(13.1) changes its position and directs the oil delivered
to the accumulator charging valve (13) to the receiver.
When the pressure level in the service brake circuit de-
creases to 160 bar, the control valve (13.2) changes its
position and directs the pilot oil to the control valve
(13.1). Also, the control valve (13.1) changes its position
and directs the oil delivered to the accumulator charging
valve (13) to the service brake circuit.
13.3 Pressure relief valve The pressure relief valve (13.3) ensures the operation of
the rear service brake circuit in the event of a hose
breakage in the front service brake circuit. The pres-
sure--relief valve (13.3) adjusts the operating pressure of
the rear service brake circuit to 120 bar.
13.4 Pressure relief valve The pressure relief valve (13.4) ensures the operation of
the front service brake circuit in the event of a hose
breakage in the rear service brake circuit. The pressure--
relief valve (13.4) adjusts the operating pressure of the
front service brake circuit to 120 bar.
10 (79) B 16151--5 en 1108 / AR

13.5 Non--return valve Prevents the pilot pressure from discharging from the
service brake circuit.
14. Double action brake pedal Adjusts the hydraulic pressure proportional to the angle
of the brake pedal to the service brake cylinders and
transmission pump HD control (inching).
14.1 Pressure--reducing valve Adjusts the hydraulic pressure (1) proportional from the
angle of the brake pedal (14) to the HD control (1.1).
14.2 Pressure--reducing valve Adjusts the hydraulic pressure proportional to the brake
pedal’s (14) angle to the service brake cylinders (19 and
20).
15. Pressure accumulator Serves as an oil reserve for the service brake circuit of
the front brake cylinders (19).
16. Pressure switch Controls the minimum charge pressure of the front ser-
vice brake circuit.
17. Pressure accumulator Serves as an oil reserve for the service brake circuit of
the rear brake cylinders (20).
18. Pressure switch Controls the minimum charge pressure of the rear ser-
vice brake circuit.
19. Front service/parking Perform front service/parking brake operations on the
brake cylinders basis of the hydraulic control pressure.
20. Rear service/parking Perform the rear service/parking brake operations on the
brake cylinders basis of the hydraulic control pressure.
21.Sequence valve Directs the operating pressure to the parking brake cir-
cuit.
22.1 Safety brake operating Directs the operating pressure to the front brake cylin-
valve (front) ders (19) and removes it when necessary.
22.2 Safety brake operating Directs the operating pressure to the rear brake cylin-
valve (rear) ders (20) and removes it when necessary.
23.1 Pressure switch (front) Controls the minimum operating pressure of the front
parking brake circuit.
23.2 Pressure switch (rear) Controls the minimum operating pressure of the rear
parking brake circuit.
24. Pressure gauge Indicates the charge pressure level for the accelerator
pedal (3), pressure--reducing valve (14.1), and parking
brake circuit.
25. Air and oil cooler Cools the oil in the transmission circuit.
26. Return filter Cleans the oil in the transmission circuit.
27. Transmission oil receiver Serves as stabilization space for the transmission oil.
28. Steering pump Produces the required amount of oil for the steering and
carrier auxiliary control.
B 16151--5 en 1108 / AR 11 (79)

29.Priority valve Distributes the oil delivered from the steering pump (28)
primarily to the carrier control or secondarily to the carri-
er auxiliary functions.
29.1 Orifice Stabilizes the operation of the priority valve (29) spool.
29.2 Orifice Stabilizes the operation of the priority valve (29) spool.
30. Steering valve (orbitrol) Distributes the oil from the priority valve (29) to the
steering system as required.
30.1 Pressure relief valve Adjusts the maximum operating pressure level of the
control valve (30).
30.2 Non--return valve Prevents the pilot pressure from being discharged from
the control circuit.
30.3 Non--return valve Operates as the intake valve (anti--cavitation valve) for
the control line R of the control valve (30).
30.4 Non--return valve Operates as the intake valve (anti--cavitation valve) for
the control line L of the control valve (30).
30.5 Pressure relief valve Limits the maximum pressure level of the control line R
of the control valve (30).
30.6 Pressure relief valve Limits the maximum pressure level of the control line L
of the control valve (30) (external force).
30.7 Orifice Stabilizes the operation of the pressure relief valve
(30.1).
31. Steering cylinders Steer the carrier based on the amount of oil from the
control valve (30).
32. Pressure--relief valve Limits the maximum pressure level of the steering cir-
cuit.
33. Hydraulic oil receiver Serves as stabilizations space for the oil in the drilling
circuit.
34. Measuring point assembly
35. Measuring point assembly
36. Collecting piece Collects and returns the depressurised return oil from
the tramming control circuit to the transmission’s oil re-
ceiver.
38. Pressure--relief valve Limits the oil pressure produced by the safety brake re-
lease pump (39).
39. Safety brake release Produces oil flow to release the safety brake -- e.g., dur-
pump ing towing.
40. Filling pump Oil filling for drilling hydraulics and transmission.
41. Non--return valve Prevents the oil flow back to the filling pump
42. 3--way valve Directs the oil flow into the drilling circuit of into the
transmission circuit
50. Pressure gauge Indicates rear service brake pressure. (option)
12 (79) B 16151--5 en 1108 / AR

51. Pressure gauge Indicates front service brake pressure. (option)

52.1 Check valve (front) Allows to release the front safety brake circuit with exter-
nal pressure
52.2. Check valve (rear) Allows to release the rear safety brake circuit with exter-
nal pressure
B 16151--5 en 1108 / AR 13 (79)

3. TRANSMISSION DIAGRAM (ABA--SYSTEM) (OPTION)
46
44
50 51
45
43
RELEASE
R6
48
S 1 5 0 .1
C
47
S 1 5 0 .2
Fig. 2.Transmission circuit hydraulic diagram (ABA--system)
14 (79) B 16151--5 en 1108 / AR

3.1. ABA--system (option)

ITEM FUNCTION
43. Pressure switch Switches the alarm light H150 on if the charging pres-
sure drops below 110 bar in front axle service brake cir-
cuit.
44. Pressure switch Switches the alarm light H150 on if the charging pres-
sure drops below 110 bar in rear axle service brake cir-
cuit.
45. Pressure switch Switches the safety brake on if charging pressure drops
below 75 bar in front axle service brake circuit.
46. Pressure switch Switches the safety brake on if charging pressure drops
below 75 bar in rear axle service brake circuit.
47. Pressure switch Switches the safety brake on if transmission charging
pressure drops below 10 bar.
48. Pressure switch Switches the alarm light H91 on if the transmission pres-
sure drops below 15 bar.
50. Pressure gauge Indicates rear service brake pressure. (option)
51. Pressure gauge Indicates front service brake pressure. (option)
B 16151--5 en 1108 / AR 15 (79)

3.2. Transmission pump

1.17
1.4
1.8
Ps
Fa
1.10
B Y1 Y2
1.10
Mb 1.17
1.12 1.2
T2 G X2
Ma
1.9 S
R
1.15
T1
A
1.11
X1
ITEM FUNCTION ITEM FUNCTION
G Charge pressure to safety brakes, B Connection
accelerator
Ps Pilot pressure test point 1.2 DA cartridge, pilot pressure valve
Ma High pressure test point 1.4 Pressure cut--off relief valve
Mb
R Air bleeding plug 1.8 Shuttle valve
S Suction inlet line 1.9 High pressure safety relief, line A
T1 Drain line to air cooler 1.10 High pressure safety relief, line B
T2 2--bar drain relief line, direct to tank 1.11 Filter
Fa After filter, charge pressure test 1.12 Charge pressure relief valve
point
X1 Pilot pressure acting on servo--cylin- 1.15 Orifice
X2 der
Y1 Forward direction, inlet pilot port 1.17 Visual contamination indicator
Y2 Backward direction, inlet pilot port
A Connection
16 (79) B 16151--5 en 1108 / AR

3.3. Tramming motor (2)
ITEM FUNCTION ITEM FUNCTION

A High pressure port A 2.1 Control part and selector valve
B High pressure port B 2.2 Port plate and control cylinder
X1, Control pressure port 2.3 Start of control setting screw for
X2 proportional control valve
X3 Control pressure port 2.4 Flushing and charge pressure
valve
G High pressure measuring point 2.5 Selection valve
M1 Control cylinder pressure test point 2.7 Relief valve
T Case drainage port 50 min. angle adjustment
51 max. angle adjustment
B 16151--5 en 1108 / AR 17 (79)

3.4. Accumulator charging valve (13)

13.2
13.1
B3
13.3
13.4 MA
13.5
13.1
13.2 ....
13.4
B3
MA B3
MA MA
13.3
Fig. 3.Accumulator charging valve
13.1 Control valve

13.2 Control valve
13.3 Pressure relief valve
13.4 Pressure relief valve
13.5 Non--return valve
18 (79) B 16151--5 en 1108 / AR

3.5. Brake pedal (14)
F1
F2 X
P
Mx
P1
P2
Fig. 4.Brake pedal
The brake pedal adjusts the hydraulic pressure proportional to the brake pedal’s angle to
the service brake cylinders and transmission pump HD control (inching).
B 16151--5 en 1108 / AR 19 (79)

3.6. Accelerator pedal (3)
Fig. 5.Accelerator pedal

Adjusts the hydraulic control pressure proportional to the accelerator pedal’s angle to the
throttle cylinder.
20 (79) B 16151--5 en 1108 / AR

3.7. Throttle cylinder (4)
P
T
Fig. 6.Throttle cylinder
Adjusts the diesel engine’s speed according to the control pressure from the accelerator
pedal.
1. Throttle cylinder
B 16151--5 en 1108 / AR 21 (79)

3.8. Sequence valve (21)
B
3
1
Fig. 7.Pressure relief valve
The sequence valve directs the operating pressure to the parking brake circuit.
A. Pressure relief valve
B. Pressure adjustment screw
22 (79) B 16151--5 en 1108 / AR

3.9. Safety brake operating valve (22.1 / 22.2)
Fig. 8.Safety brake operating valve (front and rear)
The safety brake operating valves direct and remove the operating pressure from the front
and rear brake cylinders.
B 16151--5 en 1108 / AR 23 (79)

3.10. Priority valve (29)
Fig. 9.Priority valve
The priority valve distributes the oil delivered from the steering pump (28) primarily to the
carrier steering or secondarily to the carrier’s auxiliary functions.
The priority valve distribute and trace the hydraulic flow from the supply pump of the
hydraulic system to the hydraulic components which control and run the vehicle. The
priority valve are used only with the HKUS 5T hydrostatic steering unit.
When connected, the steering unit and the priority valve represent sophisticated hydraulic
tracing system that controls the flow in both main pipelines of the hydraulic system (the
working and control one) at any time of its operation.
24 (79) B 16151--5 en 1108 / AR

3.11. Steering valve (30)
Option
24
24
Standard
51 30.6 30.5
+
50 30.3
30.4
P 1
T
R 30.1 30.7
30.2
30.2
L
30.5 R--line
30.3
30.1
LS 30.6 L--line
30.4
Fig. 10.Control valve

The tramming and steering valve distributes the oil from the priority valve to the steering
as required.
The steering unit consist of a rotary valve and a rotary meter. Via a steering column the
steering unit is connected to the steering wheel of the vehicle. When the steering wheel
is turned, oil is directed from the steering system pump via the rotary valve and rotary
meter to the cylinder ports L or R, depending on the direction of turn. The rotary meter
meters the oil flow to the steering cylinder in proportion to the angular rotation of steering
wheel.
1. Control valve 30.6 and 30.4 L--line
30.1 Relief valve (P--T) 30.5 and 30.3 R--line
30.2 Check valve 30.7 Orifice
24. Pressure gauge (charging pressure)
50. Pressure gauge (rear service brake 51. Pressure gauge (front service brake
circuit) (option) circuit) (option)
B 16151--5 en 1108 / AR 25 (79)

3.12. Air and oil cooler (25)
OUT
2.5 bar
L
IN
IN
OUT
Fig. 11.Air and oil cooler
1. Check valve
L = Drain connection
2. Flow control valve
The air and oil cooler cools the oil in the transmission circuit.
The flow controller is used to adjust the radiator fan speed (factory setting is 1900 rpm).
The adjustment is performed when the diesel engine is running at maximum speed
26 (79) B 16151--5 en 1108 / AR

3.13. Return oil filter (26)

2
2.5 bar
3.5 bar
1
Fig. 12.Return oil filter
The return oil filter cleans the oil in the transmission circuit.
B 16151--5 en 1108 / AR 27 (79)

3.14. Transmission oil receiver (27)

4
1
R6
R6
S1
S2
R5
Fig. 13.Transmission hydraulic receiver

The transmission hydraulic receiver serves as stabilizing space for the transmission oil.
1. Oil filling cap
2. Drain plug
3. Oil level sight class
28 (79) B 16151--5 en 1108 / AR

3.15. Pressure relief valve (12 and 32)
Fig. 14.Pressure--relief valve

The pressure relief valve (12) limits the maximum pressure of the service brake circuit.
The pressure relief valve (32) limits the maximum pressure of the steering circuit.
B 16151--5 en 1108 / AR 29 (79)

3.16. Brake cylinder
D C
E
1
A B
F
D
Fig. 15.Brake cylinder
The brake cylinder performs the front/back service/parking brake operations on the basis
of the hydraulic control pressure.
1. Service brake bleed screw
2. Safety brake bleed screw
D The Mico cylinder provides 1.7kNm (=1240 lbf) pull on brake rod for
safety/emergency braking. This effect is via spring shown at A.
D During vehicle operation the spring is depressed by a hydraulic pressure from the
vehicle system of at least 11 bar= (157 p.s.i.) active on the piston B this releases
the brake pull rod allowing normal operation of vehicle.
D Hydraulic release pressure is piped to port C.
D During this mode the brakes can be separately applied via a food pedal or other
hydraulic pressure source of up to 117 bar = (1700 p.s.i.) applied at port D. This
acts on piston E which then acts on collar F applying a braking force to the pull rod.
The maximum force that can be applied is 2.1 kNm = (1550 lbf) which will effect
100% brake performance from the axle brake system.
The overall operation is then as follows:
-- Machine starts = C hydraulic pressure = brakes FREE
-- Service brake operation = D hydraulic pressure = brakes ON
-- Machine stops = Nil pressure = brakes ON
30 (79) B 16151--5 en 1108 / AR

4. GENERAL DESCRIPTION OF THE HYDROSTATIC

TRANSMISSION CIRCUIT
50 5 1
210
D
D
D
RELEASE
R6
1.17
42
41
40
23.1
S 1 5 0 .1
22.1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
38
23.2
39
Fig. 16.Transmission circuit hydraulic diagram
B 16151--5 en 1108 / AR 31 (79)

The hydrostatic transmission circuit can be shared by certain other circuits:

-- charge pressure circuit
-- control pressure circuit
-- high pressure circuit
-- flushing circuit
4.1. Charge pressure circuit

4.1.1. Function
The charge pressure circuit has several functions: to generate pilot pressure for the
control system, to flush the internal parts of the pump (1), and to fill the closed--loop system
by compensating for the leakage oil and the flow of flushing oil through the hydraulic motor
(2). The compensation is needed for avoiding cavitation inside the closed--loop system.
When the swash plate of the tramming pump (1) is in the neutral position, flow is generated
to neither pressure line A nor line B. The flow provided by the charge pump (1.5) is fed
to the charge pressure relief valve (1.12) and through the charge pressure filter (1.11) to
the DA--valve (1.2). The outlet of the relief valve is directly connected to the pump housing.
The rest of the charge pump (1.5) flow that is not needed for swivelling the pump (1) or
for compensating for the leakage is fed through the housing to the pump leakage line.
When the machine is not moving and the diesel engine (5) is running, the entirety of the
flow from the charge pump (1.5) runs through the leakage line.
4.2. Charge pressure filtering

The tramming pump (1) has integrated charge pressure filtering. Inside the foot of the filter
(1.11), a cold--start valve (1.13) is integrated into the system. When the pressure
difference over the filter element exceeds the value set by the valve’s spring, the oil is fed
back to the suction line of the charge pump (1.5). This can happen when the viscosity of
the oil is high on account of the low temperature of the oil or when the filter element is dirty.
When the oil is fed back to the suction line, there is no flow to the charge pressure circuit
inside the tramming pump and therefore no pilot or DA pressure is generated. In this
situation, driving is not possible.
32 (79) B 16151--5 en 1108 / AR

5. CONTROL PRESSURE CIRCUIT

5.1. General
The pump (1) of the hydrostatic transmission is a closed--loop axial piston pump of swash
plate design. The angle of the swash plate is controlled by means of the control cylinder
(1.3).
In the pump (1), two controls are combined. The hydraulically piloted HD control (1.1)
takes care of the maximum angle of the pump (1). The hydrostatic automotive control DA
(1.2) takes care of operating the swivel angle on the basis of the diesel engine’s (5) speed.
The DA--control (1.2) makes it possible to drive the machine like a normal car; more
engine speed means more driving speed. The behavior is similar to that of a machine
equipped with a torque converter.
5.1.1. DA-- control (1.2) of the pump (1)
The pump (1) has an integrated charge pump (1.5) inside the port plate. The charge pump
(1.5) is an internal gear pump with fixed displacement. The flow provided by the charge
pump (1.5) is directly proportional to the speed of the diesel engine.
The flow from the charge pump (1.5) is fed through an integrated charge pressure filter
to the DA--valve (1.2) . At the DA--valve (1.2), the oil is fed through a measuring orifice
(1.6). Depending on the pressure drop generated in the measuring orifice (1.6), the
DA--valve (1.2) generates a pilot pressure that is proportional to the flow and therefore
proportional to the diesel engine’s speed.
In idle mode, the flow of the charge pump (1.5) generates -- through the DA--valve (1.2)
-- a pressure insufficient for moving the control piston (1.3) or swivelling the swash plate.
When the diesel engine’s speed increases, the DA--pressure is raised an equivalent
amount, causing the swash plate to swivel to a bigger angle.
The DA--control (1.2) takes also care of the anti--stalling function. As soon as the diesel
engine (5) starts to stall and decreases its running speed, the flow from the charge bump
(1.5) drops accordingly. That causes the DA--pressure to drop as the pressure difference
over the measuring orifice (1.6) of the DA--valve (1.2) becomes smaller. The pilot pressure
generated can no longer keep the pump (1) operating at the wider angle, and the swash
plate starts swivelling towards the neutral position. The smaller swivel angle involves
lower power consumption; therefore, the engine recovers from stalling.
B 16151--5 en 1108 / AR 33 (79)

5.1.2. HD-- control (1.1) of the pump (1)

The hydraulically piloted servo control valve HD (1.1) feeds the pilot oil to either side of
the control piston (1.3) depending on the position of the spool of the control valve (1.1).
The valve spool is operated by the pilot pressure fed to either port a or b depending on
the driving direction required. The control system has a mechanical feedback from the
position of the control piston (1.3) to the spool of the servo control valve (1.1).
The centering springs inside the control cylinder (1.3) bring the swash plate to neutral
position whenever the pressure difference between the control chambers of the control
cylinder (1.3) is not sufficient for moving the control piston.
34 (79) B 16151--5 en 1108 / AR

6. HIGH PRESSURE CIRCUIT

Selection of driving direction is performed with an electrically operated directional valve
(6.1).
When driving direction selection has not been performed and the diesel engine (5) is
running, the angle of the pump (1) is zero. This means that there is no oil flow in the high
pressure circuit and the carrier doesn’t move.
If selection of driving direction has been done and the speed of the diesel engine (5) is
increased, the control cylinder (1.3) of the pump (1) begins adjusting the angle of the
swash plate and the pump (1) starts to supply oil to the high pressure circuit.
The tramming motor (2) is a variable--displacement axial piston motor with a bent axis
design. The motor (2) has a DA--control system. The pilot pressure PS in the control
chambers of the tramming pump (1) is fed to ports P2 and P3 of the control block for
tramming direction / tramming speed (6) via pilot lines X1 and X2.
There is an option of disconnecting the control of the motor (2) by means of the solenoid
valves (6.2 and 6.3). If control of the motor (2) is disconnected, the solenoid valves (6.2
and 6.3) will not be active and slow tramming speed will be selected.
If control of the motor (2) is enabled, the solenoid valves (6.2 and 6.3) are active and the
pilot pressure PS is fed from the tramming direction / tramming speed control block (6)
from port X3 or X4 (depending on the tramming direction) to port X1 or X2 of the motor
(2). Depending on which side of the selector valve (2.1) the pilot pressure PS is brought
from, the selector valve (2.1) connects based on high pressure line pressure HP to the
piston rod side of the control cylinder (2.2) and the active pilot pressure to the proportional
control valve (2.3). At the proportional control valve (2.3), the PS pressure acts on a large
pilot piston area and the HP pressure acts in conjunction with a spring on the opposite side
-- on a smaller piston area. When the force caused by the pilot pressure overcomes the
sum of the force of the spring and the force caused by the active high pressure HP, the
control valve (2.3) changes its position. The high pressure is fed to the piston side of the
control cylinder (2.2). The motor (2) starts to swivel to a smaller angle. That means a
higher rotating speed and lower torque.
The motor (2) starts to swivel in a wider arc when the system pressure HP is high enough
to move the proportional control valve (2.3) back to a neutral position.
If the pilot DA--pressure PS coming from the pump (1) decreases or the high pressure in
the system increases, the motor (2) correspondingly swivels back to a bigger angle.
B 16151--5 en 1108 / AR 35 (79)

The return oil from the tramming motor (2) flows along the another high--pressure line into
the suction port of the transmission pump (1).
When the pressure inside the driving circuit rises to the pre--set maximum level, the
pressure cut--off (1.4) sees to the safe functioning of the circuit. The high pressure
selected by a shuttle valve (1.8) acts at the pressure cut--off (1.4) valve against a spring.
When the pressure exceeds the set value of 440 bar, the pilot pressure behind the orifice
(1.7) is fed to the
tank (27). That causes the swash plate to swivel against neutral position. The pump (1)
swivels to an angle such that the flow produced compensates for the leakage inside the
high pressure circuit and maintains the set pressure level.
The pressure cut--off (1.4) causes the pump (1) to swivel to neutral position; therefore, no
oil is driven through the high pressure safety valves (1.9 and 1.10) at this point and no heat
is generated when driving of the machine is blocked.
36 (79) B 16151--5 en 1108 / AR

7. FLUSHING CIRCUIT
The motor (2) is equipped with a flushing valve (2.4). The flushing valve (2.4) feeds a
certain amount of oil through the motor housing in order to flush the housing internally and
to at the same time to change the oil in the closed--loop system. The charge pump (1.5)
inside the tramming pump (1) feeds oil to the low--pressure side of the closed--loop system
in order to compensate for the leakage as well as the flow from the flushing valve. The aim
is to maintain the charge pressure level in the low--pressure side of the closed--loop
system.
The flushing valve (2.4) includes three components. The selection valve (2.5) connects
the low--pressure side to the motor housing. The orifice (2.6) inside the flushing valve (2.4)
determines the flushing flow, which normally is high enough for cooling the system but low
enough not to disturb the charge pressure even at low diesel engine speeds. The
integrated relief valve (2.7) will guarantee the minimum charge pressure.
7.1. Operation of safety and service brake circuits

7.1.1. Switching on the safety brake
The safety brake circuit receives oil from transmission pump (1) connection G. Then the
oil flows through the orifice (10) and sequence valve (21) to the safety brake operating
valves (22.1 / 22.2). When switching on the safety brake, push the operating valve’s (22.1
/ 22.2) control button SB1 (The light inside the button SB1 will come on). Then the
operating valve’s (22.1 / 22.2) control spools will prevent the oil from flowing to the front
brake cylinders (19) and rear brake cylinders (20).
At the same time, the operating valves (22.1 / 22.2) release the control pressure from the
piston side of the front brake cylinders (19) and rear brake cylinders (20). The safety brake
indicator lamp -- H150 -- on the driving panel will be lit when the control pressure drops
below 5 bar either in front or rear safety brake circuit. The springs inside brake cylinders
19 and 20 are released and the safety brake engages.
NOTE! In TC5-- carriers; when pushing the safety brake control button SB1 the
alignment of the tramming direction selector valve(6.1) is centralized and the
transmission pump(1) is returned to zero angle.
7.1.2. Switching off the safety brake

When switching off the safety brake, push the control button SB1 of the operating valves
(22.1 / 22.2) so that the light goes off. Then the control spools of the operating valves (22.1
/ 22.2) will change the position and the oil flows to the front cylinders (19), rear brake
cylinders (20), pressure switches (23.1 / 23.2). When the control pressure exceeds 5 bar
in front and rear safety brake circuits, the safety brake indicator light on the driving panel
turns off. The springs inside brake cylinders 19 and 20 are compressed and the safety
brake disengages.
B 16151--5 en 1108 / AR 37 (79)

7.2. Service brake circuit

General
The service brake circuit is constructed of two separate circuits which differ in function:
the hydromechanical brake circuit and hydrostatic brake circuit. The hydromechanical
brake circuit is further divided into two different circuits: the front brake circuit and rear
brake circuit.
The brake pedal (14) is constructed of two regulating valves: the pressure relief valves
14.2 and 14.1. When the brake pedal (14) is operated, both control valves (14.1 and 14.2)
are affected simultaneously.
38 (79) B 16151--5 en 1108 / AR

50 51
210
D
D
D
RELEASE
R6
1.17
42
41
40
23.1
S 1 5 0 .1
22 .1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
23.2
38
39
Fig. 17.Hydraulic diagram of safety and service brake circuits
B 16151--5 en 1108 / AR 39 (79)

7.2.1. Hydromechanical braking

The hydromechanical brake circuit gets oil from the gear pump (11). The output from the
pump (11) flows first to the pressure relief valve (12) and then to the accumulator charging
valve (13).
If the brake pedal (14) is not in use and the pressure accumulators (15 and 17) of the
hydromechanical brake circuit do not need any extra oil, the brake circuit pressure
increases to 190 bar and the control valve (13.2) changes its position. Then the pilot oil
from the control valve (13.1) is directed to the receiver. At the same time, the control valve
(13.1) changes its position and directs the oil delivered to accumulator charging valve (13)
port P to accumulator charging valve (13) port S and on through the filter (26) to the
receiver (27).
If the hydromechanical brake circuit needs oil (the brake pedal (14) is in use and the
pressure accumulators (15 and 17) are empty) and the pressure is decreased to 160 bar,
the control valve (13.2) changes its position and directs the oil flow from the brake circuit’s
main line to the spring side of the control spool of the control valve (13.1). The control valve
(13.1) spool changes its position and directs the main oil flow through the non--return valve
(13.5) and pressure relief valves (13.3 and 13.4) to ports A1 and A2 of the accumulator
charging valve (13).
From port A1, oil flows to the front brake cylinders’ pressure switch (16), the front brake
cylinders’ pressure accumulator (15), and port P1 of the pressure relief valve (14.2) of the
brake pedal (14). From port A2, oil flows to the rear brake cylinders’ pressure switch (18),
the rear brake cylinders’ pressure accumulator (17), and port P2 of the pressure relief
valve (14.2) of the brake pedal (14). When the brake pedal (14) is operated, oil flows
through ports F1 and F2 of the pressure relief valve (14.2) to the front brake cylinders (19),
rear brake cylinders (20), and measuring point collector (34).
The control pressure value of the pressure relief valve (14.2) is directly proportional to the
change of the brake pedal (14) angle. The greater the change of the angle, the higher the
control pressure and braking force.
The task of the pressure accumulators (15 and 17) is to ensure a sufficient amount of oil
for brake pedal operation. The pressure switches (16 and 18) control the charge pressure
level of the hydromechanical service brake circuits. If the pressure drops below 145 bar,
warning light H21 on the driving panel will be lit.
40 (79) B 16151--5 en 1108 / AR

7.2.2. Hydrostatic braking

The hydrostatic brake circuit receives oil from transmission pump (1) connection G. Then
the oil flows through ports P and X of the brake pedal (14) pressure relief valve (14.1) to
tramming direction / speed control block (6) port P1.
When tramming direction has been selected and the brake pedal (14) is used, oil flows
through ports P and X of the brake pedal (14) pressure relief valve (14.1), the tramming
direction selector valve (6.1), and orifice 8 or 9 (depending on the tramming direction) to
control ports Y1 or Y2 of the pump (1) HD control (depending on the tramming direction).
The pilot control pressure delivered to the pump (1) HD control (1.1) is reduced in direct
proportion to the brake pedal (14) position via the pressure relief valve (14.1). The
reduction in the pilot control pressure delivered to the HD control (1.1) and the mechanical
feedback limit the maximum angle and maximum output of the pump (1). Through
restriction of the maximum angle, the pump (1) output can be restricted irrespective of the
pilot control pressure of the DA valve (1.2). With restriction of the pump (1) output, the
transmission can be used in conjunction with the hydromechanical braking system when
the service brake is activated.
B 16151--5 en 1108 / AR 41 (79)

7.2.3. Testing the brakes (carrier 5)
TESTING THE BRAKES

Always ensure the proper functioning and sufficient capacity of the brakes before
tramming.
Do not operate the vehicle with a faulty safety/parking brake. If this is not complied with,
damage to the vehiche or serious personal injury may occur.
SERVICE BRAKES
Start the engine and let it run until the transmission oil temperature reaches normal.
The holding effect of the service brakes depends both on the condition of the brake and
on the pressure within the brake circuit.
BRAKE PEDAL OPERATION

Raise the machine on the ground support so that there is no contact between tyres and
ground.
Release the safety brakes by pushing the button.
Select one tramming direction switch and accelerate (1500 rpm.) to put the tyres
rotating.
Release the acceleration pedal and push on the service brake pedal--> tyres must
rapidly stop rotating.
SAFETY/PARKING BRAKE
The brake’s holding effect depends on the condition of the equipment.
The brake’s holding effect is adequate when slow gear is engaged. The engine runs at
1500 rpm. The safety / parking brake must be applied and park brake test button (S25)
must be pushed and held in position.
The vehicle must not move.
55095211--C
Fig. 18.Instruction plate for TC5 brake testing.
42 (79) B 16151--5 en 1108 / AR

7.2.4. Testing the brakes (carrier 6)
TESTING THE BRAKES

Always ensure the proper functioning and sufficient capacity of the brakes before
tramming.
Do not operate the vehicle with a faulty safety/parking brake. If this is not complied with,
damage to the vehiche or serious personal injury may occur.
SERVICE BRAKES
Start the engine and let it run until the transmission oil temperature reaches normal.
The holding effect of the service brakes depends both on the condition of the brake and
on the pressure within the brake circuit.
BRAKE PEDAL OPERATION

Raise the machine on the ground support so that there is no contact between tyres and
ground.
Release the safety brakes by pushing the button.
Select one tramming direction switch and accelerate (1500 rpm.) to put the tyres
rotating.
Release the acceleration pedal and push on the service brake pedal--> tyres must
rapidly stop rotating.
SAFETY/PARKING BRAKE
The brake’s holding effect depends on the condition of the equipment.
The brakes need to be tested. Engage the safety/parking brake, select a slow gear with
the gear selector, select a forward driving direction.
Press the accelerator pedal, and increase the engine speed to 1500 rpm.
The vehicle must not move.
55164583--A
Fig. 19.Instruction plate for TC6 brake testing.
B 16151--5 en 1108 / AR 43 (79)

44 (79) B 16151--5 en 1108 / AR

7.3. Operation of the control circuit

The steering circuit gets oil from the operating pump (28) of the transmission control
circuit. From the operating pump (28), the oil flows to the pressure relief valve (32) and
port P of the priority valve (32).
If the tramming/steering valve (30) is not in use, connection P of the tramming/steering
valve (30) is closed. This also means that there is no pressure in the LS line of the
tramming/steering valve (30). Thus, the oil pressure affects only the orifice (29.1) end of
the priority valve (29) and the priority valve (29) control spool directs the oil from port P
of the main flow priority valve (29) to port EF and on to the carrier circuit (diagram
55023200). Some of the oil flows from port P of the priority valve (29) to port CF and on
to port P of the tramming/steering valve (30).
On the basis of the tramming direction, operation of the tramming/steering valve (30) will
cause the oil to flow through port P of the tramming/steering valve (30) either to control
line R and on to the pressure relief valve (30.5), non--return valve (30.3), and control
cylinder 31 or, alternatively, to control line L and on to the pressure relief valve (30.6),
non--return valve (30.4), and control cylinder 31. At the same time, the oil flows through
the orifice (30.7) to the pressure relief valve (30.1) and through connection LS of the
tramming/steering valve (30) to port LS of the priority valve (29) and on through the orifice
(29.2) to the spring end of the control spool of the priority valve (29). Then the priority valve
(29) spool changes its position and directs all the oil to the tramming/steering valve (30).
B 16151--5 en 1108 / AR 45 (79)

7.4. Operation of the transmission circuit in different situations

7.4.1. Cold start
50 51
210
D
D
D
RELEASE
R6
1.17
42
41
40
23. 1
S 1 5 0 .1
22.1
52.1
22.2
C
C
52.2
S 1 5 0 .2
38
C
23.2
39
Fig. 20.Cold start circuit diagram
46 (79) B 16151--5 en 1108 / AR

Cold start
In a cold start situation, the oil viscosity could be so high that the pressure difference that
builds up over the charge pressure filter (1.11) is too great for the cold start valve’s (1.13)
spring setting and the oil flows through the valve back to the charge pump (1.5) intake line.
When the oil is directed to the intake line, neither charge pressure nor pilot control
pressure builds up in the transmission pump (1). Tramming is not possible. The situation
is similar when the filter (1.11) is clogged and the pressure difference becomes too high.
After the oil has heated up sufficiently, the pressure difference over the filter (1.11) drops,
the cold start valve (1.13) closes, and oil flows through the filter (1.11) to the charge
pressure circuit.
B 16151--5 en 1108 / AR 47 (79)

7.5. Tramming forwards

7.5.1. Tramming forwards (low speed)
50 51
210
D
D
D
RELEASE
R6
42
41
40 G
2 3.1
S 1 5 0 .1
22.1
52.1
22.2
C
52.2
S 1 5 0 .2
C
38
C
23.2
39
Fig. 21.Hydraulic diagram -- forward, low speed
48 (79) B 16151--5 en 1108 / AR

The oil delivered by the charge pump (1.5) causes a charge pressure to accumulate; this
is also used as a pilot control pressure to control the pump (1). The pressure is kept at an
appropriate level with the pressure relief valve (1.12).
The pilot control pressure is directed outside the pump (1) through the brake pedal (14)
pressure relief valve (14.1) to the tramming direction selector valve (6.1), which, under
electrical control, delivers the pressure to the b side of the valve of the HD control (1.1),
causing the spool to deviate toward the right. At the same time, the DA control (1.2) builds
up a control pressure from the charge pressure proportional to the diesel engine (5)
speed. The pressure is delivered through the deviated spool of the HD control to the left
side of the tramming pump (1) control cylinder (1.3). This causes the pump (1) angle to
swing in the positive direction, and the pump (1) starts to deliver oil to the high pressure
circuit marked in red. Diesel engine (5) speed is affected with the hydraulic accelerator
pedal (3), which adjusts the pilot control pressure delivered by the pump to the appropriate
level for the throttle cylinder (4).
In the high pressure circuit, the oil flows through the transmission motor (2) back to the
intake side of the pump (1) and runs the motor (2) in the direction that moves the carrier
forwards. The high pressure circuit’s pressure has a direct effect -- through the tramming
direction selector valve (2.1) of the motor (2) -- on the tramming motor (2) control cylinder
(2.2) and keeps the motor at its maximum angle, i.e. a low tramming speed range. The
flushing valve (2.4) installed in conjunction with the motor (2) continually delivers a small
amount of oil, passed through the orifice, from the intake side of the high pressure circuit
through the cooler (25) to the receiver (27), which cools the system. The amount of oil
removed is replaced by delivering oil from the charge pump (1.5), to the intake side of the
high pressure circuit, through the non--return valve of the pressure relief valve (1.10). The
correct charge pressure at the intake side of the pump (1) is thus ensured, preventing
cavitation in the pump.
B 16151--5 en 1108 / AR 49 (79)

7.5.2. Tramming forwards (high speed)
2 10
50 51
D
D
D
RELEASE
R6
41
40
42
G
23.1
22.1
S 1 5 0 .1
52.1
22. 2
C
C
52.2
S 1 5 0 .2
C
23.2
38
39
Fig. 22.Hydraulic diagram -- forward, high speed
50 (79) B 16151--5 en 1108 / AR

High--speed tramming differs from low--speed tramming only in terms of adjustment of the
tramming motor (2). The control pressure of the DA control (1.2) of the transmission pump
is delivered to the X1 port of the motor (2) by electrically controlling the tramming speed
selector valve (6.2). From the X1 port, the pressure is delivered to the proportional
regulating valve (2.3) via the selector valve (2.1). The pilot control pressure affects the
large pilot control area of the proportional regulating valve (2.3), meeting the high
pressure circuit’s pressure and the spring that affect the smaller area on the other side of
the regulating valve (2.3). When the diesel engine’s (5) speed increases and the pilot
control pressure caused by the DA valve (1.2) overcomes the force produced by the spring
and the high pressure circuit pressure, the proportional regulating valve (2.3) changes its
position; the high pressure circuit’s pressure affects the piston side of the motor (2) control
cylinder (2.2), and the motor (2) starts to swivel to a minimum angle. That increases the
tramming speed until the high pressure circuit’s pressure rises high enough to return the
regulating valve (2.3) to the neutral position. The regulating valve (2.3) and thus the motor
(2) angle seek equilibrium on the basis of the relationship between the pilot control
pressure of the DA valve and the high pressure circuit pressure. For example, during
tramming up a ramp, there will be an attempt to increase the high pressure circuit pressure
when the tramming resistance rises. Then the motor (2) swivels to a bigger angle and the
tramming speed decreases.
B 16151--5 en 1108 / AR 51 (79)

7.6. Tramming backwards
50 51
210
D
D
D
RELEASE
R6
41
40
42
G
23.1
22. 1
S 1 5 0 .1
52.1
38
22.2
C
C
52.2
S 1 5 0 .2
C
23.2
39
Fig. 23.Hydraulic diagram -- backward, low speed
52 (79) B 16151--5 en 1108 / AR

During tramming backwards, the electrical tramming direction selector valve (6.1) directs
the HD control (1.1) spool to the opposite direction from that used when tramming
forwards. Thus, the pilot control pressure produced by the DA valve (1.2) affects the right
side of the pump control cylinder (1.3) and swivels the pump (1) to a negative angle. The
high pressure circuit oil flows in the opposite direction than that used when tramming
forwards, and the carrier moves backwards. That is, the pressure side and intake side
change places in the high pressure circuit. Otherwise, operation is similar to that
encountered when the tramming forwards.
B 16151--5 en 1108 / AR 53 (79)

50 51
210
D
D
D
RELEASE
R6
41
40
42
23.1
22.1
S 1 5 0. 1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
38
23.2
39
Fig. 24.Hydraulic diagram -- backward, high speed
54 (79) B 16151--5 en 1108 / AR

During tramming backwards, the electrical tramming direction selector valve (6.1) directs
the HD control (1.1) spool to the opposite direction from that used when tramming
forwards. Thus, the pilot control pressure produced by the DA valve (1.2) affects the right
side of the pump control cylinder (1.3) and swivels the pump (1) to a negative angle. The
high pressure circuit oil flows in the opposite direction than that used when tramming
forwards, and the carrier moves backwards. That is, the pressure side and intake side
change places in the high pressure circuit. Otherwise, operation is similar to that
encountered when the tramming forwards.
B 16151--5 en 1108 / AR 55 (79)

7.7. Tramming down a ramp (low speed)
50 51
21 0
D
D
D
RELEASE
R6
41
40
42
23.1
S 1 5 0 .1
22.1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
38
23.2
39
Fig. 25.Tramming down a ramp (low speed)
56 (79) B 16151--5 en 1108 / AR

Low speed
During tramming down a ramp, the speed of the vehicle tends to exceed the desired value
and the motor (2) starts to operate like a pump; i.e., the motor (2) tries to pump oil to the
intake side of the pump (1). As a result, the pump (1) starts to operate like a motor and
tries to increase the diesel engine’s (5) speed. Thus, the unintended increase of tramming
speed on the ramp can be controlled to some extent with diesel engine (5) braking. In
tramming down a ramp, a higher pressure builds up in the intake side than in the pressure
side of the high pressure circuit’s pump (1).
B 16151--5 en 1108 / AR 57 (79)

7.8. Tramming down a ramp (high speed)
50 51
21 0
D
D
D
RELEASE
R6
41
40
42
23.1
S 1 5 0 .1
22.1
52.1
22.2
C
C
52.2
S 1 5 0 .2
C
38
23.2
39
Fig. 26.Tramming down a ramp (high speed)
58 (79) B 16151--5 en 1108 / AR

High speed
High--speed tramming differs from low--speed tramming in terms of adjustment of the
tramming motor (2). Because the pressure of the pressured side drops when tramming
down a ramp, the proportional regulating valve (2.3) changes its position thanks to the
control pressure of the DA--control (1.2). As a result of this, the pilot pressure affects the
piston side of the motor’s (2) control cylinder (2.2) and the motor (2) is adjusted (2) towards
the minimum angle. With the minimum angle, the braking moment of the motor (2) is at
its lowest. Thus, the motor’s braking is weaker in high--speed tramming than in low--speed
tramming.
B 16151--5 en 1108 / AR 59 (79)

8. ADJUSTMENTS
8.1. Tramming pump and motor
10 8
(Optional)
X2
X1
G
R
1
Y1
B
Y2 9
4
(Optional)
2
A
5
6 3
T2 7 G* (Optional)
G MB
MA
1. Pressure cut--off
2. Inching valve/lever (optional)
3. Case flushing port (optional)
4. Zero position control
5. Travel direction valve (in this case, hydraulically operated)
6. charge pressure relief valve
7. Pressure relief and charge valve A
8. Bypass valve (2 bar)
9. Pressure relief and charge valve B
10. Rotary throttle (optional)
60 (79) B 16151--5 en 1108 / AR

Installation
Pump A4VG / DA Size 71 Measuring points A4VG/ Pressure gauge
DA--A6VM/DA (pressure range)
A, B Service lines SAE “1” MA Service line 600 bar
G Pressure connec- M 18*1.5 GA6VM Service line A / B
tion for auxiliary cir- 600 bar
cuits
T1 ,(T2 ) Oil inlet and return M 26*1.5 MB Service line B 600 bar
T1 ,(T2 ) Oil discharge M 26*1.5 GA4VM charge pressure 40 bar
S Suction port M42*2 R Housing pressure 10 bar
MA /MB Service line, Mea- M12*1.5 S Negative suction
1 bar (absolute)
suring connections pressure
R Bleeding M12*1.5 X1 /X2 Pilot pressure 40 bar
X1 /X2 Control pressure M12*1.5 G* 600 bar
PS Control pressure M12*1.5
supply
Y1 / Direction control M14*1.5
Y2
Motor A6VM / DA Size 107

A, B Service lines SAE “1”
T1 Case drainage port M 18*1.5
X1 /X2 Pilot pressure ports M 14*1.5
Gv Operating pressure M 14*1.5
G* Control pressure M 14*1.5
B 16151--5 en 1108 / AR 61 (79)

Direction of rotation
(Optional)
1
a X1
B
X2
(Optional)
(Optional)
MA A
A
The direction of rotation of the motor is determined by the direction of rotation of the
variable displacement pump in conjunction with pilot pressure a and b at the HD--control
valve. The relationship can be seen from the directional arrows (1 clockwise).
Important: The direction of rotation of the pump and motor is always defined as viewed
from the drive shaft, from the front of the unit.
Warning!
The pilot pressure lines (X1/X2) from the pump always connect to the motor in such a way
that they are on the opposite side to the high--pressure side.
62 (79) B 16151--5 en 1108 / AR

A4V / DA A6VM / DA
Direction of rota- Clockwise Anti--clock- Clockwise Anti--clockwise
tion wise
Pilot pressure y2 y1 y2 y1
Control pressure X2 X1 X2 X1 X1 X2
in
Direction of B--A A--B A--B B--A A--B B--A
through flow
Service pressure MA MB MB MA
B 16151--5 en 1108 / AR 63 (79)

8.2. Measuring equipment

The following pressure gauges (damped design) and measuring devices should be
available:
2 pressure gauges rated up to 600 bar HP measurements at measuring ports MB / MA
/ GAIG*.
2 pressure gauges rated up to 40 bar. Pilot pressure measurements at the measuring
ports (X1/X2) (control lines) and charge pressure measurements at measuring port G.
1 pressure gauge rated up to 10 bar. Housing pressure measurements at port R of the
variable displacement pump and in the oil motor drain line.
1 vacuum pressure gauge rated up to 1 bar absolute. Measurements in suction line of oil
motor.
1 thermometer rated up to 100q C
1 tachometer rated up to 3000 rpm. Prime mover speed measurement.
1 volt-- and ammeter. Measuring range I = 1.5 A, U up to 30 volts. For checking solenoids.
Flushing
We recommend that a flushing run for the filtering of the main circuit be performed during
commissioning of the installation.
If a flushing run is carried out, this must be undertaken under zero load prior to the actual
function test. Under normal circumstances should last an hour.
With the installation ready for operation, two HP super--fine filters, mounted as shown in
service lines A and B between the variable displacement pump and the oil motor, will
ensure that a flushing run can be carried out in both directions without additional assembly
work.
At the same time, this will ensure that the pump and motor are protected before the first
run takes place. The pore size of the flushing filter should correspond to that of the
hydraulic installation. It should, however, have a beta value of at least E30 = 100. The
flushing filters should be fitted with a clogging indicator instead of a bypass valve.
separate filling
64 (79) B 16151--5 en 1108 / AR

Commissioning
-- Has the tank been cleaned and flushed?
-- Have the lines been cleaned, and are pipes free of tension and hoses correctly
mounted?
-- Are all lines connected correctly as shown in the circuit diagram?
-- Fittings and flanges properly screwed in?
-- Are coupling or drive elements between prime mover and pump or motor and
gearbox correctly mounted and aligned?
-- Does the direction of rotation of the prime mover agree with that of the pump?
-- Is the fixture correctly mounted in the direction of flow?
-- Connect measuring devices for test measurements during commissioning.
-- Fill oil tank with the prescribed fluid to the maximum oil level mark.
Important: Depending on the installation position of the pump, fill the housing via return
line port T1 , T2 and motor housing via drainage port T up to the overflow. If, due to
installation conditions, the suction line has not been filled prior to starting, this must be
filled separately.
8.3. Initial start--up

Rotate the prime mover by means of the starter motor until the oil flows out of gauge port
“G” of A6VM / DA without bubbles.
Start the prime mover in the normal way, checking the charge pressure at gauge port “G”
of A4V / DA.
Do not drive the vehicle yet!
NB: Continually check the oil level in the tank. If necessary, add more oil. Foaming
indicates leakage in the suction line.
Please note: An oil--tight suction line is not necessarily airtight.
During the start--up phase, pressure oscillations can occur at the charge pressure gauge.
At idle speed, the charge pressure must find its level at a constant 15...20 bar.
Turn off the prime mover. Connect the electrical control and check the functioning of the
solenoids.
Check the oil level in the tank.
Start the prime mover.
Check function without a load.
Check the measuring devices.
Keep installation running until it has warmed up to 50...60q (measured in the circuit).
Pay attention to any noises.
Once the operating temperature is reached, switch off the prime mover.
B 16151--5 en 1108 / AR 65 (79)

Check setting data

The operating temperature should be kept at a relatively constant level.
Lock out inch pedal rods
Start the drive motor, idle speed
Blocked state: switch for travel direction at “0”.
Slowly increase motor speed to maximum, at the same time checking the measuring
devices
Charge pressure:
Motor idle speed
Psp = ca. 15...20 bar
Max. motor speed
Psp = . . . 28 . . . . . . bar*
Housing pressure: R = min. . . . bar
= max. . 2 bar
Suction pressure: Test port ‘a’ suction filter
= min. . . 0.8 bar*
= max. . . bar*
charge pressure: Travel direction switch in forward position
(In “road” gear, fully braked) Check setting data for A4V / DA pump
Start of control
HP 40...50 bar--motor--speed . 1150 . . . rpm, Psp 6 bar*
HP . . . . . bar--motor--speed . . 1900 . . . rpm, Psp 18 bar*
Checking pressure cut-- off valve HP 440 bar*
!
Should be 30...40 bar below setting of safety valve
Checking safety relief valve HP 470 bar*
!
Block pressure cut--off valve
!
Operate safety valves for very short period only (risk of overheating).
66 (79) B 16151--5 en 1108 / AR

Engage inch pedal rods

Check: Repeat checking of start and end of control and set the inch pedal rods so that,
from an engine speed of + / -- 100 rpm, the setting lever on the control valve moves to
provide constant high pressure of HP -- 20 bar* until the maximum motor speed is reached.
!
The high pressure level must be 30...40 bar lower than the safety valve
setting.
Leak test
Stop the prime mover.
Tighten all fittings, flanges, and plugs, even if they are already tight. Retighten only when
the installation is depressurised.
* For supplementary information, see order confirmation.
B 16151--5 en 1108 / AR 67 (79)

Important setting information

Applicable for troubleshooting operations on the unit: (NB: Safety regulations must be
observed)
Before any adjustment work is carried out on DA--motors, the following conditions for
operation must be observed:
Setting, commissioning, or checking of the operating data for the A4V.XX.DA primary
section must be carried out before any adjustment is made to the secondary part
A6V.XX.DA.
The operating temperature must be approx. 50...60q (circuit temperature).
Partial inching of pressure cutoff must be in operation. On vehicles without partial inching,
ensure that the safety valves do not operate.
Setting and adjustment of the variable displacement motor should never be carried out
without a pressure gauge.
Any setting or adjustment operations must be conducted at maximum operating pressure
and maximum engine speed.
When you perform any setting operations on the variable displacement motor, suitable
precautions must be taken to prevent the vehicle moving.
The best precaution is to jack up the vehicle and put the brake on.
68 (79) B 16151--5 en 1108 / AR

Measuring ports MA or MB
on the pump or G A
G A High pressure gauge
0...600 bar
G * High pressure gauge
0...600 bar
--Start drive motor, full load
speed, travel direction
valve forward/reverse
--Search for beginning of
control by screwing control
start set screw in and out
“Beginning of control”
refers to the point where
high pressure G * builds
up.
When the brake pedal is
depressed at maximum en-
gine speed, the operating-
pressure is 260...270 bar.
The adjusting pressure M1
is reduced.
Control: Pressure gauge at
G (MA or MB) has maxi-
mum pressure
Pressure gauge at G'
approx. 10 bar, Diesel en-
gine running under load
--Unscrew adjustment
screw further by 1/4 turn
(direction of rotation -- anti--
clockwise) and tighten the
locknut.
This is necessary in order
to achieve what we refer to
as a high pressure safety
factor.
Check: Gauge G * must be
at zero pressure.
Gauge G must show maxi-
mum operating pressure.
Diesel engine is running
under full load.
B 16151--5 en 1108 / AR 69 (79)

8.4. Throttle cylinder

P
B T
C
A
Adjusting the diesel engine‘s (5) minimum and maximum speed

1. Release the throttle cylinder (4) locking screws (A).
2. Check that the throttle cylinder (4) controls are not under load.
3. Adjust the diesel engine‘s (5) minimum speed to 950 rpm with the diesel engine
idling adjusting screw (B).
4. Lock the throttle cylinder (4) fastening screws (A).
5. Adjust the diesel engine‘s (5) maximum speed with the adjusting screw in the
throttle cylinder (4) end (C) as follows:
-- Remove the hydraulic hose from connection T at the throttle cylinder (4) end.
-- Plug connection T and the removed hose end.
-- Open the lock nut of the throttle cylinder (4) adjusting screw (C).
-- Turning the adjusting screw (C) outward increases the diesel engine‘s
speed, and turning it inward decreases the engine speed.
-- Secure the adjusting screw (C) lock nut.
-- Attach the removed hose to connection T in the throttle cylinder (4).
-- Start the diesel engine (5) and measure the minimum and maximum diesel engine
speed (max. speed 2300 rpm).
-- Readjust if necessary.
8.5. Pressure switches (S150.1, S150.2, S56, S57)

Pressure switches S150.1, S150.2, S56, and S57 are adjusted at a separate adjusting
bench. The pressure switch settings are as follows: S150.1 and S150.2: 5 bar, S56: 145
bar, S57: 145 bar.
8.6. Pressure switches (S57B, S56B, S200, S201)

Pressure switches S57B, S56B, S200 and S201 are adjusted at a separate adjusting
bench. The pressure switch settings are as follows: S57B: 75 bar, S56B: 75 bar, S200:
10 bar, S201: 15bar.
70 (79) B 16151--5 en 1108 / AR

8.7. Adjusting the pressure relief valves (12 and 32)
2
1
T
P
1. Lock nut
2. Adjusting spool
Perform the adjustment of the pressure relief valves (12 and 32) at the separate test bench
as follows:
1. Open the lock nut of the pressure relief valves’ (12 and 32) adjusting spool and turn
the adjusting spool until fully open.
2. Connect the pressure hose and pressure gauge (250 bar) to the pressure relief
valve’s (12/32) port 1.
3. Connect the tank hose to port 2 of the pressure relief valve (12/32).
4. Start the test bench power pack and adjust the system’s maximum pressure to 220
bar and maximum flow to about 20 L/min.
5. Connect the flow to port 1 of the pressure relief valve (12/32).
6. Turn the adjusting spool of the pressure relief valve (12/32) inward until the
pressure is 200 bar (valve 12 = 200 bar) , (valve 32 = 220 bar) in the pressure
gauge connected to port 1 of the pressure relief valve (12/32).
7. Secure the lock nut of the adjusting spool of the pressure relief valve (12/32).
8. Remove the control from port 1 of the pressure relief valve (12/32).
9. Switch the power pack off and remove the hoses.
B 16151--5 en 1108 / AR 71 (79)

8.8. Adjusting the sequence valve (21)
A B
3
1
Fig. 27.Sequence valve

Perform the adjustment of the sequence valve (21) at the separate test bench as follows:
1. Open the sequence valve’s (21) adjusting spool (A) lock nut (B) and turn the
adjusting spool fully inward.
2. Connect the pressure hose to the sequence valve’s port 1.
3. Connect the tank hose to the sequence valve’s port 3.
4. Connect the pressure gauge (16 bar) to the sequence valve’s port 2.
5. Start the test bench power pack and adjust the system’s maximum pressure to 12
bar and
maximum flow to about 10 L/min.
6. Connect the flow to port 1 of the sequence valve (21).
7. Turn the adjusting spool of the sequence valve (21) outward until the pressure is
connected to port 2 of the sequence valve (the pressure connection to port 2 is
shown on the pressure gauge).
8. Secure the lock nut of the adjusting spool of the sequence valve (21).
9. Remove the control from port 1 of the sequence valve (21).
10. Switch the power pack off and remove the hoses.
72 (79) B 16151--5 en 1108 / AR

9. TROUBLESHOOTING
9.1. Brakes
Fault Cause Action
Low service Worn braking surfaces. Replace worn surfaces.
b k output.
brake t t Low braking pressure. Check the adjusting pressure.
Replace faulty components.
Air is trapped in brake circuit. Vent brake cylinders.
Low safety Worn braking surfaces. Replace worn surfaces.

b k output.
brake t t Brake clearance (in brake Adjust brakes.
cylinder) too high.
Brake cylinder springs Replace springs.
fatigued.
Safety brake is Air is trapped in brake circuit. Vent system.

nott released
l d Brake cylinder seals leaking. Replace seals.
properly
properly.
Leaking connections. Tighten connections.
B 16151--5 en 1108 / AR 73 (79)

9.2. Steering
Fault Cause Action

The wheels do Air trapped in the control cyl- Vent control system.
not remain inder or pipeline between the
turned in the de- cylinder and control valve.
sired direction
but instead
move back and
forth to some Worn joints in the control sys- Replace worn joints.
extent when the tem controls.
steering wheel
is not turned.
The steering
Air is trapped in the control Check oil level and investigate
wheel must be
system -- for example, if the possible leaks.
turned quite a
oil level in the receiver is too
long way (for
low or the hydraulic pump in-
example, 1/4
take hose is leaking.
turn) before the
wheels begin to
turn.
The wheels turn Oil leaks in the hydraulic cir- Replace faulty parts.
during tram- cuit between control valve and
ming, usually cylinder due to:
slowly, although -- faulty control cylinder
the steering -- worn ORBITROL control
wheel is not valve
turned. When -- faulty damping valve
the steering
wheel is turned,
the wheels do
not turn or they
turn slowly.
Steering is un- Dirt particles in the ORBI- Clean the steering valve.
stable and the TROL steering valve are Check the oil purity with, for
steering wheel causing sticking of the adjust- example, oil analyser. Change
is rigid during ing valve spools. the oil.
turning. The
turning move-
ment of the
steering wheel
tends to contin-
ue -- for exam-
ple, when the
steering wheel
is released.
74 (79) B 16151--5 en 1108 / AR

Fault Cause Action

The steering The steering system lacks oil, Check the pump output
wheel turns which could be caused by the pressure with the pressure
lightly about 8o following: gauge at the measuring point.
to either side of -- faulty hydraulic pump Replace faulty/worn
the middle posi- -- faulty safety relief valve or components.
tion but turning flow regulator valve
is heavy after -- faulty non--return valve in
this. The power the ORBITROL steering valve
steering does
not operate.
The steering Jammed steering wheel arm Replace faulty/worn
wheel is very bearing or faulty ORBITROL components.
heavy when steering valve.
turned or it can-
not be turned.
B 16151--5 en 1108 / AR 75 (79)

9.3. Hydrostatic transmission
Fault Target Cause(s) Action

The machine Tramming Directional Select a tramming
moves neither direction control valve direction.
forward nor selector valve (6.1) in middle
backward. (6.1) position.
Change or repair the
Faulty directional directional control valve
control valve (6.1).
(6.1).
Oil receiver Oil level too low. Check the oil level and add
(27) oil if necessary.
Intake hose has Tighten the intake hose.
become loose.
Hoses and Bent or broken Straighten or replace intake
hose intake hose. hose.
connections. Faulty pump Repair connection.
connection.
Intake pump Filter is clogged. Replace filter.
filter (1.11)
Cold start Impurities in Clean valve.
valve (1.13) valve.
Charge pump Diesel engine (5) Check the diesel engine’s
(1.5) runs in the (5) rotation direction.
wrong direction.
Faulty charge Repair or replace charge
pump (1.5) (no pump (1.5).
pressure at G).
Variable Faulty or Clean faulty high pressure
displacement clogged high valve.
pump A4VG pressure valves
(1) (1.9 or 1.10), no
pressure MA/MB.
Variable Faulty variable Check for possible leaks in
displacement displacement the motor (2). Repair or
motor A6VM motor (2). replace motor (2).
(2)
Shaft and Faulty Check and repair
variable connection. connection.
displacement
motor
connection
76 (79) B 16151--5 en 1108 / AR


Tramming starts Tramming Jammed Clean valve (6.1).
too late, strange direction directional
sounds. selector valve control valve
(6) (6.1) spool.
Oil receiver Heavy oil Change oil.
(27) contamination.
Heavy foaming, Check oil level and add oil
oil level too low if necessary.
in receiver.
Intake hose Intake hose is Tighten intake hose
not airtight. connections. Check hose
and replace if faulty.
Variable Faulty DA Change DA control valve
displacement control valve (1.2).
pump A4VG (1.2).
(1)
Variable Faulty motor (2). Check for possible leaks in
displacement motor (2). Repair or
motor (2) replace motor (2).
A6VM
Motor (5) speed Diesel engine Insufficient Repair or replace diesel
drops (5) engine (5) engine (5).
dramatically. power, faulty
engine.
Variable Settings of high Check pressure at points
displacement pressure valves MA, MB,
pump A4VG (1.9 and 1.10)
(1) are too low.
Insufficient Diesel engine Diesel engine (5) Reduce load. Switch on the
drive, both (5) does not reach rear drive/pressure rise.
tramming its nominal Repair or replace diesel
directions. speed or loses it engine (5).
too easily.
Charge pump Insufficient Check charge pressure at
(1.5) charge pump point G and adjust if
(1.5) charge required.
pressure.
B 16151--5 en 1108 / AR 77 (79)


Oil heats up Oil receiver Oil level too low. Add oil or replace with right
quickly and (27) Wrong oil. oil.
dramatically.
Intake hose Intake hose is Check intake hose and
not tight, sucks intake hose connection.
in air. Repair or replace faulty
hose or connection.
Variable Main pressure Check pressure at points
displacement limits (1.9 and MA, MB, , and adjust if
pump A4VG 1.10) set for too required.
(1) low a pressure.
Damaged pump. Repair or replace pump (1).
Radiator (25) Dirty radiator Clean radiator ribs.
ribs.
Variable Faulty motor (2). Check for leaks in motor
displacement (2), and repair or replace
motor A6VM motor if necessary.
(2)
78 (79) B 16151--5 en 1108 / AR


Cannot reach Diesel engine Diesel engine Check diesel engine and
tramming (5) does not reach repair if required.
speed. its nominal
speed.
Charge pump Charge pressure Check charge pressure at
(1.5) too low. point G and adjust if
required.
Check DA- adjusting valve
(1.2), and repair or replace
it if necessary.
Faulty charge Repair or replace charge
pump (1.5), too pump (1.5).
low output.
Variable Motor (2) does Check motor angle and
displacement not swivel at a adjust if necessary.
motor A6VM tight enough
(2) angle.
Adjusting spool Repair or replace adjusting
is not working spool.
properly.
Jerks Tramming Intermittent loss Check solenoid
in hydraulic direction of power in connections. Replace
braking. selector tramming solenoids if faulty.
direction valve.
Poor Diesel engine Lack of power. Check diesel engine and
acceleration. (5) repair if necessary.
Leaks in shaft Variable Faulty or Replace shaft seal.
seals. displacement hardened shaft
pump A4VG seal.
(1)
Variable Faulty or Replace shaft seal.
displacement hardened shaft
motor A6VM seal.
(2)
B 16151--5 en 1108 / AR 79 (79)

Instrucciones originales
498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE

LLANTA
Índice de contenidos
1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ..................................................... 3
2. MARCAS EN EL NEUMÁTICO ..................................................................................................... 5
3. LLANTAS ....................................................................................................................................... 6
3.1. Marcas en la llanta ........................................................................................................................................... 7
4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ....................................................... 8

4.1. Inspecciones previas al montaje de un neumático en una llanta ....................................................... 8
4.2. Inspección magnética de la llanta ............................................................................................................... 9
5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ..................................................................... 10

5.1. Seguridad en la colocación de neumáticos .............................................................................................. 10
5.2. Presurización del neumático ......................................................................................................................... 10
5.3. Jaula de seguridad ........................................................................................................................................... 11
Copyright © Sandvik Mining and Construction 1 (14)

ID: 498 2 es 2009-12-14
2 (14) Copyright © Sandvik Mining and Construction
ID: 498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA
1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ID: 11151
Siga siempre las normativas de seguridad locales y específicas

para minas cuando manipule las ruedas o los neumáticos de los
equipos de perforación de roca.
Nunca se posicione bajo un equipo que esté elevado sobre los

gatos.
Apoye siempre de forma adecuada el equipo de perforación de

roca cuando extraiga las ruedas. Asegúrese también de que la
estructura de apoyo sea suficientemente resistente, porque los
equipos pueden pesar de 3000 a 60000 kilos, dependiendo de
su tipo. Preste especial atención a la capacidad de transporte
de carga del suelo sobre el que está colocado el soporte.
Cuando manipule las ruedas, tenga en cuenta las cargas extra

provocadas por el inflado de los neumáticos.
Cuando extraiga la rueda del eje de oscilación, preste atención

a los cambios de peso del eje y al hecho deque el extremo del
eje de la rueda que se va a extraer puede elevarse. Peligro de
aplastamiento. Recomendamos utilizar cuñas de madera para
evitar el balanceo del eje de oscilación.
Se recomienda encargar a personal cualificado la inspección y

el montaje de los neumáticos y las llantas.
La extracción de una rueda es una operación especializada, que requiere conocimientos y equipos
especializados.
Antes de extraer una rueda, asegúrese siempre de que puede trabajar de forma segura y según lo
indicado por las normativas de seguridad locales y específicas para minas.
Deberá disponerse de herramientas adecuadas para una extracción segura de las ruedas.
Antes de aflojar ninguna de las tuercas de la rueda, compruebe siempre lo siguiente:
1. ¿Se ha estado conduciendo con el neumático desinflado (80% o más por debajo de la presión
de funcionamiento recomendada)? En caso de duda, compruebe la presión.
2. ¿Existen sospechas de deterioro o daños evidentes en el neumático o los componentes de la
rueda?
Si se cumplen estas condiciones, antes de aflojar las tuercas de la rueda, el neumático deberá
desinflarse completamente extrayendo el núcleo de la válvula.
Si la llanta y el neumático están en buenas condiciones, desinfle el neumático a una presión de 35
kPa (0,35 bares, 5 psi), antes de aflojar las tuercas de la rueda.

ID: 498 2 es 2009-12-14
Si no puede utilizar ningún dispositivo para extraer la rueda, puede hacerlo manualmente. Esta
operación se realiza desde atrás, vista desde la dirección de la superficie de rodamiento del
neumático. La rueda puede volcarse, por lo que previamente usted deberá asegurarse de que hay
suficiente espacio para que la rueda pueda rodar sin provocar lesiones ni daños materiales si se
cayera. La rueda de un equipo de perforación puede llegar a pesar varios cientos de kilos. Extreme
las medidas de precaución en las tareas de mantenimiento de la rueda sobre terrenos inclinados.
La mayoría de los equipos de perforación pueden elevarse sobre sus gatos, de forma que el
neumático quede visiblemente elevado sobre el suelo. Si saca la rueda, coloque siempre un soporte
debajo del eje. Desatornille los pernos y extraiga la rueda.

ID: 498 2 es 2009-12-14
2. MARCAS EN EL NEUMÁTICO ID: 11146
2
1
3
5
6
ID: 30003
1 Ancho del neumático 2 Diámetro de la llanta

3 Ply rating (PR) (resistencia) 4 Condiciones ambientales
5 Año de fabricación (50 = semana Nº 50, 6 Fabricante
08 = año 2008)

ID: 498 2 es 2009-12-14
3. LLANTAS ID: 11149
Existen tres tipos principales de llanta: llantas de una pieza, llantas segmentadas y llantas multipieza.
Los equipos de perforación Sandvik suelen usar llantas multipieza.
1 1 4
2
3 5
3
ID: 30015
1 Anillo lateral 2 Anillo de bloqueo

3 Anillo del asiento del talón 4 Llanta
5 Disco
Asegúrese de que la llanta es correcta para el tamaño del neumático usado.
Todos los neumáticos sin cámara deben colocarse en llantas sin cámara. Coloque siempre un anillo
tórico nuevo.
Si no aparecen marcas en las paredes laterales del neumático que indiquen que se trata de un
neumático sin cámara, los neumáticos deben colocarse con una cámara adecuada en llantas con
cámara. Debe usarse una aleta. Las aletas y cámaras nuevas son una parte necesaria para el
ensamblaje de una llanta con cámara.
En ambos casos también se recomenda colocar válvulas y anillos de sellado nuevos.

ID: 498 2 es 2009-12-14
3.1. Marcas en la llanta ID: 11150
Las ruedas de disco están marcadas con la siguiente información:

• Designación del tamaño de la llanta
• Identificación del fabricante de la llanta
• Fecha de fabricación
Los anillos están marcados con la siguiente información:

• Identificación de la llanta en la que debe colocarse la pieza
• Identificación del fabricante
• Fecha de fabricación (al menos el mes y el año)
• Designación de altura de la brida (en anillos lateriales para llantas EM)
Designación del tamaño de la llanta

8.5 – 20
• 8.5 código de ancho (pulgadas)
• 20 código de diámetro nominal (pulgadas)

ID: 498 2 es 2009-12-14
4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ID: 29718
4.1. Inspecciones previas al montaje de un neumático en una llanta ID: 29720
El desmontaje de las ruedas y la inspección de los componentes de las ruedas son operaciones
especializadas, que requieren conocimientos y equipos especializados.
Todos los componentes de las ruedas multipieza deben inspeccionarse antes de su ensamblaje.
Realice una inspección y asegúrese de que los componentes de la llanta y el neumático coinciden.
No reutilice una llanta o un componente de una llanta que esté:
• doblado o encorvado
• corroído
• roto
• partido
ID: 29739
1. dado de sí
Nunca use un anillo de bloqueo (anillo de cierre) que haya dado

de sí.
No utilice las llantas si:
• Los orificios de los tornillos están desgastados o presentan una forma elíptica.
• La llanta se ha reparado mediante soldadura.
• La llanta presenta un desgaste avanzado en el área del asiento del talón.

ID: 498 2 es 2009-12-14
Las bridas de la llanta, los anillos y las superficies del asiento del talón del neumático de la llanta
deben estar limpias y libres de óxido.
No reutilice los neumáticos si:
• La máquina se ha conducido con neumáticos vacíos o despresurizados casi por completo.

• Existen signos de desgaste en el neumático o el neumático tiene más de 10 años.
• El estado general del neumático no es adecuado, por ejemplo: existen fracturas o queda muy poca
superficie de rodamiento.
• El neumático presenta daños irreparables.
• El neumático ha estado en funcionamiento reparado.
Compruebe que el neumático está limpio y seco y que no contiene materiales extraños.
Los componentes de ruedas multipieza no deben intercambiarse. Use exclusivamente las piezas de
recambio incluidas en el paquete de piezas de recambio suministrado por Sandvik para la llanta en
cuestión.
4.2. Inspección magnética de la llanta ID: 30027
Cuando la llanta alcance de 12000 a 15000 horas de servicio, debe realizarse una inspección de
partículas magnéticas. Si la inspección no se lleva a cabo, la llanta y sus piezas deben retirarse del
servicio.
Consulte al fabricante de la llanta los intervalos de horas recomendados para la realización de
inspecciones magnéticas en las llantas.
La inspección siempre debe repetirse en intervalos de 12000 a 15000 horas de servicio.
Si se detectan deterioros durante las inspecciones visuales, la inspección de partículas magnéticas
debe realizarse inmediatamente, antes de seguir usando la llanta. Si la inspección no se lleva a cabo,
la llanta debe retirarse del servicio.
Para realizar una inspección de partículas magnéticas en un ensamblaje de llanta, el neumático debe
extraerse primero.
Esta instrucción es una directriz. Respete siempre las normas
de agencia, obligatorias, indicadas por las autoridades, o
específicas de la mina, relativas a las inspecciones magnéticas
en llantas.

ID: 498 2 es 2009-12-14
5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ID: 30030
5.1. Seguridad en la colocación de neumáticos ID: 30032
Cuando presurice un neumático, tome siempre las siguientes precauciones de seguridad:

• Nunca use llantas / piezas de llantas dañadas.
• Use lubricantes adecuados.
• Si se desplaza un anillo de bloqueo, desinfle el neumático extrayendo el núcleo de la válvula, antes
de realizar el ajuste.
• No aplique una fuerza excesiva y nunca golpee ensamblajes inflados.
• Use siempre la jaula de seguridad para el inflado.
• Si no dispone de ninguna jaula de seguridad, colóquese a una distancia prudencial y en el lado de
la superficie de rodamiento del neumático. Presurice siempre a distancia (al menos 1,5 m).
• Use protectores auditivos.
• Nunca se siente encima ni se apoye en un neumático mientras se está inflando.
• Supervise siempre el neumático mientras se está inflando.
5.2. Presurización del neumático ID: 30036
La colocación de neumáticos es una operación especializada, que requiere conocimientos y equipos

especializados.
El neumático no debe inflarse a más de 50 kPa (7 psi , 0,5 bares), antes de haber comprobado la
ubicación correcta de los componentes.
Cuando el neumático esté colocado en una llanta y todos los componentes estén correctamente
posicionados, continuar inflando hasta 150 kPa (22 psi, 1,5 bares).
No exceda nunca un nivel de inflado de 150 kPa (22 psi, 1,5 bares) sin equipos de seguridad
adecuados.
Asegúrese de que los talones están correctamente situados contra la brida de la llanta. Inspeccione
el neumático y asegúrese de que no presenta deformaciones. Cualquier deformación requiere una
inspección por parte de un especialista.
La aplicación de estas precauciones es indispensable para continuar con el inflado, en una jaula de
seguridad o similar, a la presión de funcionamiento recomendada.
Nunca exceda el valor máximo de presión permitido.
Si no existe una indicación de "presión máxima permitida" en el neumático, consulte el manual del
equipo o póngase en contacto con el importador o el fabricante del neumático para averiguar la
presión máxima o la presión de funcionamiento recomendada para la llanta y el neumático
correspondientes.
Se recomienda anotar la recomendación de presión en el manual del equipo para futuras referencias.

ID: 498 2 es 2009-12-14
5.3. Jaula de seguridad ID: 26731
Siempre que sea posible, use la jaula de seguridad.

La jaula de seguridad es un dispositivo de seguridad para la presurización de neumáticos, diseñado
para minimizar las consecuencias derivadas de una posible explosión de un neumático. La red de
seguridad alrededor de la jaula de seguridad detendrá los componentes de la llanta o las partes del
neumático que salgan disparados en caso de explosión del neumático.
ID: 26763
Figura: Jaula de seguridad con un inflador de neumáticos automático.
Tras el inflado, los componentes de la rueda y el neumático deben inspeccionarse aún dentro de la
jaula de seguridad para garantizar que están correctamente posicionados y sujetos.
Si es necesario realizar ajustes adicionales en los componentes de la rueda o el neumático, el
neumático debe desinflarse extrayendo el núcleo de la válvula, antes de realizar el ajuste.
Cuando presurice un neumático, tome siempre las siguientes precauciones:
Trabaje con cuidado y precaución.
Antes de inflar el neumático, asegúrese de que los

componentes de la llanta y el neumático coinciden. Asegúrese
de que el neumático encaja correctamente en la llanta. Preste
especial atención a la compatibilidad entre las partes de la llanta
cerrada, y compruebe que todas las partes están en su posición
adecuada.

ID: 498 2 es 2009-12-14
Use siempre una jaula de seguridad o dispositivos similares

cuando infle los neumáticos. Nunca presurice los neumáticos
de máquinas pesadas a más de 150 kPa (22 psi, 1,5 bares) sin
jaula de seguridad o sin tomar otras precauciones de seguridad
similares. Tras la presurización, siempre compruebe que el
neumático encaja correctamente en la llanta antes de sacar la
rueda de la jaula de seguridad.
Levante la rueda acoplada a la máquina de montaje o al

vehículo. La rueda seguirá puesta aunque el neumático explote
mientras se está inflando.
Use siempre protectores auditivos. Incluso al retirar la válvula,

se excede el límite de ruido de 90 dB. Si no se usan protectores
auditivos, en caso de explosión de un neumático, se sufrirán
lesiones auditivas permanentes.
Nunca se coloque junto a la rueda, se siente en el neumático ni

se apoye en el neumático mientras se está inflando. Infle el
neumático desde una distancia adecuada.
Colóquese a una distancia prudencial (al menos 1.5 m) y en lado

de la superficie de rodamiento. Use el tipo de pieza de entrada
para la manguera de aire que pueda acoplarse a la válvula.
Observe el neumático mientras se está inflando. Supervise la

presurización y compruebe que los talones del neumático se
elevan correctamente en la llanta. Asegúrese de que las piezas
de la llanta de tipo multipieza se han colocado correctamente.
Lleve el neumático con la llanta multipieza a la jaula de
seguridad tras la presurización a 150 kPa (22 psi, 1,5 bares).
Está prohibida la presencia de personal no autorizado cerca de

la rueda mientras se esté inflando el neumático.
Si detecta algún tipo de anomalía, vacíe y compruebe el

neumático, la llanta y el montaje. Si el neumático no se eleva
normalmente en la llanta, o si escucha un ruido chirriante
durante la presurización, vacíe el neumático, extráigalo y
averigüe la causa del problema. Nunca use un neumático
dañado.

ID: 498 2 es 2009-12-14
www.sandvik.com
V 57280 - 2 en 0905
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 92 003-02-R/03.03
Verstellpumpe A4VG 71-180 ersetzt/replaces 01.02
Variable Pump A4VG 71-180

Baureihe/Series 32
Reparaturanleitung / Repair Instructions

2 Bosch Rexroth AG | Mobile Hydraulics A4VG | RDE 92 003-02-R/03.03
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT CONTENTS
Seite/
Page
A4VG A4VG
Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-9 Seal kits and sub assembly groups
Triebwelle abdichten 10 Sealing of the drive shaft
Hilfspumpe abdichten 11 Sealing of the boost pump
Stellkolbendeckel abdichten 12-13 Sealing of the control piston cover
Speisedruckventil abdichten 14 Sealing of the boost pressure valve
Druckbegrenzungsventil abdichten 15 Sealing of the pressure relief valve HD
Druckabschneidung abdichten 16 Sealing of the pressure cut-off valve
Ansteuergerät abdichten 17 Sealing of the control device
Ansteuergerät HW 18 Control device HW
Ansteuergeräte EP - HD 19-22 Control devices EP - HD
4/3 Wegeventil DA 23 Control device DA
Regelventil abdichten / überprüfen 24 Sealing of the regulator valve
Pumpe demontieren 25-29 Pump disassembly
Verstellung demontieren 30-31 Dismantling of the control
Zylinder demontieren 32 Dismantling of the cylinder
Überprüfungshinweise 33-34 Inspection notes
Stellkolben, Triebwerk montieren 35-37 Positioning piston, rotary group assembly
Triebwerk einbauen 38-41 Installation of the rotary group
Pumpe montieren 42-44 Assembly of the pump
Montageanweisung für Anziehdrehmomente 45-48 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 49-50 Safety regulations
Einstellhinweise 51-57 Adjustment instructions
RDE 92 003-02-R/03.03 | A4VG Mobile Hydraulics | Bosch Rexroth AG 3
Schnittbild
Sectional view
HW/D
EP/D HD/D
Schnittbild
Sectional view
DA/D
Allgemeine Reparaturhinweise
General repair instructions
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying
out repair work at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate

verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

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 befüllen.
Fill the hydraulic units with the operating medium

before commissioning.
Dichtsätze und Baugruppen

Seal kits and sub assembly groups
Dichtsatz für Triebwelle.
Seal kit for drive shaft.
Äußerer Dichtsatz.
Peripheral seal kit.
Triebwerk komplett.
Complete rotary group.
Stellkolben
Positioning piston
Stellkolben - Turcon-Glyd-Ring Dichtung

Positioning piston - Turcon-Glyd-ring seal
Deckel Stelldruck
Führungsbuchse
Stellzylinder
Turcon-Glyd-Ring
Lecköl
Pumpengehäuse
Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung At present the change of the control into Turcon seal is made
der Verstellung auf Turcon-Dichtungen. for A4VG.
Die Stückliste der kompletten Einheit erhält dabei eine neue The parts list of the complete unit will receive a new identification
Ident.- Nummer. number.
Typenschlüssel, Typnummer und Außenabmeßungen bleiben Type reference and outside dimensions remain unchanged
dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich (pump housing will change at the area of the positioning piston.
vom Stellkolben. Stellkolben ändert sich in eine angefaste Positioning piston will change into chamfering design).
Ausführung).
Pumpengehäuse / Pump housing Pumpengehäuse / Pump housing

mit Lagerbuchse / with bush ALT / OLD mit Turcon-Dichtung / with Turcon seal NEU / NEW
* *
Die Umstellung der Verstellung auf Turcon-Dichtung ist The change of the control into Turcon seal design
im allgemeinen mit einer Funktionsverbesserung improves in general the function (DA-behaviour, lower
verbunden (DA-Verhalten, geringerer Temperatureinfluß temperature-influence on control times).
auf Stellzeiten).
Bei gleicher Düsenbestückung können sich die Stellzeiten The control times will slightly change with the same throttle
geringfügig verändern. sections. Therefore our customers have to be informed
about this change.
Baugruppen
Sub assemblies
Anschlußplatte
Valve plate
Ansteuergerät HW
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.
Control device HW
Note:
Size 71 control device as size 40 - 56 with flat seal.
alt / old Ansteuergerät HD

Hinweis:
Control device HD
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.
Ansteuergerät EP
Hinweis:
alt / old Control device EP

Note:
Size 71 control device as size 40 - 56 with flat seal.
neu / new
4/3 Wegeventil DA
Hinweis:
alt / old
Control device DA
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.
Baugruppen
Sub assemblies
Hilfspumpe
Boost pump
Regelventil
Control valve
HD - Ventil
High pressure valve
ND - Ventil
Low pressure valve
Druckabschneidung
Pressure cut-off
Triebwelle abdichten
Sealing of the drive shaft
Triebwelle abkleben.
Sicherungsring ausbauen.
Protecting the drive shaft.

Remove retaining ring.
Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.
Screw in sheet metal screw into the holes fitted

with rubber.
Pull out shaft seal with pliers.
Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.
Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.
Hilfspumpe abdichten
Sealing of the boost pump
*
*
Achtung!
* Angefaste "Seite" zum Deckel montieren.
Note!
* Mount chamfered side facing cover.
Lage kennzeichnen,
Befestigungsschrauben ausbauen.
Mark position,
remove fixing screws.
Deckel abdrücken.
Pry-off cover.
Kontrolle:
O-Ring, Nut, Lauffläche, Anschlußplatte.
Check:
O-ring, groove, gliding surface, connection plate.
Stellkolbendeckel abdichten
Sealing of the control piston cover
Achtung!
Korrekt mechanische 0-Lageneinstellung
überprüfen
Attention!
Check correct mechanical 0-position.
Lage kennzeichnen.
Mark position.
Deckel verdrehen und mit leichten

Hammerschlägen lösen.
Rotate cover and release by tapping gently

with hammer.
Stellkolbendeckel abdichten
Sealing of the control piston cover
Deckel kennzeichnen. Maß X festhalten, Konter-

mutter lösen, Stellschraube gegenhalten.
Mark cover. Must be fixed, loosen counter nut,

hold adjustment screw.
X
Deckel demontieren.
Remove cover.
Deckel von Stellschraube "abschrauben".
Lift off by turning the setting screw.
Kontrolle!
O-Ring (1), Nut (2), Gehäuse (3).
Check!
O-ring (1), groove (2), housing (3).
Achtung!
Korrekte mechanische Nullageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.
(siehe Einstellhinweise Seite 54)
Attention!
Adjustment of the correct zero position to be carried
out after installation into the machine or on the test
bench.
(see adjustment instructions on page 54)
Speisedruckventil abdichten
Sealing of the boost pressure valve
Ventil komplett ausbauen.

Hinweis:
Einstellschraube nicht verändern.
Achtung!
Nach Einbau Ventileinstellung überprüfen!
Remove valve completely:

Note:
Do not change adjustment screw.
Attention!
Check valve setting after installation.
Druckbegrenzungsventil abdichten
Sealing of the pressure relief valve HD
Ventil komplett ausbauen.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.
Remove valve completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".
*
Druckabschneidung abdichten
Sealing of the pressure cut-off valve
Einstellteil komplett ausschrauben.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.
Unscrew setting cartridge completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".
Ansteuergerät abdichten
Sealing of the control device
DA
DA alt / old
HD
alt / old
DA
neu / new
HD
neu / new EP
alt / old
HW
EP
neu / new
NG 71 ... 125
NG 180
Ansteuergerät abbauen. Remove control device.

NG 71: Abdichtung der Ansteuergeräte wie NG 40 - 56 Size 71: Sealing of control device as size 40 - 56
mit Flachdichtung. with flat seal.
Achtung! Korrekte hydraulische Nullageneinstellung überprüfen. Attention! Check correct hydraulic 0-position.
Befestigungsschrauben demontieren.
Remove fixing screws.
Ansteuergerät abdrücken.
Pry-off the control unit.
Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).
Check
Sealing surface (1), gasket (2), O-rings (3).
Ansteuergerät HW
Control device HW
NG 90-180
Size 90-180
Kontrolle:
O-Ringe und Dichtung.
Check:
O-rings, gasket.
Ansteuergeräte EP - HD
EP - HD Control devices
Ansteuergerät HD - EP alt (NG 90 - 180)

HD - EP (Size 90 - 180) control unit old
HD alt / old
EP alt / old HD alt / old
EP alt / old
Neues Ansteuergerät HD - EP (NG 71)

New HD - EP (Size 71) control unit alt / old
131,0 mm
neu / new
77,4 mm
202,0 mm
alt / old
214,4 mm
neu / new
Ansteuergerät HD neu (NG 90 - 180)

HD - control unit new (Size 90 - 180)
Ansteuergerät EP neu (NG 90 - 180)

EP - control unit new (Size 90 - 180)
* Markierung Montageposition HD *
* Marking the assembly position HD
*
* *
* Markierung
Montageposition HD * Assembly position marker HD
Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker
Leckölkanal offen wird geschlossen. The open leakage port is plugged
Zugfeder tauschen! Exchange the tension spring!

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.
Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.
When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point
4/3 Wegeventil DA
Control device DA
4/3 Wegeventil DA alt (NG 90 - 180)

DA - control unit old (Size 90 - 180)
Ablaufdrossel
4/3 Wegeventil DA neu (NG 90 - 180)

DA - control unit new (Size 90 - 180)
Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
Regelventil abdichten/überprüfen
Sealing of the regulator valve
Blende überprüfen.
Keine Beschädigung.
Inspect orifice.
No damage.
Gewinde abkleben.
O-Ring einsetzen.
Cover threads.
Insert O-ring.
Pumpe demontieren
Removing of the pump
EP, HD, HW
Verschlußschraube / Stift
Locking screw / pin
DA
Verdrillschraube /
Timing adjustment screw
Ansteuergerät abbauen.
Remove control device.
Hilfspumpe ausbauen.
Hinweis:
Einbaulage kennzeichnen.
Remove auxiliary pump.

Note:
Mark assembly position previously.
Pumpe demontieren
Anschlußplatte mit Hilfspumpe
Achtung: Drehrichtung wird immer mit Blick

auf die Triebwelle angegeben.
Port plate with auxiliary pump
Attention: Direction of rotation is always

indicated with view on the drive shaft.
z.B. Drehrichtung "Rechts"
e.g. "clockwise" direction of rotation
Drehrichtung "rechts"
2 1
Breite Seite zur Sichel "rechts".
1. O-Ring,
2. Entlastungskanal
Direction of rotation "clockwise"

2
Broadside to the crescent "clockwise"
1. O-ring
2. Discharge channel
Pumpe demontieren
Drehrichtung "links"
"Counterclockwise" direction of rotation
2 1 1. O-Ring,
2. Entlastungskanal
1. O-ring
2. Discharge channel
Verschleißplatte 71 - 180
Wear plate 71 - 180

Pumpe demontieren
Pump disassembly
Lage der Verdrillschraube markieren (1).

Einstellmaß 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).
X
Lage der Hilfspumpe und Anschlußplatte

markieren.
Anschlußplattenbefestigung lösen.
Mark position of the connection plate.

Loosen connection plate fixation.
Anschlußplatte und Steuerplatte abheben.
Lift off port plate and control plate.
1. Zylinder nach unten drücken, nicht beschädigen.

2. Verdrillschraube herausdrehen.
1. Press the cylinder to the bottom, do not damage.

2. Remove fixing indexing screw.
Zylinder komplett mit Kolben und

Rückzugeinrichtung ausbauen.
Push off hydraulic section of rotary group.

Pumpe demontieren
Pump disassembly
WDR / Sicherungsring ausbauen.
Remove radial seal ring and retaining ring.
Triebwelle mit leichten Hammerschlägen austreiben.
Remove drive shaft with slide hammer strokes.
Schwenkwiege / Lager komplett ausbauen.
Remove swash plate / bearing cups.
Gelenkstift ausbauen.
Remove joint pin.

Verstellung demontieren
Dismantling of the control
Alt / Old
Neu / New
Alt / Old
Neu / New
Lage vom Deckel markieren, Maß "Nullage" fest-

halten - Mutter lösen.
Mark position of the cover, note measure of

"zero position" - loosen nut.
Deckel abdrehen.
Remove cover.
Verstellung demontieren
Dismantling of the control
Lage des Deckels markieren.

Befestigungsschrauben lösen, abbauen.
Mark position of the cover.

Loosen locking screw, remove cover.
Stellzylinder ausbauen.
Remove positioning ring.
Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.
Fit tool device and preload spring.

Remove take-off ring.
Ringe ausbauen.
Achtung: Teile stehen unter Federvorspannung.
Remove rings.
Remove safety ring.
Attention: Parts are under spring load.
Zylinder demontieren
Dismantling of the cylinder
Kolben mit Rückzugeinrichtung ausbauen.

Tragkugel mit Tellerfedersäule abheben.
Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.
Remove safety ring.
Scheibe 1, 2
Disc 1, 2
1 2
Überprüfungshinweise
Inspection notes
Lager Lagerschalen Kontrolle!

Bearing Bearing cup Käfig-Paar (1),
Lagerschalenpaar (2).
2
Check!
Cage set (1),
Bearing cup set (2).
Kontrolle!
Lagerbahnen (1)
Check!
Bearing surfaces (1)
Kontrolle!
Gleitfläche riefenfrei.
Check!
Sliding surface free from scoring.
Kontrolle!
Rückzugeinrichtung riefenfrei.
Check!
Check that return device is free of scoring.
Kontrolle!
1 1. Verzahnung "ausgeschlagen", Passungsrost.
2 2. Laufflächen.
1 3. Lauffläche - Wellendichtring.
3
1
Check!
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.
Überprüfungshinweise
Inspection notes
Kontrolle!
Lauffläche (1) keine Kratzer, keine Metall-
einlagerungen, 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).
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
Kontrolle!
Zylindergleitfläche (1) riefenfrei.
Steuerplatte (2) nicht riefig.
Check!
Cylinder surface (1) free of scoring.
Control plate (2) without scoring.
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.
Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly
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:
Montagezange / Assembly pliers: B+S x M22
Montage / Assembly A4VG
2
3
3
2
Pos. / Pos. / Pos. / Pos. /
1
Item 1 Item 2 / 3 Item 2 / 3 Item 1
Pos. / Item 1: Stangenführungsring montieren.
Install barguide ring.
Pos. / Item 3: O-Ring montieren.
Install O-ring.

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 nierenförmig zu-

sammendrücken. Die Verformung von Turcon-Dich-
tungen ist sorgfältig vorzunehmen, damit die Dicht-
kanten 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 einführen und in der

Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - 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.
Führungsdorn in Stellkolben einbauen.
Insert guide thorn into the positioning piston.
Führungsdorn / A4VG28 I: 277 5 017

Guide thorn: A4VG40 I: 277 5 017
A4VG56 I: 277 5 018
A4VG71 I: 277 5 019
A4VG90 I: 277 5 020
A4VG125 I: 277 5 021
A4VG180 I: 277 5 022
A4VG250 I: 277 5 023
Führungsdorn leicht einfetten.

Stellkolben mit Führungsdorn einbauen.
Grease slightly guide thorn.

Install positioning piston with guide thorn.

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.
Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.
Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege
Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.
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
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.
Triebwerk einbauen
Installation of the rotary group
Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Schwenkwiege mittig stellen mit Meßvorrichtung
(Uhr oder Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.
Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.
Gelenkstift montieren.
Fit joint pin.

Triebwerk einbauen
Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.
Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.
Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V
Teil/Part 3 Teil/Part 4
∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5
∅ ∅
Teil/Part 5
∅
2
∅
1
Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
Triebwerk einbauen
Neue Montageposition!
Triebwelle mit Lager und Wellendichtring
einbauen (siehe Seite 10).
Assemble drive shaft with bearings and radial

seal rings (see at page 10).
Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.
Assemble piston with retaining plate.

Note:
Oil piston and piston pad.
Triebwerk einbauen
Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.
Remove holding device.

Fit cylinder complete with pistons and retaining device.
Montagehilfe:
Mit O-Ring Kolben festhalten.
Assembly aid:
Hold the pistons by using an O-ring.
Triebwerk montieren DA
Assembly of the rotary group DA
Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.
Control plate clockwise rotation - indexed in the

R direction of rotation.
Note! Noise grooves are machined - in based on
directionof rotation.
Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.
L
Control plate counter clockwise rotation - indexed
in the direction of rotation.
Note! Noise grooves are machined - in based on
direction of rotation.
Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.
For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.
Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.
Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.
Hilfsvorrichtung: / A4VG71 I: 277 5 088

X Auxiliary device: A4VG90 I: 277 5 089
A4VG125 I: 277 5 090
A4VG180 I: 277 5 091
A4VG250 I: 277 5 092
Steuerplatte einsetzen - Rechtslauf.
Insert the control plate - clockwise rotation.

Triebwerk montieren DA
Assembly of the rotary group DA
Steuerplatte einsetzen - Linkslauf.
Insert the control plate - Counter- clockwise

rotation.
Anschlußplatte aufbauen.
Achtung! Federvorspannung!
Mit zwei Befestigungsschrauben überkreuz An-
schlußplatte in Gehäuseführung einsetzen -
Fertigmontage!
Assemble connection plate.

Attention! Spring preloaded!
Insert control plate into housing, guidance with two
locking screws crossing over -Finish assembly!
Verdrillschraube - Nach Markierung ausrichten.
Locking screw - Observe adjusting measure.
1. Deckel montieren.
2. Nullage nach Maß einstellen.
1. Assemble cover
2. Adjust zero position according to measure.
Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW
Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.
Control plate clockwise rotation - indexed in the

direction of rotation.
R Pos.1
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.
Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.
Control plate counter clockwise rotation - indexed

L Pos.1
in the direction of rotation.
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.
Zylinderflächen und DU-Lager einölen, neue

O-Ringe mit Fett einreiben und einsetzen.
Oil the running surfaces of the cylinder barrel and

the DU- bearing. Grease the O-rings and insert
in grooves.
Verschlußschraube
Plug
Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW
Verschlußschraube einbauen.
Screw in the plug.
Anschlußplatte mit Steuerplatte lagerichtig aufset-

zen.
Hinweis:
EP, HD, HW -Steuerplatte mit Fett einsetzen.
Place port block with control plate in correct

position.
Note:
EP, HD, HW - Put control plate with grease.
1. Deckel montieren.
2. Nullage nach Maß einstellen.
1. Assemble cover
2. Adjust zero position according to measure.
Pumpe montieren
Assembly of the pump
Achtung!
Korrekte mechanische Nullageneinstellung muß nach
Einbau im Gerät bzw. Prüfstand erfolgen.
Attention!
Adjustments of the correct zero position to be carried out
after installation into the machine or on the bench test.
Hilfspumpe montieren.
Hinweis: Drehrichtung beachten. (Siehe Seite 26, 27)
Assemble auxiliary pump.

Note: Take care of direction of rotation. (See page 26, 27)
Dichtung mit zwei Befestigungschrauben zentrieren und

NG 71 Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment anziehen.
Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.
Fünfte Schraube einsetzen und mit Drehmoment = 10,4 Nm

festziehen.
Restliche vier Schrauben nach Drehmoment festziehen.
Fit the fifth screw and tighten to a torque of 10,4 Nm.

Then tighten the other four screws to there correct torque.
Ansteuergerät montieren.
Assemble control device.

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)
Die Werte gelten für Schaftschrauben mit metrischem The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen to DIN 13 part 13, as well as head areas to DIN 912 socked
nach DIN 912 Zylinderschrauben, head cap screws,
DIN 931 Sechskantschrauben mit Schaft bzw. DIN 931 hexagon bolt or
DIN 933 Sechskantschrauben mit Gewinde bis Kopf. DIN 933 hexagon bolts with threads up to the head.
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

5. Verschlußschrauben mit Innensechskant, O-Ring und 5. Plugs with internal hexagon, O-ring and UNF-,
UNF-, UN-Gewinde nach SAE J 514 (nach N 02.106) UN- threads to SAE J 514 (nach N 02.106)
G
O-Ring / O-ring seal
Dichtung / Thread
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390
6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)
Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm
M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

A4V - Düsen / orifices
Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12
Sicherheitsbestimmungen
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Vor dem Start Before starting
● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
Sicherheitsbestimmungen
Safety regulations
Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.
Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!
Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!
Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)
Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!
Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.
Manometer an "G" anschließen. Connect pressure gauge to "G".
Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.
Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.
* bei DA-Ausführung * with the DA version
"G"
Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"
HW HD EP DA
Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.
Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"
* *
*
HW HD EP
Achtung!
Attention!
Manometer an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.
Connect pressure gauges to X1 and X2.

Adjust the zero position so that with a block drive
both pressure gauges indicate the same pressure
value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.
Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Druckabschneidung Achtung!
Pressure cut-off Sicherheitsbestimmungen beachten!
HD-Ventil ohne Bypass
1. HD-Ventile sind immer 10% höher eingestellt als die
Druckabschneidung.
Bei Veränderung eines Einstellwertes immer beide
kontrollieren.
2. Nachjustierung nur bei Betriebstemperatur
Manometer an MA und MB anschließen.
Druckabschneidung: Maß X Einstellschrauben notieren!
Einstellschraube auf Block drehen.
HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.
Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Drucklos "Einstellwert“ verändern - Kontrolle
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit gelöster Pos.1
Kontermutter Pos. 2 bis zum Anschlag mit Item 1
max. 2 Nm im drucklosen Zustand eindrehen!
Bei größerem Kraftaufwand als 2 Nm werden sonst Federteller
und Feder verbogen. Druckabschneidungseinstellung ist nicht Pos.2
mehr gewährleistet. Item 2
To block the pressure cut-off when testing the high pressure

valves, the adjustment screw (item 1), with the lock-nut (item 2)
loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached. Attention!
Forces larger than 2 Nm bends the spring and spring plate. Observe safety regulations.
The pressure cut-off setting can then no longer be guaranteed. HP valve without bypass-function
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.
HD- Ventile Connect pressure gauge MA and MB.
HP- valves Pressure cut-off: Note measurement X for setting screw!
Turn setting screw to the blocked position.
HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change zero pressure "setting value“ - then check.
Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.
Einstellhinweise - Bypassventil
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 Vehicle with hydrostatic transmission and gear shift without idling
hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlauf- setting position (free wheeling).
stellung (Freilauf).
Hydrostatischer Antrieb / Bypaß-Schaltung Hydrostatic transmission / Bypass-switching
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. In this case the travel transmission is switched on to free
Zu diesem Zweck haben die in der Verstellpumpe integrierten wheeling.For this purpose the variable displacement pump has
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. incorporated high pressure relief valves with bypass function.
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird The screw (item 1) is unscrewed to such an extent, that the valve
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich cartridge is released and free oil circulation is possible.
ist.
A4VG 125 - 250
Bypass-Schaltung
ca. 2 Umdrehungen
Pos.1 200 ± 10 Nm
Einstellhinweise - DA- Regelung

Adjustment instructions - DA control
Achtung!
Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant
gehalten werden.
Antriebsmotor starten, Leerlaufdrehzahl
Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*
Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)
Einstelldaten Pumpe A4V/DA überprüfen

Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Verdrillung
Regelende
Regelbeginn HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube
Hinweis:
Excenterjustierung - Drehrichtung beachten
Hinweis: * Einstelldaten nach Werksauftrag!

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control
Attention!
Check setting data.

Operating temperature should be kept largely
constant during the check procedure.
Start prime mover, idle speed.
Block position
Drive direction switch - "0“.
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)
Check setting data pump A4VIDA

Begin of control:
Timing HD 40 - 50 bar
adjustment screw
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Begin of control 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!

Brueninghaus Hydromatik GmbH
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 92 003-02-R/03.03
V 00497-1en 0903
Model Repair
No. Kit BRAKE ACTUATORS
03-460-220
03-460-222
02-400-201
02-400-201
(spring/hydraulic apply)
03-460-256
03-460-258
02-400-200
02-400-200
for CNH Power Components
03-460-260 02-400-200
Installation and Service Instructions
INSTALLATION
(Refer to Figures 1 & 2)
1. Remove end plug (23), gasket FIGURE 1

(22), spring (21), lock nut (20)
and retainer (19) from brake
actuator.
2. Carefully slide brake actuator
over axle push rod and into
access port of axle. NOTE: Ex-
treme care must be taken so
as not to damage axle push
rod threads and o-ring (1).
3. Secure brake actuator to axle
with bracket. Connect all neces-
sary fluid lines to actuator and
bleed system.
4. Install retainer (19) on end of
axle push rod and tighten
snugly. NOTE: Apply a high
pressure lubricating com-
pound to mating surfaces of
stop (16) and retainer (19).
5. Introduce hydraulic pressure
20.7-82.7 bar (300-1200 psi)
through spring brake inlet port
located in end plug (18). This will
expose approximately 12.7 mm
(.50") more of axle push rod.
6. Bleed hydraulic release line
through bleeder screw (10).
7. Retighten retainer (19). Torque REMOVAL
2.83-5.65 N-m (25-50 lb-in) then (Refer to Figures 1 & 2)
back off retainer two turns.
8. Install lock nut (20) on axle push 1. Introduce hydraulic pressure remove all fluid lines from brake
rod and tighten until it contacts 20.7-82.7 bar (300-1200 psi) actuator.
retainer. through spring brake inlet port 5. Remove bracket and carefully
9. Install spring (21), gasket (22) located in end plug (18). slide brake actuator off of axle
and end plug (23). Torque end 2. Remove end plug (23), gasket push rod. NOTE: Extreme care
plug (23) 24.4-27.1 N-m (22) and spring (21) from brake must be taken so as not to
(18-20 lb-ft). actuator. damage axle push rod
10. Release brake. Reapply spring 3. Remove lock nut (20) and re- threads.
release and bleed hydraulic tainer (19) from axle push rod. 6. Proceed to Disassembly on
apply section until all air is 4. Release hydraulic pressure and back page.
removed.
MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and/or
results of each application. MICO has not undertaken any such wide evaluation. Therefore, anyone who uses an application which is not recommended by the
manufacturer, first must completely satisfy himself that a danger will not be created by the application selected, or by the particular model of our product that is
selected for the application.
MICO has made every attempt to present accurate information in catalogs, brochures and other printed material. MICO can accept no responsibility for errors from
unintentional oversights that may exist. Due to a continuous program of product improvement, materials, specifications, and product documentation are subject to
change without notice or obligation.
V 00497-1en 0903
DISASSEMBLY ASSEMBLY
(Refer to Figure 2) (Refer to Figure 2)
1. Remove o-ring (1) from hous- LUBRICATE ALL RUBBER COM- 5. Install piston (11) into housing
ing (2). NOTE: Not all models PONENTS FROM REPAIR KIT (2). Note direction of piston
use o-ring (1). WITH CLEAN TYPE FLUID USED (11). NOTE: Be careful not to
2. Using a spanner wrench, re- IN THE SYSTEM. scratch or mar bore of hous-
move end plug (18) from hous- 1. Install new o-rings (4 & 5) and ing (2).
ing (2). Remove o-ring (17) new back-up rings (3 & 6) into 6. Install stop (16) into housing
from end plug (18). bore of housing (2). Note the (2). Note the direction of stop
3. Remove bleeder plug (10) from order of o-rings and back-up (16). NOTE: Apply a high
end plug (18). Remove o-ring rings. NOTE: Be careful not to pressure lubricating com-
(9) from bleeder plug (10). scratch or mar bore of hous- pound to mating surfaces of
4. Remove stop (16) from housing ing (2). stop (16) and piston (11).
(2). 2. Carefully install piston (7) into 7. Install new o-ring (9) on bleeder
5. Remove piston (11) from hous- housing (2). Note direction of plug (10) and install in end plug
ing (2). Remove o-ring (15), piston (7). (18).
cup 13) and back-up rings (12 3. Install spring (8) into housing 8. Install new o-ring (17) on end
& 14) from piston (11). NOTE: (2). plug (18). Lubricate threads of
Be careful not to scratch or 4. Install new o-ring (15), new cup end plug (18) with clean type
mar piston (11). (13) and new back-up rings (12 fluid used in system. Thread
6. Remove spring (8) from hous- & 14) on piston (11). Note the end plug into housing and
ing (2). order of o-ring, cup and back- torque 325.4-339.0 N-m
7. Remove piston (7) through end up rings. NOTE: Be careful (240-250 lb-ft).
plug (18) end of housing (2). not to scratch or mar piston 9. Install new o-ring (1) on hous-
8. Remove o-rings (4 & 5) and (11). ing (2). NOTE: Not all models
back-up rings (3 & 6) from use o-ring (1).
housing (2). NOTE: Be careful 10. Proceed to Step 2 of Installa-
not to scratch or mar bore of tion on front page.
housing (2).
l Items included in Repair Kit

* Not used in all models FIGURE 2
MICO is a registered trademark of MICO, Incorporated. MICO is registered in the U.S. Patent and Trademark Office as well as in Australia, Canada, Great Britain, Indonesia, Japan, Peoples Republic of China, and South Korea.
MICO, Incorporated MICO West Division

1911 Lee Boulevard (Zip Code 56003-2507) 701 East Francis Street (Zip Code 91761-5514)
P.O. Box 8118 / North Mankato, MN U.S.A. 56002-8118 P.O. Box 9058 / Ontario, CA U.S.A. 91762-9058
( 507.625.6426 Facsimile 507.625.3212 ( 909.947.4077 Facsimile 909.947.6054
Form No. 81-460-095 Revised 5/8/02 Printed in U.S.A.

V 00498- 1 en 1105

Hidrostatico Sandvik

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Drill Carrier TC 6; Maintenance and lubrication manual

B 00500--4 en 0409 / AR 1 (74)

2 (74) B 00500--4 en 0409 / AR

B 00500--4 en 0409 / AR 3 (74)

4 (74) B 00500--4 en 0409 / AR

Pressurized hydraulic hoses must no be touched by hand. The hoses

OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND

B 00500--4 en 0409 / AR 5 (74)

6 (74) B 00500--4 en 0409 / AR

B 00500--4 en 0409 / AR 7 (74)

8 (74) B 00500--4 en 0409 / AR

B 00500--4 en 0409 / AR 9 (74)

10 (74) B 00500--4 en 0409 / AR

4.2. Engine maintenance

B 00500--4 en 0409 / AR 11 (74)

! DANGER When servicing or repairing the equipment, shut down the

DAILY OR ONCE IN SHIFT (10 HOURS)

Fig 1. Cleaning the air filter

12 (74) B 00500--4 en 0409 / AR

Dust discharge valve

Fig 2. Dust discharge valve

Fig 3. Clean cartridge

D Undo clip fasteners 1.

B 00500--4 en 0409 / AR 13 (74)

Fig 4. Service indicator

14 (74) B 00500--4 en 0409 / AR

Check the engine oil level

1. Engine oil dipstick

B 00500--4 en 0409 / AR 15 (74)

Check the cooling system / level

! DANGER Always stop the engine before cleaning.

D The amount of contamination in the cooling system depends on the engine

16 (74) B 00500--4 en 0409 / AR

4.2.1. Engine cooling system

B 00500--4 en 0409 / AR 17 (74)

DANGER Never add cold coolant to hot engine as this may

DANGER Engine is equipped with a suction fan. Blow the

18 (74) B 00500--4 en 0409 / AR

Check the fuel level

Fig 5. Check the fuel level

D Use only clean commercial--grade diesel fuel.

B 00500--4 en 0409 / AR 19 (74)

Check the engine monitoring system, warning system

2. Engine coolant temperature. 4. Engine oil pressure. Normal

20 (74) B 00500--4 en 0409 / AR

1. Service brake. The indica- 6. Air filter indicator light is on

2. Park brake. 7. Low engine coolant level.

3. Pre--heating indicator. 8. Blinker (option). Indicator

4. Charging. 9. Water in fuel indicator (op-

B 00500--4 en 0409 / AR 21 (74)

Indicator lights (ABA-- alternative)

1. ABA--brake. 6. Air filter indicator light is on

22 (74) B 00500--4 en 0409 / AR

Check the V-- belts retention

Fig 6. Checking V--belts

Fig 7. Tension gauge

B 00500--4 en 0409 / AR 23 (74)

-- If necessary, retension belt and measure again.

Coolant / fuel pump V--belt tension

D Loosen screws (1) and (2).

1 D Press fuel pump (3) in direction of arrow

Fig 8. Tensioning / changing coolant / fuel pump belt

Changing coolant / fuel pump V--belts