Bomag BW180AD

Instructions for repair
BW 180 AD
101 870 00 ....
Tandem Vibratory Roller
Catalogue number
008 912 53
06/2002
Table of Contents
General
5
1.1 Foreword
1.2 Safety regulations
1.3 General repair instructions
1.4 Tightening torques
11
1.5 Connection overview
12
Tests and adjustments
15
2.1 Technical data
16
2.2 Special tools
19
2.3 Checking the rotation speeds
21
2.4 Pressure tests in the travel circuit
23
2.5 Checking / adjusting the neutral positions of the travel pump
25
2.6 Check the setting of the high pressure relief valves in the travel circuit
28
2.7 Pressure measurements in the vibration circuit
30
2.8 Check the setting of the high pressure relief valves in the vibration circuit 31
2.9 Checking / adjusting the vibrator shaft speeds
33
2.10 Checking the leakage rate of the vibration motor
34
2.11 Pressure test in steering circuit
35
2.12 Operation of display module for ESX-control
37
2.13 Driving against the closed brake
38
2.14 Adjusting the machine type
39
2.15 Calibration of the angle transducers
41
2.16 Adjusting the angle transducers
43
2.17 Automatic detection of step currents for the steering valves
45
2.18 Adjusting the type of travel range switch
47
2.19 Resetting the step currents in the travel system
49
2.20 Automatic detection of step currents in the travel system
50
2.21 Showing stored faults
53
2.22 Deleting stored faults
54
Flushing
55
3.1 Special tool:
56
3.2 Flushing shematic for front drum drive
58
3.3 Flushing schematic for rear drum drive system
60
3.4 Flashing the travel circuit
62
3.5 Flushing schematic for vibration drive
72
3.6 Flushing the vibration circuit
74
Trouble shooting
81
4.1 General
82
4.2 Trouble shooting diagram
83
Drum
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103
5.1 Special tools
104
5.2 Repair overview for drum
106
5.3 Removing and installing the drum
108
5.4 Removing and installing the vibrator unit on the drum drive side
114
5.5 Removing and installing the vibrator unit on the vibration drive side
119
5.6 Repairing the vibrator unit on the drum drive unit
129
BOMAG
Table of Contents
5.7 Repairing the vibrator unit on the vibration drive unit
5.8 Dismantling, assembling the change-over weights
Pivot steering
140
143
6.1 Removing, repairing and installing the pivot steering
144
6.2 Repairing the oscillation joint
148
Suppliers documentation
134
153
7.1 A4VG
155
7.2 A10VG
201
7.3 MS/MSE 02 to 18
255
7.4 Vibration motor A2FM 32
305
BOMAG
008 912 53
1 General
008 912 53
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Introduction
1.1
Foreword
These repair instructions contain all necessary information for training and repair work.
Notes on maintenance, care and trouble shooting can
be found in the operating and maintenance instructions.
1
General
Tests and adjustments
Flushing
Trouble shooting
Drum
Pivot steering
Components
This instruction manual contains only assembly

groups needed for this type of machine.
The repair instructions describe the removal or dismantling and assembly of components and assembly
groups.
The repair of disassembled assembly groups is described as far as this makes sense with respect to
available tools and spare parts supply and as far as it
can be understood by a skilled mechanic.
Danger
Danger of injury
Please observe strictly the safety regulations in

these operating instructions and the applicable
accident prevention regulations.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
You should only use genuine BOMAG spare parts.
These repair instructions are not subject of an updating service; for this reason we would like to draw your
attention to our additional technical service bulletins.
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notification.
Information and illustrations in this repair manual must
not be reproduced and distributed, nor must they be
used for the purpose of competition. All rights according to the copyright law remain expressly reserved.
BOMAG GmbH & Co. OHG
Printed in Germany
Copyright by BOMAG
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Important notes
1.2
Safety regulations
These safety regulations must be read and applied by every person involved in the repair of this
machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be
additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
These repair instructions contain headers like Note,
Attention, Danger and Environment, which must
be strictly complied with in order to avoid dangers for
health and for the environment.
Danger
Paragraphs marked like this highlight possible
dangers for persons.
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
Tools, lifting gear, lifting tackle, supports and other

auxiliary equipment must be fully functional and in
safe condition.
Use only safe and approved lifting gear of sifficient

load bearing capacity to remove and install parts or
components from and to the machine.
Be careful with cleansing agents. Do not use easily

inflammable or harmful substances, such as gasoline or paint thinners for cleaning.
Cleaning or repair work on the fuel tank is very dangerous. Do not smoke or allow any ignitable sparks
or open fire in the vicinity when cleaning or repairing
a tank. .
When performing welding work strictly comply with

the respective welding instructions.
Special safety regulations
Use only genuine BOMAG spare parts for repair

purposes. Original parts and accessories have
been specially designed for this machine.
We wish to make explicitly clear that we have not

tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original
parts or accessories.
Unauthorized changes to the machine are prohibited for safety reasons.
If tests on the articulated joint need to be performed

with the engine running, do not stand in the articulation area of the machine, danger of injury!
Do not perform cleaning work while the engine is

running.
If tests must be performed with the engine running

do not touch rotating parts of the engine, danger of
injury.
Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting
the engine in closed rooms.
Refuel only with the engine shut down. Ensure strict

cleanliness and do not spill any fuel.
Keep used filters in a separate waste container and

dispose of environmentally.
Dispose of oils and fuel environmentally when performing repair or maintenance work.
Do not refuel in closed rooms.
Do not heat up oil higher than 160 C because it

may ignite.
Wipe off spilled oil and fuel.
Note
Paragraphs marked like this contain technical information for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
Before starting repair work stand the machine on

level and solid ground.
Always secure the machine against unintended rolling.
Secure the engine reliably against unintentional

starting.
Mark a machine that is defective or being repaired

by attaching a clearly visible warning tag to the
steering wheel.
On machines with articulated joint keep the articulated joint locked during work.
Use protective clothes like hard hat, safety boots

and gloves.
Keep unauthorized persons away from the machine

during repair work.
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Do not smoke when refuelling or when checking the

acid level in the battery.
Do not check the acid level of the battery with a naked flame, danger of explosion!
Old batteries contain lead and must be properly disposed of.
There is a danger of scalding when draining off engine or hydraulic oil at operating temperature.
on machines with rubber tires a tire may busr if incorrectly assembled. This can cause severe injury.
Do not exceed the specified highest permissible tire

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

that all line connections and ports have been properly tightened and are in perfect condition.
Hydraulic oil leaking out of a small opening can

hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.
Do not step in front of or behind the drums/wheels

when performing adjustment work in the hydraulic
system while the engine is running. Block drums
and/or wheels with wedges.
Reattach all guards and safety installations after

all work has been completed.
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General
1.3
General repair instructions
Before removing or disassembling and parts, hoses

or components mark these parts for easier assembly.
Before assembly oil or grease all parts, as far as this
is necessary.
Fill new hydraulic units with hydraulic oil before

starting operation.
After changing a component thoroughly flush and

bleed the entire hydraulic system.
Perform measurements at operating temperature of

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

charge pressure test, if necessary check the speed
of the exciter shaft.
The operating pressure of the exciter shaft to a

great extent depends on the base under the vibrating drum. If the soil is too hard place the drums on
old rubber tires. Do not activate the vibration on a
hard, concreted base, danger of bearing damage.
After the completion of all tests perform a test run

and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic system depressurized.
Hydraulic system
Caution
Do not open any hydraulic components if you
have not been properly trained and without exact
knowledge.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enter
into the system.
Clean fittings, filler covers and the area around such

parts before disassembly to avoid entering of dirt.
Before disconnecting hoses, pipes or similar relieve

the system pressure with the engine shut down.
During repair work keep all openings closed with

clean plastic plugs and caps.
Do not run pumps and motors without oil.
When cleaning hydraulic components take care not

to damage any fine machine surfaces.
Chemical and rubber soluble cleansing agents may

only be used to clean metal parts. Do not use such
substances to clean seals and gaskets.
After changing a component clean the hydraulic oil

tank thoroughly.
Fill the housings of hydraulic pumps and motors

with hydraulic oil.
Use only hydraulic oils according to the specification in the maintenance instructions.
After changing a component clean the hydraulic

system as described in the flushing instructions in
order to prevent all other components from being
damaged by abrasion and metal chips remaining in
the system.
Rinse of cleaned parts thoroughly, dry them with

compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.
Change the hydraulic oil filter.
Bleed the hydraulic circuits.
Avoid the formation of rust on fine machined caused

by hand sweat.
Start up the system without load.
Check the hydraulic oil level in the tank, fill up oil if

necessary.
Grease must not used as a sliding agent for assembly work. Use hydraulic oil.
Do not start the engine after the hydraulic oil has

been drained off.
Before commissioning
Use only the specified pressure gauges. Risk of

damaging the pressure gauges under too high pressure.
Clean ports and fittings before removal so that no
dirt can enter into the hydraulic system.
Check the hydraulic oil level before and after the

work.
Use only clean oil according to specification.
Check the hydraulic system for leaks, find and rectify the cause.
008 912 53
Commissioning
After commissioning
Check system pressures and speeds.
Check fittings and flanges for leaks.
After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic
system, adjust if necessary.
Do not adjust pressure relief valves and control

valves to values above their specified values.
Electrical system
Always disconnect the battery before starting work

in the electrical system.
Ensure correct polarity when connecting the battery.
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Do not check voltage by tapping against ground.
When performing welding work always fasten the

earth clamp of the welding unit in the immediate vicinity of the welding location. Strictly disconnect the
cables from the generator before starting work.
Seals and gaskets
Generally use new seals and gaskets when performing assembly work. The required seal kits are
available as spare parts.
10
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Tightening torques
1.4
Tightening torques
Tighten fastening screws and nuts according to the table of tightening torques.
Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.

Caution
Self-locking nuts must be generally renewed.
Tightening torques for screws with metric unified thread

Screw dimension
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Tightening torque Nm* (ft-lb)

8.8
3 (2)
6 (4)
10 (7)
25 (18)
50 (37)
88 (65)
137 (101)
211 (156)
290 (213)
412 (304)
560 (413)
711 (524)
1050 (774)
1420 (1047)
10.9
5 (4)
9 (7)
15 (11)
35 (26)
75 (55)
123 (91)
196 (145)
300 (221)
412 (303)
578 (426)
785 (559)
1000 (738)
1480 (1092)
2010 (1482)
12.9
5 (4)
10 (7)
18 (13)
45 (33)
83 (61)
147 (108)
235 (173)
358 (264)
490 (361)
696 (513)
942 (695)
1200 (885)
1774 (1308)
2400 (1770)
Tightening torques for screws with metric fine thread

Screw dimension
M8 x 1
M10 x 1.25
M12 x 1.25
M12 x 1.5
M14 x 1.5
M16 x 1.5
M18 x 1.5
M20 x 1.5
M22 x 1.5
M24 x 2
M27 x2
M30 x 2
*
Tightening torques Nm* (ft-lb)

8.8
26 (19)
52 (38)
98 (72)
93 (69)
152 (112)
225 (166)
324 (239)
461 (340)
618 (456)
780 (575)
1147 (846)
1568 (1156)
10.9
37 (27)
76 (56)
137 (101)
127 (94)
216 (159)
318 (235)
466 (344)
628 (463)
863 (636)
1098 (808)
1578 (1164)
2254 (1662)
12.9
48 (35)
88 (65)
126 (119)
152 (112)
255 (188)
383 (282)
554 (409)
775 (572)
1058 (780)
1294 (1416)
1920 (1416)
2695 (1988)
Strength classes for screws with untreated, non-lubricated surface.
The values result in a 90% utilization of the screws yield point at a coefficient of friction total = 0,14.
Compliance with the tightening torques is checked with torque wrenches.
Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.
The values specified in the table apply for screws black, oiled and with surface protection A4C.
The quality designation of the screws is stamped on the screw heads.
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Fig. 1
12
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1
Proportional valve, travel system
21 Adjustment screw, hydraulic neutral position
Pressure test port X4, control chamber pressure,

travel pump
22 Pressure test port R, travel pump case pressure
Pressure test port MB high pressure, reverse travel
24 Pressure override valve 380 bar, vibration pump
High pressure port B to rear travel motor, high

pressure reverse travel
High pressure port B to front travel motor, high

pressure reverse travel
26 Pressure test port MA high pressure, forward travel
Adjustment screw, high frequency
High pressure port A to rear travel motor, high

pressure forward travel
High pressure port A to front travel motor, high

pressure forward travel
Port T1, leak oil tank A
23 Pressure test port X2, travel pump

25 Port T, flushing oil, travel motors
27 Pressure override valve 400 bar, travel pump

28 Travel pump
29 Leak oil connection T1 travel pump - T2 vibration
pump
30 Port G, charge oil from steering valves
31 Port T2, flushing oil, vibration motors
32 High pressure relief valve, forward travel, 440 bar
10 High pressure port B, to vibration shut-off valve,

high pressure low frequency
33 Charge pressure relief valve 25 bar, travel pump
11 High pressure port A, to vibration shut-off valve,

high pressure high frequency
35 High pressure relief valve, vibration, 400 bar
34 High pressure relief valve, reverse travel, 440 bar
12 Magnetic coil Y57, low frequency
36 Connecting line, charge pressure supply to vibration pump
13 High pressure test port, low frequency
37 High pressure test port, high frequency
14 High pressure relief valve, vibration, 420 bar
38 Vibration pump
15 Magnetic coil, high frequency
39 Port B, leak oil to cooler
16 Pressure test port X2, vibration pump
40 Port E, leak oil, front travel motor
17 Pressure test port X1, vibration pump
41 Port A, flushing/leak oil, travel/vibration pump
18 Pressure test port R, vibration pump case pressure
42 Port I, leak oil from brake valve
19 Proportional valve, travel system
44 Port F, leak oil from vibration shut-off valve
43 Port D, leak oil, rear travel motor
20 Pressure test port X2, travel pump
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2 Tests and adjustments
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2.1
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Technical data
Fig. 1
Dimensions in
mm
H1
BW 180 AD
3300
1920
815
1400
2400
30500
350
4700
60
1800
Weights
Operating weight (CECE)
with ROPS-cabin
Front axle load (CECE)
Rear axle load (CECE)
Static linear load, front/
rear
Dimensions
Steering/oscillation angle
Track radius, inner/outer
Travel characteristics
Travel speed (1)
Travel speed (2)
Travel speed (3)
Max. gradability without/
with vibration (soil dependent)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 9249
IFN
Nominal speed
low idle speed
16
BW 180 AD
kg
11870
kg
kg
kg/cm
5935
5935
33/33
mm
20/8
3900/5700
km/h
km/h
km/h
%
0 ... 4
0 ... 8
0 ... 11
35/30
kW
Cummins
4 BT3.9-C
Water
4
76
1 rpm
1 rpm
2500
950 50
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high idle speed

Electrical equipment
Battery
Drive system
Driven axles
Electrical equipment
Voltage supply
Battery
Generator
Starter
Travel pump
Manufacturer
Type
System
Max. displacement
High pressure (pressure
limitation)
High pressure (pressure
override)
Charge pressure
Drum drive motors
Manufacturer
Type
System
Displacement
max. leak oil rate
Vibration pump
Manufacturer
Type
System
Max. displacement
Start-up pressure (pressure override)
Operating pressure (soil
dependent)
Vibration motors
Manufacturer
Type
System
Displacement
max. leak oil rate
Brakes
Service brake
Parking brake
Brake releasing pressure
Steering
Type of steering
Steering operation
Steering angle
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1 rpm
V
V/AH
V
V/AH
V/AH
V/kW
BW 180 AD
2725 55
12
12/100
hydrostatic
front + rear
12
12/100
12/2,9
cm3/rev.
bar
Hydromatik
A4VG 71 EP
Axial piston/swash plate
71
440 10
bar
400 10
bar
26 1
cm3/rev.
l/min
Poclain
MS 18 1CX
Radial piston
2100
2
cm3/rev.
bar
Hydromatik
A10VG 45 EZ
Axial piston/swash plate
45
380 20
bar
approx. 100
cm3/rev.
l/min
Hydromatik
A2FM 32
Axial piston/bent axle
32
1
hydrostatic
Releasing the mech.
bar
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hydrostatic
25
17

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mm
BW 180 AD
1220
cm3/rev.
bar
Bosch
HY/ZFFS11/14+14
Tandem gear pump
2x14
200 10
Crabwalk, lateral offsetting of drum

Steering/charge pump
Manufacturer
Type
System
Displacement
max. steering pressure
Steering valves
Manufacturer
Type
System
Bucher
L.8S
Electrically proportional
Vibration system
Drive system
Frequency 1/2
Amplitude 1/2
Hz
mm
hydrostatic
42/55
0,83/0,33
Filling capacities
Engine oil
Fuel (diesel)
Sprinkler system
Hydraulic oil
Coolant
Exciter shaft tube
l
l
l
l
l
l
approx. 9.5
170
900
approx. 60
approx. 20
approx. 50
18
The right for technical modifications remains reserved
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2.2 Special tools
1. Vibration Reed frequency meter
BOMAG part-no.: 300 120 80
Fig. 1
2. Engine RPM-meter
Fig. 2
3. Hydraulic test case

Fig. 3
4. Electric test case

Fig. 4
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5. Gear pump testing device
Fig. 5
6. Vacuum pump for hydraulic oil tank

BOMAG part-no.: 007 610 04 (12V)
Fig. 6
20
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2.3 Checking the rotation speeds
Special tools
Vibration Reed frequency meter, engien RPMmeter

Caution
Perform measurements at operating temperature (40 C).
1. Drive the machine with both drums on an elastic

base (rubber buffers) (Fig. 1).
Fig. 1
Checking the engine speed
L Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Measure the rotation speeds.
Nominal value low idle speed
950 50 rpm
3. Run the engine with maximum speed .
4. Measure the rotation speeds.
Nominal value high idle speed
2725 55 rpm
5. Switch on vibration of both drums.
Fig. 2
Nominal value nominal speed

2500 rpm
Evaluation of test
If the nominal value is not reached, perform trouble shooting for the engine.
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Checking the vibrator shaft speed
1. Switch the vibration on at max. engine speed.
2. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).
Nominal value
high amplitude/
low frequency = 42 Hz, 2520 rpm
low amplitude/
high frequency = 55 Hz, 3300 rpm
Evaluation of test
If the nominal value is not reached, perform trouble shooting in the vibration circuit.
Fig. 3
22
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2.4 Pressure tests in the travel circuit

Special tools
Hydraulic test case
Caution
Perform measurements at operating temperature of the hydraulic oil (40 C).
1. Block the wheels with suitable chocks (Fig. 1).
Fig. 1
2. Enter code number 500 on the display module

(Fig. 2) to close the brake.
Fig. 2
3. Connect a 600 bar pressure gauge (Fig. 3) to test

port MA.
Fig. 3
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4. Connect a 600 bar pressure gauge (Fig. 4) to test
port MB.
Fig. 4
5. Connect a 60 bar pressure gauge (Fig. 5) to the

charge pressure test port.
6. Start the engine and run it with maximum speed.
7. Read high pressure and charge pressure gauges.
Nominal value
Charge pressure 26 1bar
High pressure 400 bar 10 bar
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
Fig. 5
8. Move the travel lever quickly to forward and backward, read the pressure gauges.
Nominal value
Charge pressure min. 25 bar
High pressure 400 bar to both travel directions.
Evaluation of test
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components individually.
24
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2.5 Checking / adjusting the neutral positions of the travel pump

Special tools
Hydraulic test case

Caution
Fig. 1

Fig. 2
3. Connect a 600 bar pressure gauge (Fig. 3) each

to test ports MA and MB.
Fig. 3
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Mechanical neutral position
1. As a measure to avoid signal residues from the
hydraulic neutral position connect both control
chambers X1 and X2 with a hose (Fig. 4).
Fig. 4
3. Read the pressure gauges (Fig. 5).
L Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Nominal value
Both pressure gauges must show identical pressure, if necessary correct the mechanical neutral
position.
Fig. 5
4. Adjust the neutral position (Fig. 6) so that both

pressure gauges show identical pressure (charge
pressure).
L Note
Equalize the dead range of the neutral position.
Fig. 6
26
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Hydraulic neutral position

1. Remove the hose connection between the control
chambers and screw the plugs back in (Fig. 7).
Fig. 7
3. Read the pressure gauges (Fig. 8).
L Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Do not actuate the travel lever, since this may destroy the pressure gauges.
Nominal value
Both pressure gauges must show identical pressure (charge pressure), if necessary correct the
hydraulic neutral position.
Fig. 8
4. For this purpose loosen the clamping (Fig. 9).

Caution
Do not adjust the eccentric beyond the 90
position.
5. Adjust the neutral position on the eccentric (2), so

that both pressure gauges show identical pressure (charge pressure).
6. Retighten the clamping.
Fig. 9
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2.6 Check the setting of the high pressure
relief valves in the travel circuit
Special tools
Hydraulic test case

Caution
Fig. 1

Fig. 2

Fig. 3
28
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4. Turn the setscrew (Fig. 4) of the pressure override completely in to block the valve.

Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
6. Move the travel lever quickly to both travel directions and read the pressure gauges.
Fig. 4
Nominal value
445 5 bar
Evaluation of test:
If the nominal value is only reached to one direction, clean or replace the valve (Fig. 5) if necessary.
If the nominal value is not reached to both directions check the travel pump, replace if necessary.
Fig. 5
Adjusting the pressure override

Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure relief valve.
1. Turn the setscrew (Fig. 6) back out again, until

the high pressure is limited to 400 10 bar when
the drums are blocked.
Fig. 6
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2.7 Pressure measurements in the vibration circuit
Special tools
Hydraulic test case

Caution

Fig. 1

3. Connect a 60 bar pressure gauge to the charge
pressure test port.
Fig. 2

5. Switch on vibration at high or low frequency and
read the pressure gauge.
Nominal value
Charge pressure 26 1bar
Starting pressure 380 bar 20 bar
Operating pressure (soil dependent) approx. 80
... 100 bar
Evaluation of test
If the charge pressure drops, check the components individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one frequency, check the high pressure relief valves.
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2.8 Check the setting of the high pressure

relief valves in the vibration circuit
Special tools
Hydraulic test case

Caution

Fig. 1

Fig. 2
3. Turn the setscrew (Fig. 3) of the pressure override completely in to block the valve.
Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
5. Switch on vibration at high or low frequency and

read the start-up pressure on the pressure
gauge.
Fig. 3
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Evaluation of test:
If the nominal value is only reached for one frequency, clean or replace the valve (Fig. 4) if necessary.
If the nominal value is not reached for both frequencies check the travel pump, replace if necessary.
Nominal value
400 5 bar
Fig. 4
Adjusting the pressure override

Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure relief valve.
1. Turn the setscrew (Fig. 5) back out again, so that

the start-up pressure for the vibrator shafts is limited to 380 bar.
Fig. 5
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2.9 Checking / adjusting the vibrator shaft

speeds
Special tools
Hydraulic test case

Caution

2. Start the diesel engine and shift the throttle lever
to max. speed position.
3. Select the frequency and switch the vibration on.
Fig. 1
4. Measure the speed of the vibrator shaft (Fig. 2),

rest the tester on your thumb.
Nominal value
high amplitude/
low frequency = 42 Hz, 2520 rpm
low amplitude/
high frequency = 55 Hz, 3300 rpm
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit.
Fig. 2
5. Adjust the speed on the corresponding adjustment screw (Fig. 3).
L Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
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2.10 Checking the leakage rate of the vibration motor
Special tools
Hydraulic test case

Caution

2. Block the wheels with suitable chocks.
Fig. 1
3. Disconnect the leak oil and flushing oil hose (Fig.

2) and close it with plugs.
4. Connect a leak oil hose to the leak oil port of the
motor and hold it into a measuring vessel
5. Start the diesel engine and shift the throttle lever
to max. speed position.
6. Select the frequency and switch the vibration on.
7. Measure the leak oil over a period of one minute.
Caution
This measurement detects only the external
leak oil quantity.
Fig. 2
Internal leaks, directly from the high to the

low pressure side, are not detected.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, replace the vibration motor.
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2.11 Pressure test in steering circuit

Special tools
Hydraulic test case
Note
The steering is actuated against an electronic
stop by the ESX-control. To actuate the steering
against the mechanical stop the ESX-control
must be switched to the mode Calibration of angle transducers. After the pressure test the calibration process can be aborted.
Danger
Danger of squashing!
Do not stand in the range of rotation of the

pivot steering.
Caution
Measuring the front steering pressure

1. Enter code number 600 on display module (Fig.
1).
The steering can now be actuated against the
mechanical stop.
2. Enter code number 620 or switch the ignition off
to stop this fuction.
Fig. 1
3. Connect a 600 bar pressure gauge (Fig. 2) to the

steering pressure test port.
4. Start the engine and run it at idle speed.
Fig. 2
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5. Adjust the front steering control (Fig. 3) and turn
the steering against an end stop.
6. Read the pressure gauge.
Nominal value
approx. 200 10 bar
Evaluation of test
If the nominal value is reached, check the steering cylinder.
Fig. 3
Measuring the rear steering pressure

4).
The steering can now be actuated against the
mechanical stop.
to stop this fuction.
Fig. 4
3. Connect a 600 bar pressure gauge to the rear

steering pressure test port (Fig. 5).
4. Start the engine and run it at idle speed.
Fig. 5
5. Adjust the rear steering control (Fig. 6) and turn

the steering against an end stop.
6. Read the pressure gauge.
Nominal value
approx. 200 10 bar
Evaluation of test
If the nominal value is reached, check the steering cylinder.
Fig. 6
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2.12 Operation of display module for ESXcontrol

Description
The display module (Fig. 1) is used for the output
of fault codes and display values and for the input
of code numbers.
The module consists of a three digit display and
two keys, F1 and F2.
Faults are indicated by flashing, if several faults
have occurred the displayed fault codes are alternately displayed in 3 second cycles. Display values are permanently displayed.
Values from 000 ... 999 can be displayed. Higher
values are displayed in form of ---. Negative values are indicated by a minus symbol.
Fig. 1
Entering code numbers

For calibration of the angle transducers and diagnostics of the control inputs and outputs various
code numbers must be entered on the display
module.
Code numbers are entered as follows:
1. Press both keys (F1 and F2) together for approx.
two seconds.
The display shows 000, whereby the first digit is
flashing.
2. Press key F1 as often as required to adjust the
flashing digit.
If key F1 is pressed again when figure 9 is displayed, the display will jump back to the value 0.
3. Press key F2 to adjust the next digit.
The flashing display moves one digit to the right.
4. Press key F2 to change to the third digit and adjust the desired value with the F1-key.
5. Press the F2-key again to confirm the adjusted
values and to execute the corresponding function.
6. To cancel a display function you must either enter
the code number 000 or switch the ignition off.
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2.13 Driving against the closed brake
Note
On this machine the electric plug connection to
the brake valve must not be pulled off, because
the ESX-control would in this case detect a line
interruption in the current path to the brake.
1).
The brake will not be released when actuating the
travel lever.
The warning buzzer sounds to inform the operator about this status.
to stop this function.
Fig. 1
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2.14 Adjusting the machine type
Note
Only available from program version 16.
For simple control of the machine type, the adjusted machine type is displayed in the display
module for about three seconds after switching
the ignition on.

Danger
Danger of injury!
Since the same control is used for all pivot

steered tandem rollers, it is strictly necessary
to specify the correct machine type when replacing the ESX-control.
The machine must not be operated with a
wrong type setting.
Caution
Adjustments should only be made with the
engine shut down.

1).
The function Change machine type is activated.
Table Assignment machine type machine
type code
Machine type
BW 180 AD
BW 184 AD
BW 184 AD/AM
BW 170 AD
BW 170 AD
BW 170 AD/AM
BW 174 AD
BW 174 AC
BW 174 AD/AM
Fig. 1
Serial-No.
101 870 00 ....
101 870 30 ....
101 870 50 ....
101 870 01 ....
101 870 02 ....
101 870 11 ....
101 870 31 ....
101 870 41 ....
101 870 31 ....
Code
740
740
740
731
733
733
732
732
732
2. Select and enter the correct code from the table

above.
The display then permanently shows the entered
code number.
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3. To store the machine type enter code number
726 on the display module (Fig. 2).
When entering code 726 the machine type code
is permanently stored.
L Note
The conversion process takes a few seconds.
During this time the display permanently shows
the code number, the minus point flashes in an interval of one second.
Caution
During this time the ignition must not be
switched off! Otherwise the complete adjustment process must be repeated.
Fig. 2
The new machine type will only become active after the ignition has been switched off
and on again!
By changing the machine type all settings are
deleted and must be reset as described hereunder.
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2.15 Calibration of the angle transducers

In order to assure a correct steering of the machine, both angle transducers for front and rear
drums must be calibrated.
L Note
Calibration of the angle transducers is only necessary during initial start-up in the factory, after a
disassembly or replacement of the angle transducers and after changing the ESX-control.
Caution
Calibration must always be performed for
both drums.
Calibration is only possible in steering mode

selection Steering front and Steering
rear. With any other steering selection this
function is not active. When changing to another, unpermitted steering mode during the
adjustment, the complete adjustment procedure must be repeated.
During the calibration process the machine
must not drive faster than 3 km/h, as otherwise the complete adjustment procedure
must be repeated.
The new values will only become active after
the ignition has been switched off and on
again.
1).
This code number activates the function Calibration of the angle sensors. In this case the display
permanently shows the value 600.
Calibrating the front stops
Fig. 1
1. Steer the front drum (Fig. 2) to the left hand stop.

2. When the stop is reached enter code number
601.
In this case the display permanently shows the
value 601.
3. Steer the front drum to the right hand stop.
603.
value 603.
Fig. 2
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Calibrating the rear stops
1. Steer the rear drum (Fig. 3) to the left hand stop.
611.
value 611.
3. Steer the rear drum to the right hand stop.
613.
value 613.
Calibrating the straight ahead position
Fig. 3
1. Steer the front drum (Fig. 4) to straight ahead position.

602.
value 602.
3. Steer the rear drum to straight ahead position.
612.
value 612.
Fig. 4
Note
The function Calibration is automatically terminated after all codes have been entered.
If the function Calibration is to be aborted prematurely, enter code 620 and switch off the ignition.
5. Switch the ignition off and on again to activate the
new values.
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2.16 Adjusting the angle transducers

In order to assure an optimal function of the position detection in the steering system, both angle
transducers for front and rear drums must be adjusted.
This adjustment determines the position of the
angle transducers to the transom bed.
L Note
Calibration of the angle transducers is only required during initial start-up in the factory and after disassembly or replacement of the angle
transducers.
Caution
For the adjustment the angle transducers
must have been calibrated, as otherwise the
straight ahead position will not be reached
(see previous section).
Even if only one angle transducer has been

adjusted both transducer must be adjusted
anew (see previous section).
1. Align both drums to straight ahead position.
L Note
In order to bring both drums to straight ahead position deactivate the crab-walk (green light goes
out) and change from steering front to steering
rear and back to steering front while driving..
This utilizes the automatic neutral setting of the
drums when changing the steering mode.
Steering must be stopped when switching over
and it must be assured that the automatic neutral
setting of the drum is completed.
Then stop steering, stop the machine and shut
down the engine.
Checking the front adjustment

Caution
For the following steps shut the engine down
and switch the ignition off.
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1) and read the following display.
Nominal value:
117 to 123, ideal value 120
Evaluation of display
If the value is outside this range, the angle transducer must be adjusted.
Fig. 1
Adjusting the angle transducer

1. Loosen fastening screws 3 (Fig. 2) in the slots of
angle transducer (2) and turn the transducer, until
the value is in the permissible range.
L Note
If the adjustment range in the slots is not sufficient, loosen coupling 2 (Fig. 2) between transducer and transom bed and turn also.
2. Retighten all fastening screws and check the display module once again.

Caution
Even if only one angle transducer has been
adjusted both transducer must be adjusted
anew (see previous section).
Fig. 2
Check the rear adjustment

Caution
For the following steps shut the engine down
and switch the ignition off.

3) and read the following display.
Nominal value:
117 to 123, ideal value 120
Evaluation of display
If the value is outside this range, the angle transducer must be adjusted. (see previous description).
Fig. 3
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2.17 Automatic detection of step currents

for the steering valves
For a sensitive and exact control of the steering
the step currents must be determined for the four
control solenoids of both steering valves. The
step currents are automatically adjusted after entering the code number, so that no additional meter is required.
After entering the respective code number the
current is increased by the control solenoid in 5
mA steps. After each current increase the system
waits for two seconds. If the ESX-control has detected a considerable angle change of the drum
after the expiration of the waiting time, the step
current is reached.
In order to enhance the measuring result the
measurement is performed three times. The final
step current is the mean value of the three measurements. This step current is automatically
stored and is valid from the next time the machine
is started.
L Note
The determination of the step currents is only required during initial start-up in the factory, after
replacing a steering valve, the steering valve control or after changing the ESX-control
The measurement is identical for all solenoids.
Caution
For the determination of the step current park
the machine n firm and level ground.
The steering system must be thoroughly bled

before performing this measurement.
Align the drum to straight ahead position.
again.
Danger
Danger of injury!
During the measuring process the machine

cannot be steered, the machine should therefore not be driven during the detection of the
step current.
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1. Start the engine and run it with maximum speed
(Fig. 1).
Fig. 1
2. Release the brake (Fig. 2).
Fig. 2

3).
This code activates the function Automatic
measurement of step currents for the steering
valves. In this case the display shows the value
630.
Each of the four measurements for the four control solenoids must be started separately by entering a code number.
The code number for the four control solenoids is
as follows:
Fig. 3
Solenoid
Control front left
Control front right
Control rear left
Control rear right
Code No.
631
632
633
634
4. Enter the corresponding code number for step

current detection.
During the measurement the present control current is displayed (display x 10 = current [mA]).
Once the measuring process is finished the display value 000 appears for two seconds, then
the code number 630 is displayed again. The
next measurement can be started.
5. After all four step currents have been measured
shut down the engine to terminate the function.
The new step currents apply after the next start.
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2.18 Adjusting the type of travel range

switch
For the selection of the travel speed a 3-stage
switch (Fig. 1) is installed as standard.
Fig. 1
A 24 stage switch (Fig. 2) can alternatively be installed.

The switch type must be entered using the respective code, so that the ESX-control is able to
evaluate the travel speed switch correctly.
Note
The 3-stage switch is set as standard value, i.e. a
standard machine does not require any adjustments.
Caution
Adjustments should only be made with the
engine shut down.
Fig. 2

again.
Adjusting the machine for the 24stage switch

3).
This code activates the function Parameter
change speed range switch. In this case the display shows the value 650.
L Note
This code number must be entered before the following step can be performed.
Fig. 3
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4) to select the 24-stage switch.
The display reading disappears.
3. Switch off the ignition.
With the next start the 24-stage switch is evaluated.
Fig. 4
Adjusting the machine for the 3-stage

switch
5).
This code activates the function Parameter
change speed range switch. In this case the display shows the value 650.
L Note
This code number must be entered before the following step can be performed.
Fig. 5

6) to select the 3-stage switch.
The display reading disappears.
With the next start the 3-stage switch is evaluated.
Fig. 6
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2.19 Resetting the step currents in the travel system

This function allows the resetting of step currents
in the travel system to their minimum value.
This measure avoids that the travel system is
controlled with a too high step current.
L Note
This measure is only required after replacing the
travel pump control or the complete travel pump.
It helps to move the machine before performing
the function Automatic detection of step currents.
This function does not need to be performed after
replacing the ESX-control, because a new ESX
control is always set for minimum step current.
Caution
During the input the engine must not be running.

again.
1).
This code activates the function Resetting the
step currents in the travel system. In this case
the display shows the value 665.
Fig. 1

2).
Eith this code the step current is reset to the minimum value (350 mA).
The minimum step currents apply after the next
start.
Fig. 2
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2.20 Automatic detection of step currents
in the travel system
For a sensitive and exact control of the travel system the step currents must be determined for
both travel directions. The step currents are automatically adjusted after entering the code
number, so that no additional meter is required.
After entering the respective code number the
current is increased by the control solenoid in 5
mA steps, starting with 350 mA. After each current increase the system waits for three seconds.
If the ESX-control has detected a considerable
movement of the drum after the expiration of the
waiting time, the step current is reached.
In order to enhance the measuring result the
measurement is performed three times. The final
step current is the mean value of the three measurements. This step current is automatically
stored and is valid from the next time the machine
is started.
L Note
The determination of the step currents is only required during initial start-up in the factory, after
replacing the travel pump, the travel pump control
or after changing the ESX-control
The measurement is identical for both travel directions.
Caution
For the determination of the step current park
the machine n firm and level ground.
Ensure sufficient space in front of and behind

the machine (approx. 10 m), because the machine will move during the measuring process.
Align the drum to straight ahead position.
again.
Danger
Danger of injury!
During the measuring process the machine

will start to move when the step current is
reached.
Do not leave the machine during the measuring process.
The areas in front of and behind the machine
must be free of persons.
Before starting the measurement it must be
assured that the speed sensor on the front
right hand drum drive motor works correctly.
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The measurement must not be performed if

the sensor is defective.
1. Align the seat in forward direction.
2. Switch off the Speed Control.
3. Start the engine and run it with maximum speed
(Fig. 1).
Fig. 1
Checking the function of the speed

sensor
2).
This code shows the number of travel pulses of
the sensor.
2. Move the machine to both directions.
The displayed value must change when the machine is moving.
Fig. 2
Detecting the step currents

Danger
Danger of accident!
After entering the code number the machine

can no longer be controlled with the travel lever. The function of the travel lever is only reestablished after the engine is shut down and
restarted.
In case of a danger the machine can be
stopped by shifting the travel lever to neutral
position. In this case the complete measuring
process must be repeated.
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3).
This code activates the function Automatic
measurement of step currents in the travel system. In this case the display shows the value
660.
The code number for both control solenoids is as
follows:
Travel direction
Forward
Backward
Fig. 3
Code No.
661
662
2. Enter the corresponding code number for step
current detection according to the table.
3. Move the travel lever (Fig. 4) forward or backward
as required by the entered code number.
During the measurement the present control current is displayed (display x 10 = current [mA]).
Once the measuring process is finished the display value 000 appears, then the code number
660 is displayed again. The next measurement
can be started.
4. After both step currents have been measured
shut down the engine to terminate the function.
The new step currents apply after the next start.
Fig. 4
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2.21 Showing stored faults
Note
Besides stored faults, current faults are also displayed.
Switching the function on

1).
The function Show stored faults is switched on.
Fig. 1
Switching the function off

2).
The function Show stored faults is switched off.
Fig. 2
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2.22 Deleting stored faults
Note
Stored faults can only be deleted when the engine is not running.
1).
All stored faults are deleted.
Fig. 1
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3 Flushing
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6SHFLDOWRRO
3.1 Special tool:
1. Filling and filtering unit with oil bag
2. Filter element
Fig. 1
3. Flushing filter
4. Filter element 1
5. Flushing hose 25S - 20S (2 pieces)
6. Screw socket R1 -- 25S (2 pieces)
Fig. 2
7. Double-end union 20 S
Fig. 3
8. Double-end union 16 S
Fig. 4
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6SHFLDOWRRO
9. Reducing fitting 25S - 20 S
Fig. 5
10. Elbow 20S

Fig. 6
11. Elbow 16S

Fig. 7
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Fig. 1 Schematic for front travel system
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1
Travel pump
Front drum drive motor
Elbow 20S
Double end union 20S
Flushing filter
Elbow 20S
Screw socket 1 - 25S
Flushing hose 25S - 20S
After changing a component
Flushing filter installation (Fig. 1)
1. Always flush the closed circuit.
1. Connect the flushing filter outlet "OUT" with the

travel pump.
2. Connect the flushing inlet IN with the hose
from the front drum drive motor.
Caution
Solid particles remaining in the circuit will
damage the components again within a
short period of time.
Caution
The flushing filter must be installed in the
low pressure side in the return flow to the
pump, so that only cleaned oil will enter the
travel pump.
In case of excessive oil contamination

(abrasion)
1. Open and clean all other components.
With the connection shown in the illustration the travel pump must therefore be actuated to reverse direction.
2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.
Befor flushing
Flushing of the hoses
1. Change the hydraulic oil filter element.
1. Take the front drum drive motor out of the circuit, for this purpose join the high pressure lines
at the drum drive motor together.
2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.
Flushing the complete system
Note
For filtering use the filling and filtering unit.
Pump the tank contents through a fine filter into
the oil bag or a clean container.
1. Reconnect the drum drive motor.

2. Jack the front drum up for flushing.
Bleeding
Environment
Catch hydraulic oil and dispose of environmentally! For filling use also the filtering
unit.
1. Always bleed the closed hydraulic circuit if lines

had been removed or connected.
Change the oil:

in case of excessive contamination,
oil discoloration,
oil change interval almost reached.
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Fig. 1 Schematic of rear travel system
60
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1
Travel pump
Flushing filter
Elbow 20S
Elbow 20S
Rear drum drive motor

travel pump.
from the rear drum drive motor.
Caution
Caution
travel pump.

(abrasion)
With the connection shown in the illustration the travel pump must therefore be actuated to reverse direction.

Befor flushing
1. Take the rear drum drive motor out of the circuit, for this purpose join the high pressure lines
at the drum drive motor together.

Note
1. Reconnect the drum drive motor.

2. Jack the rear drum up for flushing.
Bleeding
Environment
unit.

Change the oil:

oil discoloration,
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3.4 Flashing the travel circuit
Cleaning the hydraulic oil tank
Environment
Catch hydraulic oil and dispose of environmentally!
1. Pump the hydraulic oil from the hydraulic oil tank
into a clean container or an oil bag using the filling
and filtering unit.
2. Mark all hoses (Fig. 1) and disconnect them from
the tank cover.
3. Unscrew the fastening screws for the cover and
remove the cover.
4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.
Fig. 1
Filter installation for flushing of the

front travel circuit
Caution
Before installing the flushing filter check hoses and connections for cleanliness, clean if
necessary.
1. Disconnect the high pressure hose (Fig. 2) from

the travel pump.
Fig. 2
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2. Connect the flushing hose (Fig. 3) from filter outlet port OUT to the travel pump using an angle
fitting.
Fig. 3
3. Connect the filter inlet port IN (Fig. 4) with the

disconnected high pressure hoses from the travel
pump using a connecting socket.
Fig. 4
4. Flushing hose (Fig. 5) from filter port IN must be

connected with the high pressure hose from the
travel pump (port A).
5. Flushing hose from filter port OUT must be connected with the travel pump (port A).
Fig. 5
6. Unscrew the high pressure hoses 3 (Fig. 6) from

the front drum drive motor and join them together
with angle fittings (2) and socket (1).
7. Fill the hydraulic oil tank again with the filling and
filtering unit.
L Note
If the hydraulic oil change interval is almost
reached use new hydraulic oil.
Fig. 6
008 912 53
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63

Bleeding the travel circuit
1. Pull the plug (Fig. 7) off the engine shut-down solenoid, so that the engine cannot start.
2. Secure the drums with chocks .
Environment
Catch hydraulic oil and dispose of environmentally.
3. Install pressure test hoses to the charge pressure
test port and to the high pressure test ports in the
travel system.
Fig. 7
4. Hold the open ends of the pressure test hoses

(Fig. 8) into a container.
5. Crank the engine approx. 30 seconds with the
starter motor. Wait one minute and repeat this
procedure, until oil starts to run out from the pressure test hoses.
6. Disconnect the pressure test hoses from the high
pressure test ports.
7. Reconnect the plug to the engine shut-down solenoid.
Fig. 8

pressure test hose (Fig. 9) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.
Fig. 9
Caution
Move the travel lever only to travel direction
backward, as otherwise the flushing filter will
be subjected to oil flow from the wrong direction.
10. For bleeding shift travel lever (Fig. 10) approx. 1/

3 in travel direction backward while running the
engine with idle speed.
11. After running the engine 1 to 2 minutes with idle
speed pause for approx. one minute.
Fig. 10
64
%20$*
008 912 53

Note
This waiting time is necessary to allow air bubbles to escape through the leak oil return line.
Repeat this measure, until the charge pressure

reading immediately drops to zero when shutting
the engine down.
In this case the closed travel circuit is properly
bled.
Flushing the lines of the front travel

circuit
Caution
1. Shift the travel lever (Fig. 11) to travel direction

backward.
2. Perform the flushing process at various engine
speeds for approx. 15 minutes.
3. Shut down the engine.
Environment
4. Reconnect the high pressure hoses to the front
drum drive motor.
Fig. 11
Flushing the front drum drive motor

Danger
Do not lay under the jacked up machine.

1. Jack up the front of the machine (Fig. 12), so that
the drum can rotate freely.
2. Secure the rear drum with chocks .
Fig. 12
008 912 53
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65


Caution

backward.
Fig. 13
Filter installation for flushing of the

rear travel circuit
Caution
necessary.

the travel pump.
Fig. 14
2. Connect flushing hose 1 (Fig. 15) from filter outlet

port OUT to the travel pump using an angle fitting.
3. Connect flushing hose (2) from filter inlet port IN
with the disconnected high pressure hoses from
the travel pump using a connecting socket.
Fig. 15
66
%20$*
008 912 53

4. Flushing hose (Fig. 16) from filter port IN must

be connected with the high pressure hose from
the travel pump (port A).
5. Flushing hose from filter port OUT must be connected with the travel pump (port A).
Fig. 16
6. Unscrew the high pressure hoses 3 (Fig. 17) from

the rear drum drive motor and join them together
with angle fittings (2) and socket (1).
filtering unit.
Note
Fig. 17
Bleeding the travel circuit

1. Pull the plug (Fig. 18) off the engine shut-down
solenoid, so that the engine cannot start.
Environment
travel system.
Fig. 18

Fig. 19
008 912 53
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67

Fig. 20
Caution
10. For bleeding shift travel lever (Fig. 21) approx. 1/

3 in travel direction backward while running the
engine with idle speed.
11. After running the engine 1 to 2 minutes with idle
speed pause for approx. one minute.
L Note
Fig. 21

the engine down.
bled.
68
%20$*
008 912 53

Flushing the lines of the rear travel

circuit

Caution

backward.
Environment
15. Reconnect the high pressure hoses to the rear
drum drive motor.
Fig. 22
008 912 53
16. Repeat the bleeding process.
%20$*
69

Flushing the rear drum drive motor
Danger
Do not lay under the jacked up machine.

1. Jack up the rear of the machine (Fig. 23), so that
the drum can rotate freely.
2. Secure the front drum with chocks .
Fig. 23
Caution

backward.
Function test
Fig. 24
1. Check the hydraulic oil level (Fig. 25) in the tank,

fill up if necessary.
2. Cleaning the machine
3. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting
on a gradient.
4. Check all ports and connections for leak tightness
(visual inspection).
Fig. 25
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter
when the red control pin of the contamination indicator is pressed out during the filtering process.
70
%20$*
008 912 53

Note
This is also possible with very cold oil.
2. Clean hoses and connections and store the flushing kit in a clean and protected environment.
3. Change the flushing filter element of the filling
and filtering unit when the red control pin of the
contamination indicator is pressed out.
008 912 53
%20$*
71

)OXVKLQJVFKHPDWLFIRUYLEUDWLRQGULYH
Fig. 1
72
%20$*
008 912 53

)OXVKLQJVFKHPDWLFIRUYLEUDWLRQGULYH
1
Shut-off valve
Elbow 20S
Flushing filter
Rear vibration motor
Vibration pump
Front vibration motor

vibration pump.
from the shut-off valve.
Caution
Caution
travel pump.

(abrasion)
For the connection schematic shown here

the vibration must always be filtered with
low frequency / high amplitude.

Befor flushing
1. Take the vibration motor out of the circuit, for

this purpose join the high pressure lines together.

Note
1. Reconnect the vibration motor and pull it out of

the coupling for flushing.
Bleeding
Environment
unit.

Change the oil:

oil discoloration,
008 912 53
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73

)OXVKLQJWKHYLEUDWLRQFLUFXLW
3.6 Flushing the vibration circuit
Cleaning the hydraulic oil tank
Environment
1. Pump the hydraulic oil from the hydraulic oil tank
into a clean container or an oil bag using the filling
and filtering unit.
2. Mark all hoses (Fig. 1) and disconnect them from
the tank cover.
3. Unscrew the fastening screws for the cover and
remove the cover.
4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.
Fig. 1
Filter installation for flushing of the vibration drive

Caution
necessary.

the vibration pump.
Fig. 2
74
%20$*
008 912 53

2. Connect flushing hose 3 (Fig. 3) to high pressure

hose (5) using connecting socket (4).
3. Connect flushing hose (2) to the vibration pump
using elbow fitting (1).
Fig. 3
4. Connect the flushing hose (Fig. 4) from the high

pressure hose to flushing filter inlet IN.
5. Connect the flushing hose from the vibration
pump to the flushing filter outlet OUT.
Fig. 4
6. Disconnect hydraulic hoses 2 (Fig. 5) from both

vibration motors and join them together with
socket (1).
filtering unit.
L Note
Fig. 5
Bleeding the vibration circuit

1. Pull the plug (Fig. 6) off the engine shut-down solenoid, so that the engine cannot start.
Environment
vibration system.
Fig. 6
008 912 53
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75

Fig. 7

Fig. 8
Caution
Use only low frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
10. For bleeding switch on low frequency (Fig. 9) for

both drums at idle speed.
11. After running the engine 1 to 2 minutes pause for
approx. one minute.
Note
Fig. 9

the engine down.
bled.
76
%20$*
008 912 53

Flushing the hoses in the vibration

circuit

Caution

both drums at full engine speed.
2. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of
approx. 30 seconds.
Environment
Fig. 10
4. Reconnect both high pressure hoses to both vibration motors.
Flushing the vibration motors

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

both drums at full engine speed.
3. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of
approx. 30 seconds.
Fig. 12
008 912 53
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77

Function test
1. Check the hydraulic oil level (Fig. 13) in the tank,
fill up if necessary.
2. Cleaning the machine
3. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting
on a gradient.
4. Check all ports and connections for leak tightness
(visual inspection).
Fig. 13
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter
when the red control pin of the contamination indicator is pressed out during the filtering process.
Note
This is also possible with very cold oil.
2. Clean hoses and connections and store the flushing kit in a clean and protected environment.
3. Change the flushing filter element of the filling
and filtering unit when the red control pin of the
contamination indicator is pressed out.
78
%20$*
008 912 53

008 912 53
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79

80
%20$*
008 912 53
4 Trouble shooting
008 912 53
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*HQHUDO
General notes on trouble shooting in hydraulic systems
Check the hydraulic oil level before and after the

work.
The following tests are performed for fault diagnostics

and should enable you to encircle a fault in the hydraulic system.
Use only clean oil according to specification.
Check the hydraulic system for leaks, find and rectify the cause.
Ensure strict cleanliness, clean ports and fittings

before disconnecting.
Fill new hydraulic units with hydraulic oil before

starting operation.
After changing a component thoroughly flush and

bleed the hydraulic system.
AS far as possible conduct all measurements at operating temperature 40 ... 50 C.
After changing a component check charge and high

pressure, if necessary check the rotational speed.
4.1
General
At this point it is assumed that there is no fault in the

electric system, i.e. trouble shooting in the electric
system has already been performed.
In some cases these tests may also be conducted to
identify faults on hydraulic components of the power
transmission system.
On the basis of preliminary tests the individual measurements have the purpose to limit the cause of the
fault first of all to a general area and then to determine
exactly which oil circuit or hydraulic component is not
working correctly.
Important points for trouble shooting and

fault rectification
Hydraulic hoses
Danger
Danger of injury
Danger
Danger of injury!
Hydraulic hoses must be visually inspected at

regular intervals.
Do not touch rotating parts of the engine.

When working on the travel pump and performing
tests in the travel circuit block the drums with
suitable wheel chocks.
Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should
therefore relieve the pressure in the system before disconnecting any lines. Before repressurizing the system make sure that all line connections
and ports are in perfect condition.
Hydraulic hoses must be immediately replaced if:
the outer layer is damaged down to the inlay (e.g.

chafing, cuts, cracks, etc.)
the outer layer is brittle (formation of cracks in the

hose material)
the hose shows deformations in pressurized and

depressurized condition, which do not comply with
the genuine shape of the hydraulic hose
the hose shows deformations in bends, e.g.

squeezing, buckling, layer separation, formation of
blisters
the hose is leaking
the hydraulic hose has separated from the fitting
the fitting shows corrosion that impairs both function

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

and strength are affected
the storage time and utilization period has expired.
When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause
severe infections.
Caution
It is not recommended to open or repair hydraulic
units and components without comprehensive
knowledge.
Risk of damage to pressure gauges if incorrectly

connected.
When performing trouble shooting it is assumed that
the machine is correctly equipped and connected, that
connections and hoses are free of faults and that setscrews have not been deadjusted without permission.
Progressive tests drawn up in the trouble shooting diagram lead to the detection of faults and their rectification by trained personnel.
Ensure strict cleanliness, clean ports and fittings

before disconnecting.
Cover all openings and ports or close with plugs.
82
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7URXEOHVKRRWLQJGLDJUDP
4.2
Trouble shooting diagram

The machine drives with the travel lever in NEUTRAL
Check the mechanical neutral position
- Enter code number 500 to close the brake
- Connect control chamber ports X1 and X2 with
a hose
Neutral position
OK?
yes
no
Adjust the hydraulic neutral position

- Remove the hose connecting X1 and X2
- Run the engine with maximum speed.
- Adjust the hydraulic neutral position so that
identical pressures are indicated at MA and
MB (charge pressure)
Adjusting the mechanical neutral position
- Connect 600 bar pressure gauges to MA and

MB
- Adjust the mechanical 0-position so that identical pressures are indicated at MA and MB
(charge pressure)
- For a more exact adjustment repeat the test
with 60 bar pressure gauges
008 912 53
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83

Machine does not drive / insufficient travel performance

Check high and charge pressure
- Connect 600 bar pressure gauges to the high pressure test
port
- Connect a 60 bar pressure gauge to the charge pressure test
port
- Start the engine and run it with maximum speed
- Drive the machine against the closed brake, for this purpose
enter code number 500, actuate the travel lever for a moment
and read the pressure gauge
Nominal value:
High pressure approx. 400 bar 10 bar,
charge pressure approx. 26 bar
High pressure
OK?
yes
no
Check the brake releasing pressure

- Install a 60 bar pressure gauge to the
brake releasing line
- Start the engine and check whether
the brake valve opens when the
brake is released
Nominal value:
approx. 26 bar (charge pressure)
Brake valve
OK?
no
Replace the brake valve
yes
Mechanical fault,
blocked drive
84
%20$*
008 912 53

Charge
pressure OK?
no
yes
Check the front steering pressure

- Connect a 600 bar pressure gauge to
the steering pressure test port
- Enter code number 600
- Pull the plug off the starter solenoid
and crank the engine with the starter
- Turn the front steering against one of
the end stops and read the pressure
gauge
Nominal value:
approx. 200 bar (battery fully charged)
Steering
pressure OK?
no
Perform trouble shooting

for front steering system
yes
Check the rear steering pressure
- Connect a 600 bar pressure
gauge to the steering pressure
test port
- Pull the plug off the starter solenoid and crank the engine
with the starter
- Turn the rear steering against
one of the end stops and read
the pressure gauge
Nominal value:
approx. 200 bar (battery fully
charged)
Steering
pressure OK?
no

for rear steering system
yes
008 912 53
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85

Check leakage
of brake
- Release the brake and perform a
charge pressure test
Charge pressure
OK?
yes
- Disconnect the brake releasing

lines one after the other from the
drum drive motors and close them
with plugs; repeat the charge pressure test with the brake closed
- Repair the unit with which the
charge pressure is OK after the
brake line has been disconnected
no
Check the charge pressure relief valve
Valve OK?
no
Replace the charge pressure relief valve
yes
86
%20$*
008 912 53

Check the flushing valve
no
yes
Replace the flushing valve
Flushing valve
OK?
Check the travel pump
- Close the high pressure ports on the

pump with plugs
- Repeat the pressure test
no
High pressure
OK?
yes
Check the control chamber pressure

- Install pressure test ports with 60
bar pressure gauges to X3/X4
yes
- Actuate the travel pump to full

displacement and read the pressure gauge
Nominal value: approx. 15 bar
Pressure OK?
no
Replace/repair
the travel pump
008 912 53
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87

Check the swash time nozzles

- Unscrew the nozzles and check
for blockage
Nozzles OK?
no
yes
Clean the nozzles
Check the case pressure

- Install a pressure test port with
a 10 bar pressure gauge to G
- Actuate the travel pump to full displacement and read the pressure
gauge
Pressure OK?
no
yes
Check the leak oil return
line to the tank
88
%20$*
008 912 53

Check the servo control

- Remove the servo control
- Check the nozzles, clean if necessary.
- Check the linkage, repair if necessary
Servo control
OK?
no
yes
Repair the servo
control
Replace/repair
the travel pump
Test the travel motors individually
- Close the high pressure test ports on
the drum drive motors one after the
other with plugs
- Repeat the pressure test
- If the high pressure is O.K., replace
the travel motor excluded from the
hydraulic circuit.
008 912 53
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89

Hydraulic oil overheating >90 C
Check the high pressure relief valves in

the travel circuit
Check high pressure relief valves in vibration circuit
- Enter code number 500 to close the

brake
- Stand the drums on rubber tires
- Fully actuate the travel lever
- Check high pressure relief valves for excessive heat
- Check the high pressure relief valves for

excessive heat
- Switch the vibration on
Valves
OK?
no
Check the high pressure

relief valves/pressure override
yes
Check the thermostat valve
- Check whether the hose to the cooler heats up when a hydraulic oil
temperature of > 60 C is reached
Thermostat
OK?
no
Replace the thermostat
yes
90
%20$*
008 912 53

Check the flushing valve in the travel system
Check the flushing valve in the vibration

system
- Check the moveability of the flushing valve
- Check the moveability of the flushing valve
008 912 53
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91

No vibration at front and rear

Travel system O.K.
Check the electric power supply for the
solenoid valves
- Switch the vibration on and measure the
current consumption of both solenoids
Nominal value: approx. 1.7 A
Current
OK?
no

in the electric system
yes
- Install pressure test ports to X1 and X2
- Connect a 60 bar pressure gauge
- Run the engine with maximum speed
- Switch the vibration on and read the pressure gauge
Pressure
OK?
no
yes
92
%20$*
008 912 53

Check the vibration pump
Check the control unit
- Connect 600 bar pressure gauges to the vibration pump
- Remove the control unit
- Close high pressure ports A and B with plugs

- Run the engine with maximum speed .
- Switch the vibration on for a moment and read
the pressure gauge
- Check the nozzle, clean if necessary.

- Check the control piston, if necessary replace the control unit
Pressure
OK?
no
Replace/repair
the vibration pump
yes
Check the vibrator shaft bearings
- Remove the vibration motor
- Check end float and moveability
of the vibrator shafts
- Check the coupling
Bearing /
coupling
OK?
no
Replace / repair
the coupling
yes
Replace/repair
the vibration motor
008 912 53
%20$*
93

Speed of front and rear vibrator shafts too low

Checking the engine speed
- Switch vibration on and measure the speed
Nominal value:
Nominal speed 2600 rpm
Rated speed
OK?
no
Perform engine
trouble shooting
- Adjust high
and low frequency
yes
Drop in vibrator
shaft speed
>10%
no
yes
Check the pressures in the vibration circuit

- Connect 600 bar pressure gauges to the high pressure test
port
- Connect a 60 bar pressure gauge to the charge pressure
test port
- Switch the vibration on and read the pressure gauge
Nominal value:
Start up pressure: 380 20 bar
Operating pressure: approx. 100 bar (depending on soil)
Charge pressure: approx. 26 bar
Charge
pressure OK?
no
yes
94
%20$*
008 912 53

Operating
pressure OK?
yes
no, to high
Start-up
pressure OK?
yes
no
Check the leak oil rate

of both vibration motors
- Measure the leak oil
rate at a vibration
measure of approx.
100 bar
Nominal value:
max. 1 l/min
Check the vibrator shaft bearings

- Check end float and moveability of the vibrator shafts
Leak oil OK?
End float:
1,0 ... 3.3 mm
008 912 53
no
Replace the respective vibration motor
yes
%20$*
95

Check the vibration pump

- Close high pressure ports A and B with plugs
- Switch the vibration on for a moment and
read the pressure gauges
Nominal value:
380 20 bar
Pressure OK?
no
yes
Test the individual vibration

motors

- Install pressure test ports
with 60 bar pressure
gauges to X1and X2
- Close the high pressure hoses

of the individual vibration motors one after the other with
plugs and repeat the pressure
test
- If the high pressure is O.K., replace the travel motor excluded
from the hydraulic circuit.
- Switch the vibration on

and read the pressure
gauge
Nominal value:
approx. 15 bar
Pressure OK?
yes
Replace/repair
the vibration pump
no
96
%20$*
008 912 53

Check the servo control

- Remove the servo control
- Check the nozzles, clean if
necessary.
Servo control
OK?
no
Replace the servo

control
yes
Replace/repair
the travel pump
008 912 53
%20$*
97

No front steering
steering sticky
Check the front steering pressure

- Connect a 600 bar pressure gauge to the
steering pressure test port
- Pull the plug off the starter solenoid and
crank the engine with the starter
- Turn the front steering against one of the
end stops and read the pressure gauge
Nominal value:
Steering
pressure OK?
no
yes
Check the front steering pump

- Close the pump outlet with a 200
bar pressure relief valve
gauge
- Crank the engine with the starter
- Read the pressure gauges
Nominal value:
charged)
no
Pressure OK?
yes
Change the steering /

charge pump
Check / replace the

front steering cylinder
98
%20$*
008 912 53

Check the front steering valve

steering pressure outlet
- Turn the front steering against an end stop
Nominal value:
approx. 200 bar
Steering
pressure OK?
no
Replace the steering valve
yes
Check the moveability

of steering cylinders
and pivot bearing
008 912 53
%20$*
99

No rear steering
steering sticky
Check the rear steering pressure

- Connect a 600 bar pressure gauge to the
steering pressure test port
- Pull the plug off the starter solenoid and
crank the engine with the starter
- Turn the rear steering against one of the
end stops and read the pressure gauge
Nominal value:
Steering
pressure OK?
no
yes
Check the rear steering pump

- Close the pump outlet with a 200
bar pressure relief valve
gauge
- Crank the engine with the starter
- Read the pressure gauges
Nominal value:
charged)
no
Pressure OK?
yes
Change the steering /

charge pump
Check / replace the

rear steering cylinder
100
%20$*
008 912 53

Check the rear steering valve

steering pressure outlet
- Turn the rear steering against an end stop
Nominal value:
approx. 200 bar
Steering
pressure OK?
no
Replace the steering valve
yes
Check the moveability

of steering cylinders
and pivot bearing
008 912 53
%20$*
101

102
%20$*
008 912 53
5 Drum
008 912 53
%20$*
103

6SHFLDOWRROV
5.1 Special tools
1. Lifting device for vibrator unit
BOMAG part-no. 007 215 08
Fig. 1
2. Screw bolt for vibrator unit lifting device
Fig. 2
104
%20$*
008 912 53

6SHFLDOWRROV
008 912 53
%20$*
105

5HSDLURYHUYLHZIRUGUXP
Fig. 1 Drum
106
%20$*
008 912 53

5HSDLURYHUYLHZIRUGUXP
1
Vibrator housing
Change-over weight
Vibrator shaft
Vibrator shaft bearing
Drum drive motor
Travel bearings
Rubber buffer
Vibration motor
Vibrator shaft coupling
008 912 53
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107

5HPRYLQJDQGLQVWDOOLQJWKHGUXP
5.3 Removing and installing the drum
Note
Removal and installation of the drum is exemplary described for the front drum. The rear drum
must be removed and installed in the same way.
Removal
1. Drain the water from the corresponding water
tank for the water sprinkling system.
2. Fasten lifting gear to front and rear frame (Fig. 1).
3. Lift the machine up, until the rubber buffers are
unloaded.
Fig. 1
4. Remove the cover plates (Fig. 2) from both sides.
Fig. 2
5. Disconnect water hoses 1 (Fig. 3) from the sprinkling tubes.

6. Remove scraper brackets (2) with the sprinkling
tubes .
Fig. 3
108
%20$*
008 912 53

7. Mark the hydraulic hoses (Fig. 4) on the vibration

motor and disconnect them from the ports.

Caution
Close all openings with plugs.
Environment
Catch running out oil and dispose of environmentally.
Fig. 4
8. Mark the hydraulic hoses on the travel motor (Fig.

5) and disconnect them from the ports.

Caution
Close all openings with plugs.
Environment
Fig. 5
9. Open the hose brackets (Fig. 6) on both sides of

the support legs and pull the hoses out of the
suport legs.
Fig. 6
10. Unscrew fastening screws (Fig. 7) from the support legs.
Fig. 7
008 912 53
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109


Danger
Do not step under suspended loads.

11. Fasten lifting gear to the support leg and unscrew
fastening screws (Fig. 8).
12. Pull the support leg off and lay it down.
13. Remove the support leg also from the opposite
side.
Fig. 8
14. Lift the machine up (Fig. 9), so that the drum can
be removed from under the frame.
15. Support the frame safely.
Fig. 9
16. Check rubber buffers (Fig. 10), replace if necessary.
Fig. 10
110
%20$*
008 912 53

Installation
Danger

1. Lift up the frame and roll the drum parallel under
the frame (Fig. 11).
Fig. 11 872739
2. Assemble the support legs to the drum (Fig. 12).

3. Tighten all fastening screws for both support legs
and remove the lifting gear.
Fig. 12 872740
4. Align the bores in the support leg with the bores

in the traverse, turn in and tighten the fastening
screws (Fig. 13).
Fig. 13 872741
5. Connect the hydraulic hoses for the travel motor

(Fig. 14) by following the marking and tighten
them.
Fig. 14 872734
008 912 53
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111

6. Connect the hydraulic hoses for the travel motor
(Fig. 15) by following the marking and tighten
them.
Fig. 15 872733
7. Fasten the hose bracket (Fig. 16) to the support

legs on both sides.
Fig. 16 872732
8. Fasten the cover plates (Fig. 17) on both sides.
Fig. 17 872730
9. Install scrapers and water sprinkling tubes (Fig.

18).
Fig. 18 732731
112
%20$*
008 912 53

10. Check the hydraulic oil level (Fig. 19), top up if

necessary.

Caution
Bleed the hydraulic system before starting
operation.
11. Perform a test drive, check function of travel system and vibration.
12. Check all connections and fittings for leak tightness.
Fig. 19
008 912 53
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113

5HPRYLQJDQGLQVWDOOLQJWKHYLEUDWRUXQLWRQWKHGUXPGULYHVLGH
5.4 Removing and installing the vibrator
unit on the drum drive side
1. Remove the drum.
Environment
2. Drain the oil from the drum.
Removing the vibrator unit

1. Unscrew the fastening nuts (Fig. 1) and take off
the angle plate.
Fig. 1
2. Examine all rubber buffers 1 (Fig. 2) for wear, replace if necessary.
Fig. 2
3. Unscrew the fastening screws (Fig. 3) and take

off the drive disc with rubber buffers.
Fig. 3
114
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4. Unscrew two fastening screws opposite each other (Fig. 4) and turn in guide bolts.
5. Unscrew all other fastening screws.
Fig. 4
6. Turn adapter 1 (Fig. 5) of the lifting device with

three washers (2) into the travel motor.

Danger

7. Fasten the lifting device to a crane and slide it
over the adapter.
8. Pull the travel motor off the flange.
Caution
If dirt or chips are found in the travel motor
flush the hydraulic system before restarting
the machine.
Fig. 5
9. If necessary unscrew the fastening screws (Fig.

6) and take off the flange.
Fig. 6
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115

10. Unscrew two fastening screws opposite each other (Fig. 7) and turn in guide bolts.
11. Unscrew all other fastening screws and force the
housing off with the help of two screws.
Fig. 7
12. Fasten the lifting device to the flange and pull the
housing out of the drum (Fig. 8).
13. Take off the O-ring.
Fig. 8
Installing the vibrator unit

Caution
Fitting and contact surface of the connection
between vibration unit and drum must be absolutely dry and free of grease, oil, paint and
conserving agent.
Note
Always assemble the vibration unit on the drum
drive side first.
1. Grease and assemble the O-ring (Fig. 9).
Fig. 9
2. Fasten the lifting device to the flange and turn two

guide bolts into the drum(Fig. 10).
3. Insert the vibrator unit into the drum.
Fig. 10
116
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4. Remove the guide bolts (Fig. 11).

5. Turn in and tighten the fastening screws.
Fig. 11
6. Attach the flange to the drum drive motor, turn in

and tighten the fastening screws (Fig. 12).
Fig. 12
7. Turn adapter 1 (Fig. 13) of the lifting device with

three washers (2) into the travel motor.
Danger

8. Fasten the lifting device to a crane and slide it
over the adapter.
Caution
the machine.
Fig. 13
9. Turn in two guide bolts.

10. Push on the drum drive motor, turn in and tighten
the fastening screws (Fig. 14).
Fig. 14
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11. Attach the drive disc with rubber buffers, turn in
and tighten the fastening screws (Fig. 15).
Fig. 15
12. Attach the angle plate, turn on and tighten the

fastening nuts with washers (Fig. 16).
Fig. 16
118
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5HPRYLQJDQGLQVWDOOLQJWKHYLEUDWRUXQLWRQWKHYLEUDWLRQGULYH

5.5 Removing and installing the vibrator

unit on the vibration drive side
1. Remove the drum.
Environment
2. Drain the oil from the drum.
3. Remove the vibrator unit on the drum drive side.
Removing the vibrator unit

1. Unscrew the fastening nuts (Fig. 1) and take off
the angle plate.
Fig. 1
2. Examine all rubber buffers (Fig. 2) for wear, replace if necessary.
Fig. 2
3. Unscrew fastening screws 1 (Fig. 3) and take off

the vibration motor (2).
Caution
the machine.
Fig. 3
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4. If necessary unscrew fastening screw 1 (Fig. 4)
and pull off coupling hub (2).
Fig. 4
5. Remove coupling element 1 (Fig. 5)and pull off

coupling hub (2).
Fig. 5
6. Unscrew the fastening screws (Fig. 6) and remove the cover.
Fig. 6

off the intermediate ring.
Fig. 7
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8. Take off the V-ring (Fig. 8).
Fig. 8
9. Remove the circlip (Fig. 9).
Fig. 9
10. Attach the lifting gear side plate (Fig. 10).

Danger
Fig. 10
11. Pull the side plate off the flange using a special
pulling device (Fig. 11).
Fig. 11
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12. Press the travel bearing (Fig. 12) out, check its
condition and replace if necessary.
Fig. 12
13. Take off the V-ring (Fig. 13).
Fig. 13

off the flange.
Fig. 14
15. Turn two guide bolts into the drum and unscrew
the fastening screws (Fig. 15).
Fig. 15
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16. Fasten the lifting device to the flange and pull the
housing out of the drum (Fig. 16).
17. Take off the O-ring.
Fig. 16
18. Remove circlip 3 (Fig. 17) from coupling sleeve

(1).
19. Pull off coupling and disc (2).
Fig. 17
Installing the vibrator unit

Caution
Fitting and contact surface of the connection
between vibration unit and drum must be absolutely dry and free of grease, oil, paint and
conserving agent.
Note
Always assemble the vibration unit on the drum
drive side first.
1. Grease and assemble the O-ring (Fig. 18).
Fig. 18
2. Push on coupling sleeve 1 (Fig. 19).

3. Insert disc (2) and assemble circlip (3).
Fig. 19
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4. Turn two guide bolts into the drum (Fig. 20).
5. Attach the lifting gear to the flange and insert the
housing carefully into the drum.

Caution
Ensure correct engagement of the coupling!
After installation the vibrator shaft must still

have sufficient end float.
Fig. 20
6. Unscrew the guide bolts, turn in and tighten the

fastening screws (Fig. 21).
Fig. 21
7. Attach the flange, turn in and tighten the fastening

screws (Fig. 22).
Fig. 22
8. Press the travel bearing with spacer disc (Fig. 23)

into the drive disc.
Fig. 23
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9. Assemble the V-ring . (Fig. 24)
Fig. 24
10. Attach the lifting gear to the side plate and place
it onto the flange (Fig. 25).

Danger
Fig. 25
11. Pull the side plate onto the flange using a special
pulling device (Fig. 26).
Fig. 26
12. Insert the circlip into the groove (Fig. 27).
Fig. 27
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13. Assemble the V-ring (Fig. 28).
Fig. 28
14. Assemble the intermediate ring, turn in and tighten the fastening screws (Fig. 29).
Fig. 29
15. Attach the cover, turn in and tighten the fastening

screws (Fig. 30).
Fig. 30
16. Pull the vibrator shaft towards you (Fig. 31) (must
touch the collar of the bearing on the drive side).
Fig. 31
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17. On the vibration drive side of the drum measure

the depth to the stop of the coupling hub on the
vibrator shaft (Fig. 32).
Nominal value:
122 ... 121.8 mm
18. Compensate the difference to the measured value with shims between coupling hub and vibrator
shaft.
Fig. 32
19. Insert shims (Fig. 33) of calculated thickness.
L Note
If the fitting key is already assembled the shims
must be punched out accordingly.
Fig. 33
20. Press the coupling have 2 (Fig. 34) onto the vibrator shaft and insert coupling element (1).
Caution
Mind the fitting key!
Fig. 34
21. Slide coupling hub 2 (Fig. 35) onto the shaft and
tighten fastening screw (1).
Fig. 35
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22. Install the vibration motor 2 (Fig. 36), turn in and
tighten the fastening screws (1).
Fig. 36
23. Assemble the angle plate, turn on and tighten the

fastening nuts (Fig. 37).
Fig. 37
24. Fill in oil as specified in the maintenance instructions.
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5.6 Repairing the vibrator unit on the

drum drive unit
1. Remove the vibrator unit.
Dismantling the vibrator unit

1. Unscrew fastening screws 1 (Fig. 1) and take the
flange off the housing.
2. Unscrew plugs (2).
L Note
The bores with the plugs (2) are used to force off
the cylinder roller bearings.
Fig. 1
3. Take the flange off the housing (Fig. 2).

4. Take off the O-rings.
Fig. 2
5. Remove the safety lock (Fig. 3).

6. Force bearing (2) out of the flange with the help
of screws.
Fig. 3
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7. Take the vibrator unit (Fig. 4) out of the housing.
Fig. 4
8. Check the condition of the inner bearing race

(Fig. 5), replace if necessary.
Fig. 5
9. Pull coupling pinion 1 (Fig. 6) off the exciter shaft.

10. Check the condition of the inner bearing race (2),
pull off if necessary.
Fig. 6
11. Remove circlip 1 (Fig. 7).

12. Press bearing (2) out of the housing.
Fig. 7
130
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Assembling the vibrator unit

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

Danger
Danger of burning!
Wear protective gloves.

3. Heat the inner bearing race up to approx. 80 C.
4. Push inner bearing race 3 (Fig. 9) with the collar
towards the eccentric weight all the way against
the end stop.
5. Insert circlip (2) into the groove in the vibrator
shaft.
6. Insert the fitting key into the keyway in the vibrator
shaft.
Fig. 9
7. Heat coupling pinion (1) up to approx. 80 C and

slide it onto the shaft against the stop.
Danger
Danger of burning!

the end stop.
shaft.
Fig. 10
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11. Move the vibrator unit (Fig. 11) carefully into the
housing, until the inner bearing race is seated in
the bearing.
Fig. 11

Fig. 12
14. Grease the O-ring and lay it into the groove (Fig.
13).
Fig. 13
15. Grease the O-ring and lay it around the collar

(Fig. 14).
Fig. 14
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16. Attach the flange to the housing (Fig. 15).
Fig. 15
17. Insert and tighten fastening screws 1 (Fig. 16).

18. Insert the plugs into the forcing off bores (2) with
seal rings.
Fig. 16
19. Check the end float of the vibrator shaft (Fig. 17).
Nominal value:
0.6 ... 1.2 mm
Fig. 17
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5HSDLULQJWKHYLEUDWRUXQLWRQWKHYLEUDWLRQGULYHXQLW
5.7 Repairing the vibrator unit on the vibration drive unit
1. Remove the vibrator unit.
Dismantling the vibrator unit

the flange off the housing.
Fig. 1
2. Take the flange off the housing (Fig. 2).

3. Take off the O-rings.
Fig. 2
4. Pull radial seal 1 (Fig. 3) out of the flange.

5. Unscrew plugs (2).
L Note
The bores with the plugs (2) are used to force off
the cylinder roller bearings.
Fig. 3
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7. Force bearing (2) out of the flange with the help
of screws.
Fig. 4
8. Take the vibrator unit (Fig. 5) out of the housing.
Fig. 5
9. Check the condition of inner ring 1 (Fig. 6) for radial seal and inner bearing race (2), pull off if necessary.
Fig. 6
10. Pull coupling pinion 1 (Fig. 7) off the exciter shaft.

11. Check the condition of the inner bearing race (2),
pull off if necessary.
Fig. 7
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13. Press bearing (2) out of the housing.
Fig. 8
Assembling the vibrator unit

Fig. 9

Danger
Danger of burning!

the end stop.
shaft.
6. Insert fitting key (4) into the keyway in the vibrator
shaft.
Fig. 10
7. Slide locking ring (3) and washer (2) to fasten the

coupling onto the shaft.
8. Heat coupling pinion (1) up to approx. 80 C and
slide it onto the shaft against the stop.
136
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Danger
Danger of burning!

9. Heat the inner ring and inner bearing race up to
approx. 80 C.
the end stop.
shaft.
Fig. 11
12. Slide inner ring (1) with the chamfered side towards the outside onto the shaft.
13. Move the vibrator unit (Fig. 12) carefully into the
housing, until the inner bearing race is seated in
the bearing.
Fig. 12

Fig. 13
16. Grease the O-ring and lay it into the groove (Fig.
14).
Fig. 14
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17. Grease the O-ring and lay it around the collar
(Fig. 15).
Fig. 15
18. Attach the flange to the housing (Fig. 16).
Fig. 16
19. Turn in and tighten the fastening screws (Fig. 17).
Fig. 17
20. Press the new radial seal 1 (Fig. 18) into the
housing with the sealing lip pointing down.
21. Insert the plugs into the forcing off bores (2) with
seal rings.
Fig. 18
138
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22. Check the end float of the vibrator shaft (Fig. 19).
Nominal value:
0,6 ... 1.2 mm
Fig. 19
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'LVPDQWOLQJDVVHPEOLQJWKHFKDQJHRYHUZHLJKWV
5.8 Dismantling, assembling the changeover weights
Dismantling
1. Unscrew all other fastening screws (Fig. 1).
Fig. 1
2. Turn the screws (Fig. 2) into the tapped bores of

the cover and force the cover off.
Environment
3. Tip the oil into a suitable container.
Fig. 2
4. Pull O-rings 1 and 2 (Fig. 3) out of the grooves.
Fig. 3
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5. Take the weight (Fig. 4) out of the housing.
Fig. 4
Assembly
6. Lay the change-over weight into the housing with
the chamfered inner edge (Fig. 5) facing up.
L Note
Before reassembling check whether the weight
correctly changes its position after the cover has
been installed (without oil) .
Fig. 5
7. Place O-rings 1 and 2 (Fig. 6) with some grease

into the grooves.
Fig. 6
8. Fill the housing up to the edge with approx. 0.39

litres of silicone oil 47V 1000 cSt (Fig. 7).
Fig. 7
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9. Attach the cover (Fig. 8) to the housing.
10. Cover the fastening screws with LOCTITE green
(No. 601).
11. Tighten the fastening screws evenly with 35 Nm.
Fig. 8
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6 Pivot steering
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5HPRYLQJUHSDLULQJDQGLQVWDOOLQJWKHSLYRWVWHHULQJ
6.1 Removing, repairing and installing the
pivot steering
Removal
1. Remove the respective drum (see respective
section).
2. Disconnect the steering cylinders (Fig. 1) on both
sides from the cross-member.
Fig. 1
3. Unscrew all fastening screws from the hood (Fig.

2) and take off the hood.
Fig. 2
4. Remove steering angle transducer 1 (Fig. 3) and

cover (2).
Fig. 3
144
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5. Pull hydraulic hoses and electric cables (Fig. 4)

out of the cross member.
Fig. 4
6. Attach the lifting tackle to the cross-member (Fig.

5).

Danger
Fig. 5
7. Unscrew all fastening screws (Fig. 6) from both

sides and lower the cross-member to the ground.
Fig. 6
8. Unscrew all fastening screws (Fig. 7) and lower

the transom bed to the ground.
Fig. 7
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145

9. Check four point bearing , replace if necessary.

Danger
Support the bearing so that it cannot fall

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

Danger

1. Lift up the cross-member and place it in front of
the transom bed (Fig. 9).
Fig. 9
2. Turn in and tighten the fastening screws (Fig. 10).
Fig. 10
3. Route hydraulic hoses (Fig. 11) and electric cables through the cross member.
Fig. 11
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4. Assemble the steering angle transducer (Fig. 12)

with the angle plate.

Caution
Adjust the angle transducers before starting
operation of the machine!
Fig. 12
5. Connect the steering cylinders (Fig. 13) with the

cross-member.
Fig. 13
6. Reinstall the drum (see corresponding section).

7. Calibrate and adjust the steering angle transducers (see respective section).
8. Reassemble the hood (Fig. 14) and perform a
test drive.
Fig. 14
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5HSDLULQJWKHRVFLOODWLRQMRLQW
6.2 Repairing the oscillation joint
Dismantling the oscillation joint
1. Remove drum and pivot steering (see corresponding section).
2. Unscrew the fastening screws (Fig. 1) and remove the cover.
Fig. 1
3. Pull out the rocker bearing (Fig. 2) and take off

the supporting disc.
Fig. 2
4. Remove the cover (Fig. 3) also on the other side

and pull out the rocker bearing.
Fig. 3
148
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5. Press the joint bolt out using three screws (Fig.

4).
Fig. 4
6. Lift the beam out of the cross member (Fig. 5).
Fig. 5
Assembling the oscillation joint

1. Insert the beam into the cross member and knock
in the joint bolt (Fig. 6).
Fig. 6
2. Insert the support ring and press the joint ring

(Fig. 7) onto the joint bolt.
3. Spray the joint ring with sliding agent OKS 571
(BOMAG part-no. 009 700 26).
Caution
Insert the rocker bearing without grease, use
only sliding agent OKS 571 (BOMAG part-no.
009 700 26).
Fig. 7
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4. Spray the bearing race (Fig. 8) with sliding agent
and knock it into the cross member.
L Note
Allow the bearing to protrude for about 5 mm and
pull it completely in later when assembling the
cover.
Fig. 8
5. Assemble the cover (Fig. 9) and tighten the fastening screws evenly.

Caution
Do not mix up the cover for both sides by mistake!
Fig. 9
6. Insert the supporting disc and knock in the rocker

bearing (Fig. 10).
Fig. 10
7. Place a shim 0f 4.2 mm thickness into the cover

on the other side (Fig. 11).
Fig. 11
150
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8. Insert both Belleville springs (Fig. 12).

Caution
Observe the installation direction!
Fig. 12
9. Assemble the cover (Fig. 13) and tighten the fastening screws evenly.
10. Loosen the screws of the cover again.
Fig. 13
11. Insert the M16 threaded rod through the central

bores in both covers and preload the covers with
90 Nm (Fig. 14).
Fig. 14
12. Measure the gap (measurement Y) between

cover and cross member with a feeler gauge (Fig.
15).
Calculate the shim thickness S
S = 3.7 - Y
13. Reassemble the covers and correct the thickness
of the shims as calculated.
14. Assemble the covers with the calculated shims
and tighten the fastening screws.
Fig. 15
15. Reinstall the drum (see corresponding section).

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152
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7 Suppliers documentation
008 912 53
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153
154
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008 912 53
7.1
008 912 53
A4VG
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155

156
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008 912 53

$9*
RDE 92003-01-R/05.99
ersetzt / replaces
RDE 92003-01-R/07.96
Reparaturanleitung
Repair instructions
008 912 53
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A4VG 40 - 56 Baureihe 32
A4VG 40 - 56
Series 32
157

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Hinweis / Inhalt
Reparaturanleitung A4VG
Notice / Contents
Repair Instructions A4VG
HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen
entsprechen dem Informationsstand zum Zeitpunkt der
Drucklegung dieser Unterlage.
nderungen knnen den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, fr
deren Resultat wir keine Haftung bernehmen knnen.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.
Einstell- und Prfarbeiten sind bei Betriebstemperatur auf
dem Teststand vorzunehmen.
Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.
Sachkenntnis, die Voraussetzung fr jede Service-arbeit,
vermitteln wir in unseren Schulungskursen.
NOTICE
Specifications, descriptions and illustrative material
shown herein were as accurate as known at the time this
publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to
discontinue models or options at any time or to change
speci-fications, materials, or design without notice and
with-out incurring obligation.
Optional equipment and accessories may add cost to the
basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test
bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT
CONTENTS
Seite/
Page
A4VG
Schnittbild
Turcon-Glyd-Ring Dichtung
Allgemeine Reparaturhinweise
Dichtstze und Baugruppen
Triebwelle abdichten
Hilfspumpe abdichten
Stellkolbendeckel abdichten
Ventile abdichten
Druckabschneidung abdichten
Regelventil abdichten
Steuergert demontieren
Ansteuergerte
Pumpe demontieren
Triebwerk ausbauen
Stellkolben demontieren
berprfungshinweise
Kontrolle der Triebwerksteile
Stellkolben,Triebwerk einbauen
Pumpe montieren
Anziehdrehmomente
Sicherheitsbestimmungen
Einstellhinweise
A4VG
3-4
5
6
7-8
9
10
11-12
13
14
15
16
17
18-19
20
21
22
23-24
25-33
34-35
36
37-38
39-44
Sectional view
Turcon-Glyd-ring seal
Seal kits and sub assembly groups
Sealing of the drive shaft
Sealing of the boost pump
Sealing of the control piston cover
Sealing of the valves
Sealing of the pressure cut-off valve
Sealing of the regulator valve
Removal of the control module
Control modules
Pump disassembly
Removal of the rotary group
Disassembly of the positioning piston
Inspection notes
Inspection of the rotary group parts
Installation of the rotary group
Assembly of the pump
Tightening torques
Safety regulations
Adjustment instructions
Brueninghaus Hydromatik
158
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Schnittbild
Sectional view
HWD
DAD
EPD
HDD
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Sectional view
RDE 92003-01-R/05.99
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Schnittbild
HWD / EPD / HDD
DAD
160
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RDE 92003-01-R/05.99
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Turcon-Glyd-Ring Dichtung
Turcon-Glyd-ring seal
Deckel
Stelldruck
Fhrungsbuchse
Stellzylinder
Turcon-Glyd-Ring
Leckl
Pumpengehuse
Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung der Verstellung auf Turcon-Dichtungen.
Die Stckliste der kompletten Einheit erhlt dabei eine
neue Ident.- Nummer.
Typenschlssel, Typnummer und Auenabmeungen
bleiben dabei unverndert. (Pumpengehuse ndert sich
nur im Bereich vom Stellkolben. Stellkolben ndert sich in
eine angefaste Ausfhrung).
Alten Stellkolben nicht bei Turcon-Dichtung verwenden (scharfkantig - Dichtungen werden
beschdigt).
Pumpengehuse / Pump housing
mit Lagerbuchse / with bush
ALT / OLD
At present the change of the control into Turcon seal is

made for A4VG.
The parts list of the complete unit will receive a new
identification number.
Type reference and outside dimensions remain
unchanged (pump housing will change at the area of the
positioning piston. Positioning piston will change into
chamfering design).
Do not use old positioning piston with Turcon seal
(sharp edged - seal will be damaged)
Pumpengehuse / Pump housing

mit Turcon-Dichtung / with Turcon seal
*
NEU / NEW
*
Die Umstellung der Verstellung auf TurconDichtung ist im allgemeinen mit einer Funktionsverbesserung verbunden (DA-Verhalten, geringerer
Temperatureinflu auf Stellzeiten).
The change of the control into Turcon seal design

improves in general the function (DA-behaviour,
lower temperature-influence on control times).
Bei gleicher Dsenbestckung knnen sich die

Stellzeiten geringfgig verndern.
The control times will slightly change with the

same throttle sections. Therefore our customers
have to be informed about this change.
008 912 53
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Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out repair
work at hydraulic aggregates!
Alle ffnungen der Hydraulikaggregate verschlieen.

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

Nur original BRUENINGHAUS HYDROMATIK-Ersatzteile
verwenden.
Replace all seals.
Use only original BRUENINGHAUS HYDROMATIK
spare parts.
Alle Dicht- und Gleitflchen auf Verschlei prfen.

Achtung: Nacharbeiten an Dichtflchen z.B. durch
Schleifpapier kann die Oberflche beschdigen.
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 befllen.
Fill up hydraulic aggregates with medium
before start- up.
162
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Dichtsatz fr Triebwelle.
Seal kit for drive shaft.
uerer Dichtsatz.
External seal kit.
Gehuse
Housing
Triebwerk komplett.
Complete rotary group.
Stellkolben
Positioning piston
008 912 53
%20$*
163

Sub assemblies
RDE 92003-01-R/05.99
$9*
Baugruppen
Anschluplatte
Port block
Ansteuergerte HW - EP
Control moduls HW - EP
Ansteuergerte HD - DA
Control moduls HD - DA
Hilfspumpe
Boost pump
10
Regelventil
Control valve
164
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
11
12
Triebwelle abkleben.
Sicherungsring ausbauen.
Protecting the drive shaft.
Remove retaining ring.
13
Blechschraube in die mit Gummi gefllten

Lcher eindrehen.
Mit Zange WDR herausziehen.
Screw in sheet metal screw into the holes
fitted with rubber.
Pull out shaft seal with pliers.
14
Wellendichtring mit Buchse auf

Anschlag einpressen.
Press-in shaft seal with bush to stop.
008 912 53
%20$*
165

RDE 92003-01-R/05.99
$9*
Achtung!
* Angefaste "Seite" zum Deckel montieren.
Note!
* Mount chamfered side facing cover.
15
16
Lage kennzeichnen,
Befestigungsschrauben ausbauen.
Mark position,
remove fixing screws.
17
Deckel abdrcken.
Pry-off cover.
18
Teile der Hilfspumpe auf Verschlei untersuchen.

Pumpe kann nur komplett ausgetauscht werden.
Inspect the parts of the boost pump and wear parts.
Boost pump can only be interchanged completely.
10
166
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
19
20
Befestigungsschrauben lsen.
Deckel verdrehen und mit leichten Hammerschlgen lsen.
Loosen mounting screws.
Rotate cover and release by tapping gently with hammer.
21
Kontrolle!
O-Ring (1), Nut (2), Gehuse (3).
Check!
O-ring (1), groove (2), housing (3).
22
Kontermutter ausbauen, Stellschraube gegenhalten.

Deckel kennzeichnen. Ma festhalten, Kontermutter lsen.
Remove locknut whilst holding setting screw.
Mark cover. Must be fixed, loosen counter nut.
008 912 53
%20$*
167
11

RDE 92003-01-R/05.99
$9*
23
ber 0-Lagen-Einstellschraube Deckel abdrcken

und drehen.
Pull cover off using zero position adjustment screw.
24
Kontrolle!
O-Ring (1), Nut (2), Gehuse (3).
Check!
O-ring (19, groove (2), housing (3).
25
Gewinde abdecken, kleinen O-Ring aufschieben.

Montage in umgekehrter Reihenfolge.
Cover threads, push on small O-ring.
Assemble in reversed order.
26
Achtung!
Korrekte mechanische Nullageneinstellung mu nach
Einbau im Gert bzw. Prfstand erfolgen.
Attention!
Adjustment of the correct zero position to be carried out
after installation into the machine or on the test bench.
27
Mechanische Nullage neu einstellen, dazu X1 mit X2

verbinden (>NW6).
Reset mechanical zero position. To do this, connect
X1 to X2 (size > 6).
12
168
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Ventile abdichten
PHD -Ventil
mit Bypass
PHD -valve
with bypass-function
PSP -Ventil
PSP -valve
28
29
Gewinde vor Montage des neuen O-Ringes abkleben.

(Beschdigungsschutz).
Cover threads before fitting new O-rings.
(Damage protection).
30
*
Ventilkegel mit Druckfeder ausbauen.

* mit Bypassfunktion
Remove valve poppet with spring.
* with bypass-function
31

(Beschdigungsschutz).
Cover threads before fitting new O-rings.
(Damage protection).
008 912 53
%20$*
169
13

RDE 92003-01-R/05.99
$9*
31
33
Wechsel der Dichtmutter.

Einstellma festhalten (*).
Change of the sealing nut.
Note setting measure (*).
Achtung!
Nach Einbau "Ventileinstellung" berprfen.
Attention!
After assembly check "valve setting".
14
170
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Sealing of the control valve
34
35
Regelventil ausbauen.
Remove control valve.
36
Blendendurchmesser nicht beschdigen.

Do not damage throttle diameter.
37

Before installing the new O-ring, tape the threads.
008 912 53
%20$*
171
15

RDE 92003-01-R/05.99
$9*
Removing of the control module
38
39
Befestigungsschrauben demontieren.
Remove fixing screws.
40
Ansteuergert abdrcken.
Pry-off the control module.
41
Kontrolle
Dichtflche (1), Flachdichtung (2), O-Ringe (3).
Check
Sealing surface (1), gasket (2), o-rings (3).
16
172
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Ansteuergerte
Control modules
Ansteuergert HW
HW control module
42
HD
Ansteuergert HD - EP
EP
HD - EP control module
HD
EP
44
43
Hydraulische Nullage (1) neu einstellen. Beide

Manometer mssen gleichen Druckwert anzeigen.
Reset hydraulic zero position (1).
Both gauges must indicate the same pressure.
008 912 53
%20$*
173
17

RDE 92003-01-R/05.99
$9*
Pumpe demontieren
Pump disassembly
Verschluschraube / Stift
Locking screw / pin
Verdrillschraube
Timing adjustment screw
46
45
Lage der Hilfspumpe und Anschluplatte markieren.

Hilfspumpe abbauen.
Mark position of the boost pump and the port plate.
Remove the boost pump.
47
Lage der Verdrillschraube markieren (1).

Verdrillschraube auf Demontageposition stellen (2).
Mark the position of the indexing screw (1).
Set the indexing screw to disassembly position (2).
48
Anschluplattenbefestigung lsen. Anschluplatte abheben.

Achtung! Dichtflche.
Release port plate fitting.
Take off port plate. If necessary, use screwdriver.
Attention! Sealing surface.
18
174
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Pumpe demontieren
Pump disassembly
49
Steuerplatte abdrcken.
Lage notieren.
Lift off control plate.
Note position.
50
Kontrolle!
O-Ring mit Nut (1), Gehuse (2), Quad-Ring und
Quad-Ring Nut (3).
Check!
O-ring and groove (1), housing (2), Quad-ring
and groove (3).
51
Zylinder nach unten drcken (1).

Verdrillschraube herausdrehen (2).
Triebwerk ausheben (3).
Press the cylinder to the bottom (1).
Remove fiming indexing screw (2).
Lift out rotary group (3).
"Ausbauen"
1. Zylinder
2. Schwenkwiege
3. Gelenkstift
"Remove"
1. Cylinder
2. Swash plate
3. Joint pin
52
008 912 53
%20$*
175
19

RDE 92003-01-R/05.99
$9*
Triebwerk ausbauen
53
Seegerring, WDR ausbauen.

Remove retaining ring, radial seal ring.
54
Triebwelle mit leichten Hammerschlgen austreiben.

Remove drive shaft with slight hammer strokes.
55
Lagerschalen ausbauen.
Remove bearing cups.
56
20
176
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
57
58
Steuergert abbauen.
Remove control module.
59
Stellkolben (1) ziehen.

Pull out control piston (1).
60
Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.
Mount fixture and tension spring.
Remove receiving ring.
61
Ringe ausbauen.
Sicherungsring ausbauen.
Achtung! Teile stehen unter Federvorspannung.
Take out rings.
Remove retaining ring.
Note! Parts are spring loaded.
008 912 53
%20$*
177
21

RDE 92003-01-R/05.99
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berprfungshinweise
Inspection notes
62
Alle Lager erneuern.

Replace all bearings.
63
Kontrolle!
1. Verzahnung, ausgeschlagen, Passungsrost.
2. Laufflche.
3. Einlaufrillen vom Wellendichtring.
Check!
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.
64
Stellkolbenlaufbchse (1) riefenfrei, nicht ausgelaufen.

Check that the control piston guide bush (1) is
free of grooves and has not worn out.
65
Kontrolle!
Stellkolben (1) riefenfrei.
Check!
Control piston (1) is not scored.
22
178
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Inspection of rotary group parts
66
Kontrolle!
Gleitflche riefenfrei.
Check!
Sliding surface free of grooves.
67
Kontrolle!
Verbindung Gleitstein/Schwenkzapfen spielfrei.
Check!
Make sure sliding ring/swivel pin are free of play.
68
Kontrolle!
Rckzugeinrichtung riefenfrei (1), keine Einlaufspuren (2)
im Gleitschuhbereich.
Check!
Check that return device is free of grooves (1) no wear
in slipper pad area.
69
Kontrolle!
Laufflche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check that there are no scratches or metal deposits on
sliding surface (1), and there is no axial play (2),
(otherwise: pistons must be replaced in sets).
70
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
008 912 53
%20$*
179
23

RDE 92003-01-R/05.99
$9*
Inspection of rotary group parts
71
Kontrolle!
Zylindergleitflche (1) riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte (2) nicht riefig (nur satzweise
austauschen).
Check!
Cylinder gilding surface (1) free of scratches, no traces of
wear and no embedded foreign particles. No scratches
on the valve plate (2). (Replace ONLY in sets).
72
Kontrolle!
DU-Lagerbuchse (1) nicht ausgelaufen.
Check!
DU-bearing bush (1) is not worn out.
73
Hinweis:
Bohrung bei DA-Regelung offen. Ohne
DA-Regelventil geschlossen.
Information:
Boring for DA-control open.
Without DA-control closed.
74
Kontrolle!
Lagerbahnen (1)
Check!
Bearing surfaces (1)
24
180
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Stellkolben, Triebwerk einbauen
Positioning piston, rotary group assembly
Gehuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring
Hilfswerkzeuge / Auxiliary tools:

Montagezange / Assembly pliers: B+S x M22
Fhrungsdorn / Guide thorn: A4VG28

A4VG40
A4VG56
A4VG71
A4VG90
A4VG125
A4VG180
A4VG250
I: 277 4 347
I: 277 4 049
I: 277 4 050
I: 277 4 051
I: 277 4 052
I: 277 4 053
I: 277 4 054
I: 277 4 072
Montage / Assembly A4VG
1
2
3
3
2
Pos. /
Item 1
Pos. /
Item 2 / 3
Pos. /
Item 2 / 3
Pos. /
Item 1
Pos. / Item 1: Stangenfhrungsring montieren.

Install barguide ring.
Pos. / Item 3: O-Ring montieren.

Install O-ring.
82
008 912 53
%20$*
181
25

RDE 92003-01-R/05.99
$9*
Stellkolben, Triebwerk einbauen
Positioning piston, rotary group assembly

Gehuse - 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 nierenfrmig zusammendrcken. Die Verformung von Turcon-Dichtungen ist
sorgfltig vorzunehmen, damit die Dichtkanten nicht
beschdigt 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 Gehuse einfhren und in der Aufnahmenut

plazieren. Dann Spannung lsen und Montagezange heraus
ziehen. Lage des Dichtringes prfen - 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.
Fhrungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.
Fhrungsdorn leicht einfetten.

Stellkolben mit Fhrungsdorn einbauen.
Grease slightly guide thorn.
Install positioning piston with guide thorn.
26
182
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Triebwerk einbauen
75
Stellkolben ins Gehuse einsetzen.

Hinweis:
Stellkolben vor Einbau einlen.
Insert positioning piston into the housing.
Instruction:
Oil positioning piston before assembly.
76
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
77
78
Schwenkwiege komplett ins Gehuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehuse "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.
008 912 53
%20$*
183
27

RDE 92003-01-R/05.99
$9*
Triebwerk einbauen
Kontrolle:
Sitz der Schwenklager in der

Lagerbahn.
Schwenkwiege mit Stellkolben verschwenken "Leichtgngig".

Mittig stellen mit Mevorrichtung (Uhr oder Tiefenma)
Punkt 1 und 2 kontrollieren - gleiches Ma.
Check:
Location of the swivel-bearing

in the bearing.
Swivel the swivel bearing by using the control piston

"it should move easily".
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.
79
80
Gelenkstift montieren.
Fit joint pin.
28
184
%20$*
008 912 53

$9*
008 912 53
%20$*
185

RDE 92003-01-R/05.99
$9*
Triebwerk einbauen
82
Neue Montageposition!
Triebwelle mit Lager und Wellendichtring einbauen.
Assemble drive shaft with bearings and radial seal rings.
83
84
Scheibe 1, 2
Disc 1, 2
82
2
85
Kolben mit Rckzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einlen.
Assemble piston with retaining plate.
Note:
Oil piston and piston pad.
30
186
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Triebwerk einbauen
86
Vorrichtung ausbauen.
Zylinder mit Kolben und Rckzugeinrichtung einbauen.
Remove holding device.
Fit cylinder complete with pistons and retaining device.
87
Montagehilfe:
Mit O-Ring Kolben festhalten.
Assembly aid:
Hold the pistons by using an O-ring.
008 912 53
%20$*
187
31

RDE 92003-01-R/05.99
$9*
Triebwerk einbauen
89
Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung!
Geruschkerben sind drehrichtungsbezogen eingeschliffen.
Control plate clockwise rotation - indexed in the direction
of rotation.
Note!
Noise grooves are machined - in based on direction
of rotation.
90
Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung!
Geruschkerben sind drehrichtungsbezogen eingeschliffen.
Control plate counter clockwise rotation - indexed
in the direction of rotation.
Note!
Noise grooves are machined - in based on direction
of rotation.
91
Zylinderflchen und DU-Lager einlen, 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.
92
Grundeinstellung - Verdrillschraube
A4VG...40 * = 24 0,75 mm.
A4VG...56 * = 21 0,75 mm.
Basic setting - indexing screw
A4VG...40 * = 24 0,75 mm.
A4VG...56 * = 21 0,75 mm.
93
Zylinder nach unten drcken (1).

Verdrillschraube einbauen (2).
Kerbe in Montageposition.
Press the cylinder to the bottom (1).
Screw in the indexing screw (2).
Groove in mounting position.
32
188
%20$*
008 912 53

RDE 92003-01-R/05.99
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Pumpe montieren
94
Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.
95
Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise rotation.
96
Lagerichtig aufsetzen.
Hinweis:
HW, HD, EP - Steuerplatte mit Fett auf
Anschluplatte.
Place in correct position.
Note:
HW, HD, EP - Put control plate with greas
to the port block.
97
Schrauben ber Kreuz anziehen.

Verdrillschraube auf Markierung drehen.
Tighten screws (Cross-corner).
Turn the indexing screw to marking.
98
Hilfspumpe montieren.
Assemble boost pump.
008 912 53
%20$*
189
33

RDE 92003-01-R/05.99
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Pumpe montieren
99
Ansteuergert montieren.
Mount control module.
100
34
190
%20$*
008 912 53

RDE 92003-01-R/05.99
$9*
Anziehdrehmomente
Tightening torques
Anziehdrehmomente fr Schaftschrauben
(Metrisches ISO-Regelgewinde)
Tightening torques for shaft bolts

(Metric ISO Standard Thread)
Festigkeitsklassen
Die nebenstehenden Werte fr Anziehdrehmomente gelten nur fr
Schaftschrauben mit metrischem ISO-
Gewinde
gre
8.8
Strength Classes
10.9
12.9
Anziehdrehmoment(Nm)
M3
1,3
2,0
2,3
M4
3,1
4,5
5,3
M5
6,1
8,9
10,4
leicht oder nicht gelte, unbehandelte
M6
10,4
15,5
18.0
Oberflchen, sowie nur bei Verwen-
M8
25
37
43
dung von Drehmoment- und Kraftbe-
M10
51
75
87
grenzungsschlsseln.
M12
87
130
150
M14
140
205
M16
215
310
M18
300
M 20
Regelgewinde und Kopfauflagemaen

nach DIN 912, DIN 931 und DIN 933.
Auerdem gelten diese Werte nur fr
The values for tightening torques

shown in the table are valid only for
shaft bolts with metric ISO- standard
Thread
size
8.8
10.9
M3
1,3
2,0
M4
3,1
4,5
5,3
DIN 931 and DIN 933. These values are
M5
6,1
8,9
10,4
also valid only for light or unoiled,
M6
10,4
15,5
18.0
untreated surface as well as for use only
M8
25
37
43
with torque-indicating
M10
51
75
87
wrenches and force limiting tools.
M12
87
130
150
240
M14
140
205
240
370
M16
215
310
370
430
510
M18
300
430
510
430
620
720
M 20
430
620
720
M 22
580
830
970
M 22
580
830
970
M 24
740
1060
1240
M 24
740
1060
1240
M 27
1100
1550
1850
M 27
1100
1550
1850
M 30
1500
2100
2500
M 30
1500
2100
2500
threads and head support surface

dimensions in accordance with DIN 912,
Gewindegre
Bezeichnung
Thread size
Designation
M8x1
VSTI 8 x 1
-ED/SA
=5
M8x1
VSTI 8 x 1
-ED/SA
=4
M 10 x 1
VSTI 10 x1
-ED
= 10
M 10 x 1
VSTI 10 x1
-ED
=7
M 12 x 1,5
VSTI 12 x 1,5
-ED
= 20
M 12 x 1,5
VSTI 12 x 1,5
-ED
= 15
M 14 x 1,5
VSTI 14 x 1,5
-ED
= 30
M 14 x 1,5
VSTI 14 x 1,5
-ED
= 22
M 16 x 1,5
VSTI 16 x 1,5
-ED/SA
= 30
M 16 x 1,5
VSTI 16 x 1,5
-ED/SA
= 22
M 18 x 1,5
VSTI 18 x 1,5
-ED/SA
= 40
M 18 x 1,5
VSTI 18 x 1,5
-ED/SA
= 29
M 20 x 1,5
VSTI 20 x 1,5
-ED/SA
= 50
M 20 x 1,5
VSTI 20 x 1,5
-ED/SA
= 37
M 22 x 1,5
VSTI 22 x 1,5
-ED
= 60
M 22 x 1,5
VSTI 22 x 1,5
-ED
= 44
M 26 x 1,5
VSTI 16 x 1,5
-ED/SA
= 70
M 26 x 1,5
VSTI 16 x 1,5
-ED/SA
= 51
M 27 x 2
VSTI 27 x 2
-ED
= 90
M 27 x 2
VSTI 27 x 2
-ED
= 66
M 30 x 1 ,5
VSTI 30 x 1,5
-ED/SA
= 100
M 30 x 1 ,5
VSTI 30 x 1,5
-ED/SA
= 74
M 33 x 2
VSTI 33 x 2
-ED/SA
= 120
M 33 x 2
VSTI 33 x 2
-ED/SA
= 88
Tightening torques (lb.ft)
M 42 x 2
VSTI 42 x 2
-ED/SA
= 200
M 42 x 2
VSTI 42 x 2
-ED/SA
= 147
M 48 x 2
VSTI 48 x 2
-ED
= 300
M 48 x 2
VSTI 48 x 2
-ED
= 220
Anziehdrehmomente fr Seal-Lock Bundmuttern

Tightening torques for seal-lock nuts

(Metric ISO-Standard Thread)
Festigkeitsklassen
Gewinde
ziehdrehmomente gelten nur fr Seal-
gre
Lock Bundmuttern der Festigkeitsklasse 8.8 mit metrischem ISO-Regelgewinde.
8.8
10.9
Strength classes
12.9
The values for tightening torques shown
Thread
8.8
Anziehdrehmoment (Nm)
in the table are valid only for seal-lock
M6
10
nuts of the strength class 8.8 and with
M6
7,4
M8
22
metric ISO-standard thread.
M8
16,2
M 10
40
M 10
29,5
M 12
69
M 12
50,9
M 14
110
M 14
81,1
M 16
170
M 16
125,3
Anziehdrehmomente fr Linsenschrauben mit Kreuzschlitz DIN 7985

size
ziehdrehmomente gelten nur fr Linsenschrauben mit Kreuzschlitz DIN

7985 der Festigkeitsklasse 8.8 mit
metrischem ISO-Regelgewinde
Gewinde
8.8
10.9
10.9
12.9
Tightening torque (lb.ft)
Tightening torques for cross-slotted lens head screws

DIN 7985
(Metric ISO- Standard Thread)
Festigkeitsklassen
Die nebenstehenden Werte fr An-
2,3
Tightening torques for locking screws VSTI

(Metric ISO fine thread)
Anziehdrehmomente fr Verschluschrauben VSTI

(Metrisches Feingewinde)
Die nebenstehenden Werte fr An-
12.9
Tightening Torque(lb.ft)
Strength classes
12.9
gre
M3
1,1
M4
2,9
M5
The values for tightening torques shown

in the table are valid only for crossslotted lens head screws DIN 7985 of the
Thread
size
8.8
M3
0,8
M4
2,1
M5
4,4
M6
10
M6
7,4
M8
25
M8
18,4
M10
49
M10
36,1
strength class 8.8 and with metric ISOstandard thread.
10.9
12.9
Tightening torques (lb.ft)
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Safety regulations
Allgemein
General advice
Machen Sie sich mit der Ausstattung der Maschine

vertraut.
Fahren Sie die Maschine nur, wenn Sie sich vllig
mit den Bedien- und Steuerelementen sowie der
Arbeitsweise der Maschine vertraut gemacht haben.
Benutzen Sie Ihre Schutzausrstung wie
Schutzhelm, Sicherheitsschuhe und Gehrschutz.
Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
Benutzen Sie die Maschine nur fr den ihr zugedachten Zweck.
Make yourself familiar with the equipment of the

machine.
Only operate the machine if your are completely
familiar with the operating and control elements as
well as the functioning of the machine.
Use your safety equipment like helmet, safety shoes
and hearing protection.
Make yourself familiar with your working field.
Only operate the machine for its intended purpose.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers
Please observe the guidelines of the Professional

Association and the machine manufacturer.
Vor dem Start
Before starting
Beachten Sie die Bedienungshinweise vor dem

Starten.
Prfen Sie die Maschine auf auffllige Fehler.
Fahren Sie die Maschine nicht mit defekten
Instrumenten, Kontrolleuchten oder Steuerorganen.
Alle Schutzvorrichtungen mssen fest auf ihrem
Platz sein.
Nehmen Sie keine losen Gegenstnde mit bzw.
befestigen Sie diese an der Maschine.
Halten Sie die Maschine von ligem und zndfhigem Material frei.
Prfen Sie vor dem Besteigen der Maschine, ob
sich Personen oder Hindernisse neben oder unter
der Maschine befinden.
Vorsicht beim Besteigen der Maschine, bentzen
Sie Treppen und Griffe.
Stellen Sie vor dem Start Ihren Sitz ein.
Observe the operating instructions before starting.

Check the machine for obvious faults.
Do not operate the machine with defective
instruments, warning lights or control elements.
All safety devices must be in a secure position.
Do not carry with you movable objects or secure
them to the machine.
Keep oily and inflammable material away from the
machine.
Before entering thc drivers cabin, check if persons
or obstacles are beside or beneath the machine.
Be careful when entering the drivers cabin, use
stairs and handles.
Adjust your seat before starting.
36
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Safety regulations
Starten
Beim Starten mssen alle Bedienhebel in Neutralstellung stehen.
Die Maschine nur vom Fahrersitz aus Starten.
Prfen Sie die Anzeigeinstrumente nach dem Start,
um sicher zu gehen, da alles ordnungsgem
funktioniert.
Lassen Sie die Maschine nicht unbewacht, whrend
der Motor luft.
Beim Start mit Batterieverbindungskabeln verbinden
Sie Plus mit Plus und Minus mit Minus. Massekabel
(Minus) immer zuletzt anschliesen und zuerst abtrennen.
Start
When starting all operating levers must be in
neutral position.
Only start the machine from the drivers seat
Check the indicating instruments after start to
assure that all functions are in order.
Do not leave the machine unobserved when the
motor is running.
When starting with battery connection cables
connect plus with plus and minus with minus.
Always connect negative (-) cable last and
disconnect negative cable first.
Vorsicht
Auspuffgase sind lebensgefhrlich. Bei Start in
geschlossenen Rumen fr ausreichende Luftzufuhr
sorgen!
Attention
Exhaust gas is dangerous. Assure sufficient fresh
air when starting in closed rooms!
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Hydraulic equipment
1. Hydraulic equipment is standing under high
pressure.
Unter hohem Druck austretende Hochdruck-
2.
3.
4.
5.
6.
7.
High pressure fluids (fuel, hydraulic oil) which
Flssigkeiten (Kraftstoff, Hydraulikl) knnen

die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen
Arzt aufsuchen, da anderenfalls schwere
Infektionen entstehen knnen!
Bei der Suche nach Leckstellen wegen Ver
letzungsgefahr geeignete Hilfsmittel verwenden!
Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Gerte
absenken!
Bei Arbeiten an der Hydraulikanlage unbedingt
Motor abstellen und Maschine gegen Wegrollen
sichern (Feststellbremse, Unterlegkeil)!
Beim Anschlieen von Hydraulikzylindern und
-motoren ist auf vorgeschriebenen Anschlu der
Hydraulikschluche zu achten!
Bei Vertauschen der Anschlsse umgekehrte
Funktionen (z.B. Heben/Senken) - Unfallgefahr!
Hydraulikschlauchleitungen regelmig kontrollieren und bei Beschdigung und Alterung austauschen! Die Austauschschlauchleitungen mssen den technischen Anforderungen des Gerteherstellers entsprechen!
2.
3.
4.
5.
6.
7.
escape under high pressure can penetrate the

skin and cause heavy injuries.
Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
When searching leakages use appropriate auxiliary
devices because of the danger of accidents.
Before working at the hydraulic equipment, lower
pressure to zero and lower working arms of the
rnachine.
When working at the hydraulic equipment, absolutely
stop motor and secure machine against rolling away
(parking brake, shim)!
When connecting hydraulic cylinders and motor pay
attention to correct connection of hydraulic flexible
hoses.
In case of exchanging the ports, the tunctions are
vice versa (f. ex. lift-up/lower) - danger of accidents!
Check hydraulic flexible hoses regularly and replace
them in case of dammage or wear! The new hose
pipes must comply with the technical requirements
of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
le, Kraftstoffe und Filter ordnungsgem

entsorgen!
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Einstellhinweise - Mechanische "Nullage"
Adjustment instructions - Mechanical "zero position"
HW
HD
EP
DA
101
Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschlieen.
Nullage so einstellen, da bei blockiertem
Antrieb beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
Attention!
Observe safety regulations!
Connect both control chambers with hose
NW6. Avoidance of rest signal from hydraulic
zero position.
Connect manometer to MA and MB. Adjust
zero position so that at blocked drive both
manometer indicate the same pressure valve.
Note:
Adjust death line of zero position.
102
38
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Einstellhinweise - Hydraulische "Nullage"
Adjustment instructions - Hydraulic "zero position"
HW
HD
EP
Achtung!
Attention!
103
Manometer an X1 und X2 anschlieen.

Hinweis:
Excenterjustierung
- nicht ber 90 verdrehen.
Connect manometer to X1 and X2.
Adjust zero position so that at blocked drive
both manometer indicate the same pressure
value.
Note:
Eccentric adjusting
- Do not turn over 90.
104
008 912 53
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195
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Einstellhinweise - ND-Ventil (Speisedruck)
Adjustment instructions - Low pressure valve (Boost pressure)
Achtung!
Hinweis:
Nachjustierung nur bei Betriebstemperatur.
Manometer an "G" anschlieen.
Achtung!
* Speisedruckeinstellung!
Nenndruck pH - 18 bar
Hchstdruck pH - 40 bar
Bei Max.-Drehzahl.
Hinweis:
Einstelldaten nach Werksauftrag.
"G"
*
* bei DA-Ausfhrung
Attention!
Note:
Readjusting only at operating temperature.
Connect manometer to "G".
Attention!
* Boost pressure setting!
Nominal pressure pH - 18 bar
Peak pressure pH - 40 bar
at max. speed.
Note:
Adjusting data according to order.
105
40
196
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Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Achtung!
Druckabschneidung
Pressure cut-off
HD-Ventil ohne Bypass

1 . HD- Ventile sind immer 10% hher eingestellt als die
Druckabschneidung.
Bei Vernderung eines Einsteilwertes immer beide
kontrollieren.
2. Nachjustierung nur bei Betriebstemperatur
Druckabschneidung: Ma X Einstellschrauben notieren!
Einstellschraube auf Block drehen.
HD- Ventile: Mit geringer Pumpenmenge ber Ventile
fahren. Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur.)
Drucklos "Einstellwert verndern - Kontrolle
Druckabschneidung:
Einstellschraube auf Ma (*) zurckdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD- Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
106
Attention!
Observe safety regulations.
HP valve without bypass-function
HD- Ventile
HP- valves
1 . HP valves are always adjusted 10% higher than the

pressure cut-off.
If one setting value is changed, always check both
values.
2. Readjusting only at operating temperature.
Connect manometer MA and MB.
Pressure cut-off: Note measure X setting screw! Turn
setting screw on block.
HP valves: Operate valves with small pump flow
volume.
Check setting value. ("temperature only for a short
time).
Change "setting value - check.
107
Pressure cut-off:
Turn back setting screw to measure (*).
Check pressure value and readjust.
Attention! Observe 10% pressure difference HP valves
and pressure cut-off!
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Einstellhinweise - Bypassventil
Adjustment instructions - Bypass valve
1
1
108
Fahrzeuge mit rein-hydrostatischem Fahrantrieb

bzw. mit hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung (Freilauf).
Vehicle with hydrostatic transmission and gear shift

without idling setting position (free wheeling).
Hydrostatischer Antrieb / Bypa-Schaltung
Hydrostatic transmission / Bypass-switching
In diesem Fall wird der Fahrantrieb auf freien

Umlauf geschaltet. Zu diesem Zweck haben die
in der Verstellpumpe integrierten Hochdruckbegrenzungsventile eine sogenannte Bypa-Funktion.
D.h. durch Drehen der entsprechenden
Schraube (Pos.1) wird der Ventil-Einsatz so entspannt,
da ein freier l-Umlauf mglich ist.
Bypass:Pos.1 einschrauben bis eben mit Mutter.
Mutter wieder anziehen.
In this case the travel transmission is switched on to

free wheeling.For this purpose the variable displacement pump has incorporated high pressure relief valves
with bypass function.
The screw (item 1) is unscrewed to such an extent, that
the valve cartridge is released and free oil circulation is
possible.
Bypass: Screw in item1 up to planeness with nut.
Screw up nut again.
Schleppgeschwindigkeit
Die maximale Schleppgeschwindigkeit sollte
2 km/h nicht berschreiten.
Towing speed
The max. towing speed of 2 km/h should not be
exceeded.
Hhere zulssige Schleppgeschwindigkeiten

sind abhngig von der Hydromotordrehzahl
bzw. dem eingelegten Gang.
Higher admissible towing speeds depend on the

avaiable hydr. motor speed and engaged
gear shift.
Abschleppdistanz
Die Schleppentfernung sollte 1 km nicht berschreiten.
Towing distance
The towing distance should not exceed 1 km.
Bei fehlender Einspeisung entleert sich der

Hydraulik-Kreislauf.
Zu beachten ist die Wrmeentwicklung im
Hydromotor-Triebwerk.
Abschleppvorgang beendet
Nach beendetem Abschleppvorgang Pos.1 zurckdrehen. Der ursprngliche Einstellwert der Hochdruckventile liegt somit wieder vor.
Towing operation terminated

After termination of the towing operation turn item 1
back. The original pressure value setting of the high
pressure relief valves will be avaiable again.
Valve function: Screw back item 1 up to stop.
Screw up the nut.
Ventilfunktion: Pos.1 zurckschrauben bis

Anschlag. Mutter anziehen.
42
If there is a lack of oil boosting, the hydraulic

circuit will get empty.
Take care of the heat development in the hydr.
motor-rotary group.
198
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Einstellhinweise - DA- Regelung
Adjustment instructions - DA control
Achtung!
berprfung der Einstelldaten
Betriebstemperatur soll whrend des berprfungsvorgangs weitgehend konstant
gehalten werden.
Antriebsmotor starten, Leerlaufdrehzahl
Blockzustand
Fahrtrichtungsschalter "0
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Megerte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*
Blockzustand
Fahrtrichtungsschalter - vorwrts
(Straengang und Festgebremst)
Verdrillung
Regelbeginn
109
Einstelldaten Pumpe A4V/DA berprfen

Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Regelende
HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube
Hinweis:
Excenterjustierung - Drehrichtung beachten
Hinweis: * Einstelldaten nach Werksauftrag!
110
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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)
Timing
adjustment screw
Check setting data pump A4VIDA

Begin of control:
HD 40 - 50 bar
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Readjusting - control start screw
Begin of control
111
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!
112
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustrae 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Telex 765321, Fax (07451) 8221
44
200
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7.2
008 912 53
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201

202
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Reparaturanleitung / Repair instructions

A10VG ... 28-63 Baureihe/Series 10
RDE 92750-01-R/10.01
ersetzt/replaces 07.97
Mobile Hydraulics
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Hinweis / Inhalt
Notice / Contents
HINWEIS
NOTICE
Bezeichnungen, Beschreibungen und Darstellungen

entsprechen dem Informationsstand zum Zeitpunkt der
Drucklegung dieser Unterlage.
Specifications, descriptions and illustrative material

shown herein were as accurate as known at the time this
publication was approved for printing.
nderungen knnen den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, fr
deren Resultat wir keine Haftung bernehmen knnen.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.
BRUENINGHAUS HYDROMATIK reserves the right to

discontinue models or options at any time or to change
speci-fications, materials, or design without notice and
with-out incurring obligation.
Optional equipment and accessories may add cost to the
basic unit, and some options are available only in
combination with certain models or other options.
Einstell- und Prfarbeiten 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 sicherzustellen.
Adjustment and tests have to be carried out on the test

bench under operating temperatures.
Sachkenntnis, die Voraussetzung fr jede Service-arbeit,

vermitteln wir in unseren Schulungskursen.
Protection of personnel and property has to be guaranteed by appropriate measures.

Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT
CONTENTS
Seite/
Page
A1 0VG
A1 0VG
Schnittbild
Ventile abdichten
Ansteuergerte
Pumpe demontieren
Triebwerk ausbauen
berprfungshinweise
Turcon-Glyd-Ring montieren
Pumpe montieren
Triebwerk einbauen
Pumpe montieren
Montageanweisung fr Anziehdrehmomente
Einstellhinweise
3-4
5
6-8
9
10-12
13
14
15
16
17
18-22
23-25
26
27-28
29-31
32
33-35
36-38
39
40-43
44-45
46-52
Sectional view
Sealing of the regulator valve
Removal of the control unit
Control units
Pump disassembly
Inspection notes
Turcon-Glyd-ring
Assembly guidelines for tightening torques
Safety regulations
Adjustment instructions
204
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Schnittbild
Sectional view

mit Druckabschneidung
with pressure cut-off
HW
ohne Druckabschneidung
without pressure cut-off
HDD
EPD
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Schnittbild

Sectional view
RDE 92750-01-R/10.01
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DA
206
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207

208
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Seal kits and sub-assemblies
Ansteuergert HW
Control unit HW
Ansteuergert HW mit Nullagenanzeige

Control unit HW with zero indicator
alt / old
neu / new
Ansteuergert HD
Control unit HD
alt / old
neu / new
Ansteuergert EP
Control unit EP
alt / old
neu / new
Ansteuergert DA
Control unit DA
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209

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Seal kits and sub-assemblies
Hilfspumpe mit Verschleiplatte

Boost pump with wear plates
1. HD - Ventil
2. HD - Ventil mit Bypass
3. ND - Ventil
1. High pressure valve
2. High pressure valve with bypass function
3. Low pressure valve
Druckabschneidung
Pressure cut-off
3
2
1
1. DA - Regelventil, verstellbar mit Hebel

2. DA - Regelventil, festeingestellt
3. Zuschaltventil
1. DA control valve, adjustable via a lever
2. DA control valve, fixed
3. Switching valve
210
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212
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214
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216
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Wechsel der Dichtmutter.

Einstellma festhalten (*).
Exchanging the sealing nut.
Ascertsion the adjustment dimension (*).
Achtung!
Nach Einbau "Ventileinstellung" berprfen.
Attention!
After assembly check "valve setting".
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217
15

218
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219
Ansteuergerte

Control units
RDE 92750-01-R/10.01
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NG / Size 28
Ansteuergert HW
HW control unit
NG / Size 45
Ansteuergert DA
DA control unit
18
220
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Ansteuergerte
Control units
Ansteuergert HD - EP alt
HD - EP control unit old
HD alt / old
EP alt / old
HD alt / old
EP alt / old
Neues Ansteuergert HD - EP
New HD - EP control unit old
202,0 mm
1 31 ,0 mm
21 4,4 mm
77,4 mm
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221
19
Ansteuergerte

Control units
RDE 92750-01-R/10.01
$9*
Ansteuergert HD neu
HD - control unit new
Ansteuergert EP neu
EP - control unit new
20
222
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223

224
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Pumpe demontieren
Pump disassembly
HD alt/old
EP alt/old
HD neu/new
EP neu/new
Druckabschneidung
Pressure cut-off
DA alt/old
DA neu/new
Excenterschraube
Eccentric screw
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225
23

226
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227

228
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229

230
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232
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234
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236
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238
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240
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242
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243

244
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Montageanweisung fr Anziehdrehmomente
Assembly guidelines for tightening torques
A1 0V - Dsen / orifices
Gewinde /
Thread
M6
M10
Anziehdremomente Nm /
Tightening torques Nm
bisher / up to
neu / new
6,5
28
3
1 2
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43

246
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Einstellhinweise - Mechanische "Nullage"
Adjustment instructions - Mechanical "zero position"
HW
alt / old
alt / old
DA
neu / new
HD
neu / new
EP
alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch
Achtung!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Hinweis:
Totband der Nullage - vermitteln.
Attention!
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.
46
248
%20$*
008 912 53

RDE 92750-01-R/10.01
$9*
Einstellhinweise - Hydraulische "Nullage"
Adjustment instructions - Hydraulic "zero position"
HD neu/new
HW
HD alt/old
Achtung!
beachten!
Attention!
HW mit Nullagenschalter
HW with zero position
switch
EP alt/old
EP neu/new
Manometer an X1 und X2 anschlieen.

Hinweis:
Excenterjustierung
- nicht ber 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.
008 912 53
%20$*
249
47

RDE 92750-01-R/10.01
$9*
Einstellhinweise - ND-Ventil (Speisedruck)
Adjustment instructions - Low pressure valve (Boost pressure)
Achtung!
Attention!
Hinweis:
Nachjustierung nur bei Betriebstemperatur.
Note:
Readjusting only at operating temperature.
Manometer an "G" anschlieen.
Connect pressure gauge to "G".
Achtung!
* Speisedruckeinstellung!
Nenndruck pH - 18 bar
Hchstdruck pH - 40 bar
Bei Max.-Drehzahl.
Attention!
* Boost pressure setting!
Nominal pressure pH - 18 bar
Peak pressure pH - 40 bar
at max. speed.
Hinweis:
Einstelldaten nach Werksauftrag.
Note:
Setting data is in accordance to the works order.
* bei DA-Ausfhrung
* with the DA version
"G"
*
48
250
%20$*
008 912 53

$9*
008 912 53
%20$*
251

252
$9*
%20$*
008 912 53

$9*
008 912 53
%20$*
253

254
$9*
%20$*
008 912 53
7.3
008 912 53
MS/MSE 02 to 18
%20$*
255

256
0606(WR
%20$*
008 912 53

0606(WR
Hydraulikmotoren
Hydraulic motors
MS
Reparaturen
Repairs
02
MS
MSE
05
08
11
18
Strungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
0549
5766
5763
0545
5764
0550
Ref : 800378128J
REPAR MS2-18 D/GB
Rev : A - Avr - 00
008 912 53
POCLAIN HYDRAULICS Industrie

B.P. 106
60411 VERBERIE CEDEX - FRANCE
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 99
www.poclain-hydraulics.com
%20$*
5765
0547
POCLAIN HYDRAULICS
Certifi ISO 9001
257

0606(WR
POCLAIN HYDRAULICS
Dieses Dokument richtet sich an die Hersteller von Maschinen und Systemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren
Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Installationsangaben und den Inbetriebnahmevorgang, damit ihre optimale
Funktionsweise gewhrleistet wird.
Es wird empfohlen, da smtliche Arbeiten von Monteuren mit einer angemessene Ausbildung durchgefhrt werden. Sie mssen die Informationen in diesem Dokument gelesen und verstanden haben und vom
Hersteller der Maschine bevollmchtigt sein.
Selbstverstndlich mssen die Monteure die Richtlinien zur Sicherheit
und zur Unfallverhtung beachten.
Dieses Dokument enthlt wichtige Hinweise zur Sicherheit. Sie werden
auf folgende Weise gekennzeichnet:
This document is provided to machine manufacturers integrating POCLAIN-HYDRAULICS products.. It suggests processes that manufacturers may utilize to repair products after the warranty period.
It is recommended that all operations be performed by technicians
trained accordingly. The technicians should read and understand the
information given in this document and be authorized by the machine
manufacturer.
It is essential that the technicians comply with safety instructions to prevent injury.
This document includes major safety warnings announced in this way:
Sicherheitshinweis.
Dieses Dokument enthlt weiterhin wesentliche Anweisungen zum Betrieb des Produkts sowie allgemeine Informationen. Sie werden auf folgende Weise gekennzeichnet:
Additionally, this document includes instructions essential to product

function as well as those providing general information. Both are announced similar to the following examples:
Essential instruction.
Wesentliche Anweisung.
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht fr Vorflle haftbar gemacht werden, die auf die Anwendung der in diesem Dokument empfohlenen Verfahren zurckgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich fr die Konstruktion
und die Betriebsbedingungen der Maschinen und Systeme, die mit PHProdukten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS weder fr die Folgen eines falschen Einbaus der Produkte noch fr ein falsches Parametrieren einstellbarer Werte, noch fr ungltige oder unvollstndige Gebrauchs- und Wartungsanweisungen, die den Endverbrauchern von den Maschinenherstellern zur Verfgung gestellt worden sind,
verantwortlich.
Jegliche nderung einstellbarer Parameter der PH Produkte kann eine
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HYDRAULICS seinen Kunden, jede Anwendung von POCLAIN HYDRAULICS prfen und freigeben zu lassen.
Das ffnen der Produkte fhrt zum Garantieverlust. Verwenden Sie nur
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von
Teilen anderen Ursprungs knnte den Betrieb des Bauteils und des Systems sowie die Sicherheit beeintrchtigen.
Stets um die Verbesserung seiner Erzeugnisse bemht, behlt sich
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankndigung
alle nderungen vorzunehmen, die als ntzlich fr die in diesem Dokument beschriebenen Produkte bewertet werden.
Dieses Dokument enthlt Abschnitte auf deutsch und kursiv gedruckte Abschnitte, die bersetzung in englischer Sprache darstellen.
Im Zweifelsfall ist die franzsische Version ausschlaggebend.
Die Mae sind in metrischen Einheiten angegeben. Die Entsprechungen
in anderen Mesystemen (vor allem angelschsisch) werden zur Unterrichtung angegeben.
Die Abbildungen haben unverbindlichen Charakter.
POCLAIN HYDRAULICS Industrie 1998.
Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von POCLAIN HYDRAULICS SA.
Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Industrie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftliches Einverstndnis weder gesamt noch teilweise verwendet, vervielfltigt, kopiert oder an Dritte weitergegeben werden.
FACOM ist ein eingetragenes Warenzeichen der FACOM SA.
LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA.
AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
Safety warning.
POCLAIN HYDRAULICS designs products that are integrated by its

customers in the machines they design.
Subsequently POCLAIN HYDRAULICS disclaims liability for consequences of improper integration of its products and of improper set-up
of adjustable devices. In the same way, POCLAIN HYDRAULICS may
not be liable for incomplete or improper operating and maintenance instructions provided to the end user by the machine manufacturer nor for
failures resulting from operations performed by any person using these
suggested procedures.
A re-certification of the machine may be required for every change in
set-up of adjustable devices.
In order to offer the best quality service, POCLAIN HYDRAULICS recommends to its customers to have applications approved by POCLAIN
HYDRAULICS.
Opening of products voids the warranty contract.
Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
from different sources could reduce the performance of the product and
pose a safety hazard..
In accordance with its policy of continuous improvement, POCLAIN
HYDRAULICS reserves the right to modify the specifications of all
products described herein without prior notice.
This document contains sections written in German and sections
printed in italics composing the English translation of the French sections. The French sections will be the reference in case of dispute.
All measures are expressed in metric units. Converted values to other
systems (notably US and UK) are given for reference only.
The illustrations for information only.
POCLAIN HYDRAULICS Industrie 1998.
The trademark POCLAIN HYDRAULICS is the property of POCLAIN
HYDRAULICS S.A.
This document is the property of POCLAIN HYDRAULICS Industrie.
It is strictly confidential. It must not be used, duplicated, copied or disclosed to a third party in full or in part without our prior written consent.
FACOM is FACOM SA registered trademark.
LOCTITE is LOCTITE SA registered trademark.
AUTO-TOP is AGIP SPA registered trademark.
REPAR MS2-18 D/GB
258
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Inhaltsverzeichnis
Contents
INHALTSVERZEICHNIS ............................................. 3
CONTENTS................................................................. 3
SICHERHEIT UND QUALITT ................................... 4
SAFETY AND QUALITY ............................................. 4
VOR DEN W ARTUNGSARBEITEN ....................................... 4

W HREND DER W ARTUNGSARBEITEN............................... 4
NACH DEN W ARTUNGSARBEITEN ..................................... 4
IDENTIFIZIERUNG DES BAUTEILS ....................................... 5
BEFORE SERVICING ........................................................ 4

DURING SERVICING ......................................................... 4
AFTER SERVICING ........................................................... 4
IDENTIFICATION OF THE COMPONENT................................. 5
STRUNGSBESEITIGUNG........................................ 6
TROUBLE SHOOTING ............................................... 7
WARTUNGSARBEITEN.............................................. 8
MAINTENANCE .......................................................... 8
AUSTAUSCHEN DES MOTORS........................................... 8

Ausbau..................................................................... 8
Einbau...................................................................... 8
MECHANISCHE BREMSLSUNG ........................................ 9
KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10
REPLACING THE MOTOR .................................................. 8

Removal................................................................... 8
Installation................................................................ 8
MECHANICAL BRAKE RELEASE .......................................... 9
CHECKING THE PARKING BRAKE EFFICIENCY..................... 10
REPARATUREN. ...................................................... 11
REPAIRS. ................................................................. 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11

Demontage ............................................................ 11
Wiedereinbau......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16
Demontage ............................................................ 16
Wiedereinbau......................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20
Demontage ............................................................ 20
Wiedereinbau......................................................... 23
AUSWECHSELN DES NOCKENRINGS (026)....................... 27
Demontage ............................................................ 27
Wiedereinbau......................................................... 27
AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28
Demontage ............................................................ 28
Wiedereinbau......................................................... 28
AUSWECHSELN DES VERTEILERS (047). ......................... 29
Demontage ............................................................ 29
Wiedereinbau......................................................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32
Demontage ............................................................ 32
Wiedereinbau......................................................... 33
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34
Demontage ............................................................ 34
Wiedereinbau......................................................... 35
REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11

Disassembly........................................................... 11
Reassembly. .......................................................... 13
REPLACEMENT OF THE BEARING SUPPORT (070).............. 16
Disassembly........................................................... 16
Reassembly ........................................................... 18
REPLACING THE BRAKE SHOES....................................... 20
Disassembly........................................................... 20
Reassembly ........................................................... 23
REPLACEMENT OF THE CAM (026) .................................. 27
Disassembly........................................................... 27
Reassembly ........................................................... 27
REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
Disassembly........................................................... 28
Reassembly ........................................................... 28
REPLACEMENT OF THE VALVING (047). ........................... 29
Disassembly........................................................... 29
Reassembly ........................................................... 29
REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32
Disassembly........................................................... 32
Reassembly ........................................................... 33
REPLACING THE SENSOR (OPTIONAL) .............................. 34
Disassembly........................................................... 34
Reassembly ........................................................... 35
WERKZEUG-LISTE .................................................. 36
TOOLING INVENTORY............................................. 36
Standard Werkzeug................................................ 36
Spezialwerkzeuge .................................................. 37
ANZIEHDREHMOMENTE NM 10%........................... 38
ERSATZTEILE.......................................................... 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 0205-08-11-18. .............................................................. 42
MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE
02-05-08-11-18. ......................................................... 44
800378128J
008 912 53
Standard tools ........................................................ 36

Special tools........................................................... 37
TIGHTENING TORQUES IN [LBF.FT] 10% .......... 38
SPARE PARTS LIST ................................................ 39
SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-1118. ............................................................................. 42
DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
REPAR MS2-18 D/GB
%20$*
259

0606(WR
POCLAIN HYDRAULICS
Sicherheit und Qualitt
Safety and Quality
Vor den Wartungsarbeiten
Before servicing
Alle notwendigen Sicherheitsvorkehrungen treffen

(Menschen und Material) und die geltenden Sicherheitsvorschriften beachten.
Parkbremse bettigen und Maschine mit Keilen
festsetzen.
Energieerzeugung (Motor) des Hydrauliksystems
abstellen und die Stromversorgung ausschalten.
Gegebenenfalls eine Sicherheitszone einrichten.
Be extremely careful to prevent personal injury and

to avoid damage to material. Comply with all safety
regulations.
Die Auenflchen der Bauteile reinigen, um

Schmutz und Fett restlos zu entfernen.
Warten, bis das Hydrauliksystem vollstndig abgekhlt und druckentlastet ist (die Speicher entlasten).
Wash dirt and grease from exterior of the components.
Das heie oder unter Druck stehende l

kann zu schweren Verbrennungen mit
Entzndung fhren.
Bei einem Unfall einen Arzt hinzuziehen.
Hot or pressurized hydraulic fluid may

cause serious burns & infections to the
human body.
Consult a physician in case of accident.
Apply the parking brake and prevent the machine

from rolling with tire blocks.
Stop the hydraulic system power source (engine)
and disconnect the battery.
If necessary, block off the safety area.
Await the complete cooling down and depressurization of the hydraulic system (accumulators must be
purged).
Whrend der Wartungsarbeiten
During servicing
Bestimmte Bauteile sind sehr schwer. Sie mssen

bei der Abnahme vom Rahmen mit einer angemessen
ausgelegten Hebevorrichtung gehalten werden.
Die Sauberkeit ist wesentlich beim Betrieb der Hydraulikbauteile. Die meisten Teile knnen mit einem
sauberen Lsungsmittel gereinigt werden.
Whrend der Handhabung alle empfindlichen Oberflchen gegen Ste schtzen (Zentrierungen, gleitende
Teile, Auflagen, Dichtungs- und Lagerauflagen usw.).
Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity
when removing from the machine frame.
Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned
with a clean solvent.
During handling, protect all sensitive surfaces from
shocks (piloting and interface surfaces, thrust & bearings surfaces, seal races, etc...)
Diese Flchen vor dem Wiederzusammenbau reinigen.

Systematisch die demontierten Dichtungen beim
Wiederzusammenbau durch neue ersetzen. Wir empfehlen, vor der Montage alle Dichtungen zu fetten.
Always install new O-rings, seals & gaskets discarding the old ones. We recommend lubricating all
seals prior to assembly.
Alle gleitenden Flchen durch Aufbringen eines Films

sauberer Hydraulikflssigkeit len, der eine korrekte
Schmierung beim ersten Neustart gewhrleistet.
Lubricate all surfaces which have relative motion

between parts by coating them with a film of clean hydraulic fluid to assure lubrication at first start.
Niemals die Hydraulikflssigkeit, die sich bei hohen

Temperaturen entznden kann, erwrmen. Einige Lsungsmittel sind ebenfalls entzndlich.
Never heat hydraulic fluid, as it may flame at high

temperature. Some solvents are also flammable.
Whrend der Arbeiten nicht rauchen.
Do not smoke during servicing.
Nach den Wartungsarbeiten
After servicing
Die Bauteile wieder einbauen und das Hydrauliksystem

gem den Anweisungen in den folgenden Dokumenten wieder in Betrieb nehmen:
INSTALLATION MS D/GB (ref: 800078173V)
INSTALLATION CIRCUITS D/GB (ref. 677777853U)
Reinstall the components and restart the hydraulic

system according to instructions defined in the following
documents:
INSTALLATION MS F/GB (ref. 677777844K)
!
4
Clean up these surfaces before reassembling.
INSTALLATION CIRCUITS F/GB (ref. 677777831V)
Die Einstellung der Sicherheitsventile

nicht erhhen.
REPAR MS2-18 D/GB
260
%20$*
Do not overset relief valves.
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Identification of the component
Identifizierung des Bauteils
MS18-2-D11-F19-2A10-K000
B
D
000143896J
C
40712
001
0349
A : Handelsbezeichnung:
Ex : MSE18-2-D11-F19-2A10-K000
A: Commercial description:
E.g : MSE18-2-D11-F19-2A10-K000
B : Code : Artikelnr.:
Ex : 000143896J
B: Code: Part number.

E.g : 000143896J
C : Serie : Herstellungsnummer
Ex : 001
C: Series: Manufacturing batch number.

E.g : 001
D : Num : Chronologische Ordnungsnummer

Ex : 40712
D: Num: Chronological serial number.

E.g : 40712
Bei smtlichen Ersatzteilbestellungen

mssen die Artikelnummer und die chronologische Ordnungsnummer angegeben werden.
800378128J
008 912 53
The part number and the chronological

serial number must be specified to order
spare parts.
REPAR MS2-18 D/GB
%20$*
261

0606(WR
POCLAIN HYDRAULICS
Strungsbeseitigung
BECHDIGUNG ABRIEB ERKENNUNG DURCH FILTER VORBEUGUNG
Strung
Ursachen
Ohne
Last
LAUTE
GERUSCHE DES
MOTORS
Unter
Last
MOTOR DREHT SICH

NICHT
DER MOTOR DREHT

SICH NICHT MIT
NORMALER LASTDREHZAHL
DER MOTOR DREHT

SICH UNREGELMSSIG
USSERE LUNDICHTIGKEITEN
Regelmiges
Brummen
Lagerteil verschlissen
Lagerteil ersetzen
Vibrationen
Lockere Befestigungen
und / oder Anschlsse
Mit entsprechendem Drehmoment anziehen
Klappern
Speisedruck zu niedrig
Speise- und Austauschdruckventil kontrollieren.
Kavitation
Interne Lecks zu gro
Zylinderblock und lverteiler

ersetzen
Der Motor wird nicht versorgt
Den Antrieb der Pumpe und ihre Versorgung berprfen
Kein Druckanstieg im
Kreis
Hochdruck-Begrenzungsventile
kontrollieren (Regler)
Zylinderblock und lverteiler

ersetzen
Die Bremse bleibt angezogen
Den Steuerkreis der Bremse

kontrollieren
Der Frdermenge der

Pumpe ist unzureichend
Die Antriebsdrehzahl und den

Zustand der Pumpe kontrollieren
Den Zustand des Zylinderblocks und des lverteilers

berprfen
Der Betriebsdruck ist zu

niedrig
Den Zustand des Sicherheitsventils kontrollieren (Regler)
Die Frdermenge der

Pumpe schwankt
Steuerdruck und Frdermenge

der Pumpe kontrollieren
Den Zustand des Zylinderblocks und des lverteilers

berprfen.
Gehusedruck zu gro
Den Leckagekreis und den Zustand des Filters berprfen
Dichtungen beschdigt
Die Dichtungen ersetzen
Fehlerhafte Montage
Das Anziehmoment der Montageschrauben, der Entlftungsschrauben und der Anschlsse

kontrollieren
REPAR MS2-18 D/GB
262
Abhilfe
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Trouble shooting
DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION
Troubles
Causes
Without
load
Regular rumbling
Worm bearing support
Replace the bearing support
Vibrations
Mountings and/or hydraulic

piping becoming loose
Tighten to torque
Clattering
Boost pressure too low
Check the setting and condition of counter-pressure valve
Cavitation
Excessive internal leaks
Replace the cylindersblock

and distribution valve assembly
No supply to the motor
Check pump drive and pump

inlet
The circuit does not reach

working pressure
Check condition of safety

valve (regulator)
Replace the cylinders block

and distribution valve assembly
The brake stays engaged
Check the brake pilot circuit
Pump flow is too low
Check drive speed and condition of the pump
Check condition of cylindersblock and distribution valve

assembly
Working pressure is too

low
Check safety valve setting

pressure (regulator)
Irregular flow
Check the pump flow
Excessive leaks
Check condition of cylindersblock and distribution valve

assembly
Too high casing pressure
Check the leakage circuit and

filter condition
Seals damaged
Replace seals
Incorrect assembling
Check tightening of mounting

screws, bleed screws and
unions
NOISY MOTOR
Under load
THE MOTOR DOES

NOT REVOLVE
THE MOTOR DOES

NOT REVOLVE AT
ITS NORMAL SPEED
UNDER LOAD
THE MOTOR REVOLVES IRREGULARLY
EXTERNAL OIL
LEAKS
800378128J
008 912 53
Remedies
REPAR MS2-18 D/GB
%20$*
263

0606(WR
POCLAIN HYDRAULICS
Wartungsarbeiten
Maintenance
Austauschen des Motors
Replacing the motor
Ausbau
Removal
Druck im Arbeitskreis abbauen.

Leckageleitung am Tank abschrauben, um ein
Leerlaufen zu verhindern.
Die Rohre oder Schluche, die am Motor angeschlossen sind, abklemmen.
Drehzahlsensor abklemmen.
Die Befestigungsschrauben demontieren und den
Motor ausbauen.
Das Motorgehuse entleeren.
Einbau
Die zum Ausbau angegebenen Arbeitsgnge in umgekehrter Reihenfolge ausfhren.
Fr weitere Informationen beziehen Sie sich bitte auf
folgende Dokumente:
INSTALLATION MS D/GB (ref: 800078173V)
INSTALLATION CIRCUITS D/GB (ref: 677777853U)
Release the pressure in the supply circuit.

Disconnect the drain line at the tank level to avoid
its siphoning.
Disconnect and plug the pipes or hoses which are
connected to the motor.
Disconnect the speed sensor.
Disconnect the mounting screws, and remove the
motor.
Drain the casing.
Installation
Execute the removal operations in the reverse order.
Please refer to the following documentation brochures:
INSTALLATION MS F/GB (ref: 677777844K)

INSTALLATION CIRCUITS F/GB (ref: . 677777831V)
REPAR MS2-18 D/GB
264
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Mechanische Bremslsung
Mechanical brake release
Bei bestimmten Reparaturfllen

oder zum Abschleppen der Maschine mu die integrierte Parkbremse
gelst werden.
In certain service situations, it may

be necessary to release the motor
brake.
Stopfen (142) aus der Schutzkappe (141) herausziehen.
Extract and release the plug

(142) from the brake cover (141).
142
6499
Schraube im Kolben festziehen
Tighten the screw in the piston
6556
Mutter so weit anziehen, bis die

Welle frei dreht.
And tighten the nut until the

motor shaft turns freely.
6555
Force [lbf]
F02-F04
18000
[4.000]
42
[30.9]
M12
F05-F07
20000
[4.500]
47
[34.6]
M12
F08
34000
[7.600]
110
[81.1]
M16
F11
45000
[10.000]
140
[103]
M16
F12
45000
[10.000]
140
[103]
M16
F19
45000
[10.000]
140
[103]
M16
Brakes
Entsprechendes
Drehmoment Nm
Kraft N
Bremsen
Nach Bremslsung, einen neuen Stopfen

(142) einbauen.
800378128J
008 912 53
Equivalent torque [lbf.ft]
Mutter Nut
After brake release, mount a new plug

(142).
REPAR MS2-18 D/GB
%20$*
265

0606(WR
POCLAIN HYDRAULICS
Checking the parking brake efficiency.
Kontrolle der statische Haltebremse.
Bei fahrbaren Maschinen den Test auf ebenem

Grund durchfhren.
Bremssteuerdruck:
For a rolling machine, make the test on a horizontal ground.
Pilot brake pressure : minimum 12 bar [174 PSI]

Maximum 30 bar [435 PSI]
mini 12 bar
Maxi 30 bar.
Sich vergewissern, da der Bremsversorgungsdruck gleich Null ist,

Die Bremse ber die hchstgelegene Schraube
(112) entlften,
Den Motor mit Maximaldruck beaufschlagen,
Purge the brake using the screw (112) located at

the highest level,
Supply the motor up to the setting pressure.
Die Motorwelle darf sich nicht drehen, da andernfalls die Bremse ausgetauscht werden mu :
The motor shaft must not turn, otherwise it is necessary to replace the brake :
10
Make sure that the brake supply pressure is zero,
Mehrscheibenbremsen nicht einfahren.
REPAR MS2-18 D/GB
266
%20$*
Do not run multidisc brakes in.
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Repairs.
Reparaturen.
Auswechseln der
kolbendichtung
Brems-
Replacement of the O-ring

of the brake piston.
Demontage
Disassembly
Remove the motor.

Place the motor on the bearing
support.
Den Motor ausbauen.

Motor auf das Lagerteil stellen.
Muttern zum Schutz der

Gewindebolzen wieder
aufsetzen
Schutzkappe (141) abnehmen

und beseitigen.
Protect the studs by

reinstalling the nuts
Remove and discard the brake

cover.(141)
141
6500
O-Ring (143) herausziehen und

beseitigen.
Extract and discard the O-ring

(143).
143
6501
Tellerfeder (108) zusammendrcken:
Compress the washer (108).
Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite

36) (fig 6502)
Mit Hilfe des Dorns und einer
Schraube Klasse 12.9 (siehe
Werkzeug Seite 36)
Presse (fig 6503). Die Kraft F
beibehalten (siehe Schaubild
Seite 9)
Using a mandrel and an extractor (see tools page 36)

(fig 6502)
Using a mandrel and a
screw class 12.9 (see tools
page 36)
Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9)
Einsatzrichtung des Sicherungsrings markieren.
Mark the mounting direction of the snap ring.
6502
6503
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
11
267

0606(WR
POCLAIN HYDRAULICS
Sicherungsring (109) mit Hilfe
einer Zange fr Innenringe herausnehmen (siehe Werkzeuge Seite
36)
Remove the snap ring (109)

using internal snap ring pliers. (see
tools page 36)
Extractor and pliers (fig 6504
and 6505)
Press and pliers (fig 6506
and 6507)
Abzieher und Zange (fig

6504 und 6505)
Presse und Zange (fig 6506
und 6507)
Bei Verwendung der Presse das Lagerteil nicht auf

den Gewindebolzen absttzen.
Tellerfeder (108) herausziehen.
6504
6505
6506
6507
If you use the press do

not place the bearing
support on the studs.
Extract the washer (108).
108
6508
Bremskolben (107) herausziehen.
Extract the brake piston (107)
6513
O-Ring (106) beseitigen.
Discard the O-ring (106).

106
6511
12
REPAR MS2-18 D/GB
268
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Wiedereinbau.
Vor dem Wiedereinbau ist unbedingt
sicherzustellen, da alle Teile, Nuten
und Dichtungs-Auflageflchen sauber
sind.
Reassembly.
Before reassembling, it is necessary to ensure that all parts, the
surface condition of the piston seal
contact surface and the grooves are
clean.
Es drfen keine Rost-,

Schmutz- oder Wasserspuren vorhanden sein
Mit Korrosionsschutzfett (siehe

Werkzeug Seite 36) einschmieren:
die Nut, die obere Flche des
Bremskolbens, die Tellerfeder, den
Sicherungsring und die Auflageflche
der Kolbendichtung im Bremsgehuse.
All traces of rust, mud,

water must be removed.
Neuen O-Ring (106) auf den

Kolben (107) montieren.
Coat with anti-oxidizing grease (see

tools page 36), the grooves, the top
of the brake piston, the spring
washer, the snap ring and the piston seal contact surface in the
brake body.
Install a new O-ring (106) on
the piston (107).
Der Ring mu fest an

den Kolben gepret und
nicht verdreht werden.
The ring should be tight

on the piston and not
twisted.
106
6512
Bremskolben (107) einsetzen.
Achtung,
wenn
die
Dichtung ber die Nut
des
Sicherungsrings
gefhrt wird.
Install the brake piston (107).
Take care when passing

the seal over the snap
ring groove.
107
6509
Tellerfeder
(108)
einlegen.
Install the spring washer (108).
108
6513
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
13
269

0606(WR
POCLAIN HYDRAULICS
Tellerfeder (108) zusammendrcken:
Compress
(108).
the spring washer
Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite

36) (fig 6502)
Presse (fig 6503). Die Kraft F
einbehalten (siehe Schaubild
Seite 9)
Using a mandrel and an extractor (see tools page 36)

(fig 6502)
Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9)
Bei Verwendung der

Presse das Lagerteil
nicht auf den Gewindebolzen absttzen.
If you use the press do

not place the bearing
support on the studs.
6502
6503
Sicherungsring (109) mit Hilfe

einer Zange fr Innenringe gem
der bei der Demontage angebrachten Kennzeichnung montieren: (siehe Werkzeuge Seite 36)
Abzieher und Zange (fig
6504 und 6505)
Presse und Zange (fig 6506
und 6507)
Install the snap ring (109) using

internal snap ring pliers in line with
the mark made during disassembly
. (see tools page 36)
6504
Extractor and pliers (fig 6504

and 6505)
Press and pliers (fig 6506
and 6507)
6506
Neuen, mit Korrosionsschutzfett

eingeschmierten O-Ring (143) in
die Nut einsetzen (siehe Werkzeuge Seite 36).
Install a new O-ring (143)

coated with anti-oxidizing grease in
its groove. (see tools page 36)
6505
6507
143
6515
Neue Schutzkappe (141) auf

den Anschnitt legen.
Place the new cover (141) on

the entry chamfer .
141
6516
14
REPAR MS2-18 D/GB
270
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Schutzkappe mit Hilfe des
Dorns einrasten lassen (siehe
Werkzeug Seite 36).
Click the cover into place using

the right mandrel. (see tools page
36).
Sich vergewissern, da
der Auenrand
des
Schutzkappe in die Nut
eingreift ist.
Make sure that the outer

edge of the cover is engaged in the groove.
6517
Neuen Stopfen (142) einsetzen.
Sich vergewissern, da
zwischen Schutzkappe
und Stopfenrille einwandfreier Kontakt besteht.
Install a new plug (142).
Make sure about the contact between the cover

and the plug groove.
142
6518
Motor wieder einsetzen.
800378128J
008 912 53
Install the motor.
REPAR MS2-18 D/GB
%20$*
15
271

0606(WR
POCLAIN HYDRAULICS
Auswechseln
teiles (070)
des
Lager-
Replacement of the bearing

support (070)
Demontage
Disassembly
Motor herausnehmen.
Motor auf der Bremse oder Verschlussplatte absttzen (Motor ohne
Bremse).
Remove the motor.

Place the motor on the brake or on
the end cover (motor without
brake).
Position des Lagerteiles

(070) in Bezug auf Nockenring
(026) und Verteilerdeckel (040)
kennzeichnen.
Mark the position of the

bearing support (070) in relation to
the cam (026) and to the valving
cover (040).
070
025
040
Schrauben
nehmen.
(042)
heraus-
6519
Remove the screws (042).
042
6520
Lagerteil (070) herausnehmen.
Remove the bearing support

(070).
070
6521
Nockenring
nehmen.
(026)
heraus-
Remove the cam (026).

026
6524
16
REPAR MS2-18 D/GB
272
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
O-Ring (027) vom Verteilerdeckel (041) entfernen.
Discard the O-ring (027)

from the valving cover (041).
027
041
6525
O-Ring (027) vom Lagerteil

(071) entfernen.

from the bearing support (071)
027
071
6522
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
17
273

0606(WR
POCLAIN HYDRAULICS
Wiedereinbau
Reassembly
Vor dem Wiedereinbau ist unbedingt sicherzustellen, da die Nut

sauber ist
Before reassembling it is necessary

to ensure that the groove is clean

Schmutz- oder Wasserspuren vorhanden sein.

water must be removed
Neuen,
mit
Korrosionsschutzfett eingeschmierten O-Ring
(027) in die Nut des Lagerteiles
(071) einsetzen (siehe Werkzeuge
Seite 36) .

coated with anti-oxidizing grease
(see tools page 36) in the groove of
the bearing support (071).
027
071
6523
Neuen,
mit
Korrosionsschutzfett eingeschmierten O-Ring
(027) in die Nut des Verteilerdekkels (041) einsetzen (siehe Werkzeuge Seite 36) .

coated with anti-oxidizing grease
(see tools page 36) in the groove of
the valving cover (041)
041
6525
Nockenring (026) gem der

bei der Demontage markierten
Kennzeichnung montieren.
Groe Ansenkungen in
Richtung Lagerteil
Den Nockenring anhand von zwei

einander
gegenberliegenden
Schrauben (042) zentrieren.
18
Install the cam (026) in line

with the marks made during disassembling.
The big chamfers oriented

towards bearing support
Center the cam using two screws

(042) diametrically opposite.
REPAR MS2-18 D/GB
274
026
%20$*
6526
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Lagerteil montieren
Bei
Wellenmotoren
mssen die Anschlsse
quer zur Einbauachse
des
Motors
liegen.
(Abb. 6521)
Install the bearing support

For shaft motors the
ports must be perpendicular to the mounting
axis of the motor. (Fig
6521)
6521
A
6527
Befestigungsschrauben (042)
einsetzen und mit dem angegebenen Drehmoment anziehen. (siehe
Schaubild Seite 38).
Install and tighten the mounting

screws (042) to the right torque.
(see table page 38).
042
6520
Motor wieder einsetzen.
800378128J
008 912 53
Install the motor.
REPAR MS2-18 D/GB
%20$*
19
275

0606(WR
POCLAIN HYDRAULICS
Auswechseln der
backen
Brems-
Vor der Demontage kann man die

Abnutzung der Bremsbelge durch
die Inspektionsffnungen kontrollieren.
Replacing the brake shoes.
Before disassembling it is possible

to make a visual checking of the
brake pads wear via the inspection
ports.
2055
Demontage
Disassembly
Das Auswechseln des

Bremsbacken und das
Schleifen der Trommeln
mu auf allen Motoren
der gleichen Achse vorgenommen werden.
The
same
repairs
should be made on
each motor of the same
axle when replacing
shoes
and
brake
drums.
Befestigungsmuttern der Felge

lsen.
Maschine auf der Hhe der
auszubauenden Felge hochheben.
Rad abnehmen (Reifen).
Mechanische Bremse lsen.
Loosen the wheel rim retaining

nuts.
Raise the machine on the side
of the wheel rim to be removed.
Remove the wheel rim (tyre).
Release the mechanical brake.
Trommel (096) abziehen.
20
Reibflche der Trommel

berprfen, die weder tiefe
Rillen (tiefer als 0,2 mm)
noch abnormale Abnutzungserscheinungen aufweisen darf, sonst mu
sie geschliffen werden.
(Ra 1,6 bis 3,2)
Extract the drum (096).
Check the friction surface condition of the

drum which should show
no
deep
scratches
(deeper than 0,2 mm
[0.0078 in]) nor abnormal
wear. Otherwise, the
brake drum should be
replaced. (Ra 1.6 to 3.2)
REPAR MS2-18 D/GB
276
%20$*
096
6528
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Rckholfeder (154.a) abbauen.
Remove
(154.a).
the
return
spring
154.a
6529
6530
Halterungsfedern (154.b) abbauen.
Remove the retention springs

(154.b).
154.b
2
6531
Bremsbacken aus der Bettigungsvorrichtung lsen.
Release the brake shoes from

the regulating mechanism.
6532
Rckholfedern (154.c) abbauen.
Remove
(154.c).
the
return
springs
154.c
6533
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
21
277

POCLAIN HYDRAULICS
Bremsbacke (154.1) abbauen.
0606(WR
Remove the brake shoe (154.1)
154.1
6534
Den mechanischen Bremshebel

vom Bremsseil lsen und Bremsbacke (154.2) entfernen
Releasing the mechanical brake

control lever from its cable, remove
the brake shoe (154.2)
154.2
6535
6536
22
REPAR MS2-18 D/GB
278
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Wiedereinbau
Vorrichtung
entstauben, sich vergewissern,
da der Radzylinder
dicht ist.
Reassembly
Remove all dust from the

whole assembly. Make
sure there are no leaks at
the wheel cylinder.
Reibflche der Trommel berprfen, die weder tiefe Rillen (tiefer als
0,2 mm) noch abnormale Abnutzungserscheinungen
aufweisen
darf, sonst mu sie geschliffen
werden.
Check the friction surface condition

of the drum which should show no
deep scratches (deeper than 0.2
mm) [0.0078in] nor abnormal wear.
Otherwise, the brake drum should
be replaced.
Den Bremshebel am Bremsseil

(098) befestigen und Bremsbacke
(154.2) einbauen
Attaching the control lever on

the brake cable (098), install the
brake shoe (154.2)
6549
098
154.2
6536
6535
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
23
279

POCLAIN HYDRAULICS
Rckholplatte an die Bremsbacke (154.2) montieren.
0606(WR
Mount the return plate on the
brake shoe (154.2)
6537
6538
Bremsbacke (154.1) einsetzen.
Install the brake shoe (154.1)
6539
Bremsbacken auf der Bettigungseinrichtung positionieren.
Position the brake shoes on the

regulating mechanism.
6532
Rckholfedern (154.c) einsetzen.
Install the return springs (154.c)
154.c
6533
24
REPAR MS2-18 D/GB
280
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Bremsbacken in die Bettigungseinrichtung einbauen.
Install the brake shoes in the

regulating mechanism
6532
Halterungsfedern (154.b) einsetzen.
Install
(154.b).
the
retention
springs
1
154.b
2
Rckholfedern (154.a) einsetzen.
6531
Install the return spring (154.a).
154.a
6530
Reibungsdurchmesser D der
Trommel und der eingesetzten Backen messen.
Measure the brake drum friction

diameter D and that of the brake
shoes, which have been installed.
Durchmesser D diameter
6529
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
25
281

0606(WR
POCLAIN HYDRAULICS
Backendurchmesser anpassen,
um bei Bremsen mit mechanischer
Einstellvorrichtung mit Hilfe des einen Zahnrads (156.1), oder bei
Bremsen mit automatischer Bremsennachstellung mit Hilfe der zwei
Zahnrder (156.2 und 156.3), das
ntige Spiel zwischen Belag und
Trommel zu erzielen. In diesem
Fall mu die Wirkung auf die Zahnrder symmetrisch (a) sein. Den
Hebel (156.4) muss zu diesem
Zweck freigngig sein.
Bremsen
Brake
250 x 60
270 x 60
325 x 80
350 x 60
Adjust the brake shoes diameter to obtain correct clearance between the brake padding and the
drum using the adjusting wheel
(156.1) for brakes equipped with
mechanical adjustment system or
two adjusting wheels (156.2 and
156.3) for brakes equipped with
automatic clearance adjustment. In
this case, the adjusting wheels
should be adjusted symmetrically
(a). Release the lever slightly
(156.4) to enable this operation to
take place.
Trommeldurchmesser (mm)
Drum diameter [in]
nominal
maximum
250 [9.84]
252 [9.92]
270 [10.63]
272 [10.70]
325 [12.79]
350 [13.78]
327 [12.87]
352 [13.85]
Trommel aufsetzen und berprfen, ob sie frei dreht.
1 5 6 .4
1 5 6 .2
1 5 6 .3
6540
Total Spiel (mm)

Total clearance [in]
0.55 [0.02]
0.80 [0.03]
0.80 [0.03]
0.80 [0.03]
Install the drum, check that it

can turn freely.
6528
Wenn ntig, den Radzylinder

entlften.
Felge montieren.
Siehe Dokument INSTALLATION
MS D/GB (ref: 800078173V)
26
Bleed the wheel cylinder, if

necessary.
Install the wheel rim.
See documentation INSTALLATION
MS F/GB (ref 677777844K )
REPAR MS2-18 D/GB
282
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Auswechseln des Nockenrings (026)
Replacement of the cam

(026)
Demontage
Dazu die im Kapitel Auswechseln
des Lagerteils unter Demontage
beschriebenen Arbeiten ausfhren,
Seite 16
Wiedereinbau
des Lagerteils unter " Wiedereinbau " beschriebenen Arbeiten ausfhren, Seite 18.
Allerdings mu bei Motoren mit 2
Schluckvolumen
mit
einem
Schluckvolumenverhltnis
ber
oder unter 2 die Winkelposition bercksichtigt werden.
Beispiel: Motor MS18, Schluckvolumen 1747-1049-698
3
Kleines Schluckvolumen: 698 cm
Buchstabe P
3
Mittleres Schluckvolumen: 1 049 cm
Buchstabe M
Die Buchstaben P oder M mssen
sich in der Achse befinden und in
Richtung des Schiebers fr das
Wechseln des Schluckvolumens
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
Disassembly
Do operations described in chapter
"replacement of the bearing support" section "disassembly" page 16
Reassembly
"replacement of the bearing support" section "reassembly" page 18.
The angular position of the cam
must be respected on dual displacement motors with a displacement ratio different from 2.
Example : Motor MS18 with displacement 1747-1049-698.
3
Small displacement : 698 cm
[42.59 cu.in] letter P
3
Medium displacement : 1049 cm
[64.01 cu.in] letter M.
The letter P or M must be located in
the axis and towards the displacement change spool, with the blind
hole towards the fixing of the cam
on the bearing support.
M
M
MS08
MSE08
A
R A
MS18
MSE18
MS11
MSE11
R A
800378128J
008 912 53
2035
REPAR MS2-18 D/GB
%20$*
27
283

0606(WR
POCLAIN HYDRAULICS
Auswechseln des kompletten Zylinderblocks (010)
Replacement of the cylinders block assembly (010)
Demontage
Disassembly

des Lagerteils unter Demontage
beschriebenen Arbeiten ausfhren,
Seite 16

"replacement of the bearing support" section "disassembly" page 16
Nach Demontage des Nockenrings den Zylinderblock ausbauen.
After removing the cam, remove the cylinders block.
6541
Wiedereinbau
Reassembly
Neuen O-Ring (027) einsetzen.
Install a new O-ring (027).
6542
Kompletten Zylinderblock (010)

einsetzen.
Install the cylinders block assembly (010).
6541
Dazu
die
im
Kapitel
Auswechseln des Lagerteils unter
"Wiedereinbau" beschriebenen Arbeiten ausfhren, Seite 18
28
Do operations described in
chapter "replacement of the bearing
support" section "reassembly" page
18
REPAR MS2-18 D/GB
284
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Auswechseln des Verteilers

(047).
Replacement of the valving

(047).
Demontage
Disassembly
Dazu
die
im
Kapitel
Auswechseln des kompletten Zylinderblocks
(010)
unter
Demontage beschriebenen Arbeiten ausfhren, Seite 28.
chapter "replacement of the cylinders bloc assembly (010)" section
"disassembly" page 28.
Position des Verteilers

(047) in Bezug auf Verteilerdeckel (041) kennzeichnen. (Motor mit 2
Hubvolumen).
Mark location to the

valving (047) in relation
to the valving cover
(041) (Dual displacement motor).
Den Verteiler (047) durch Anheben an den Ausrichtungszapfen

oder am Flansch vom Verteilerdekkel (041) abmontieren.
Separate the valving (047) from

the cover (041) by levering at the
indexing pins or at the flange.
2031
Den Verteiler vor Staub

schtzen.
Protect the valving from

dusts.
Federn (052) ausbauen.

Dichtungen und Gegendichtungen (048) vom Verteilerdeckel
(041) herausziehen und beseitigen.
Remove the springs (052).

Remove and discard the seals
and back-up rings (048) from the
cover (041).
Wiedereinbau
Reassembly

Schmutz- oder Wasserspuren vorhanden sein.
Neue Dichtungen und Gegendichtungen (048) len und einsetzen; dabei die Gegendichtungen so
wenig wie mglich verformen.

water must be removed.
Lubricate and install new seals

and back-up rings (048), ensuring
the back up rings are twisted as little as possible.
1135
Die Federn (052) in ihr zuvor

mit Fett geflltes Gehuse einsetzen.
Die
Dichtungsauflageflchen
des Verteilers (047) fetten.
Den Verteiler(047) in den Verteilerdeckel (041) drcken
800378128J
008 912 53
Place the springs (052) in their

housings, previously filled with
grease.
Lubricate the faces of the seals
of the valving (047).
Press the valving (047) into the
cover (041).
REPAR MS2-18 D/GB
%20$*
29
285

0606(WR
POCLAIN HYDRAULICS
Die Einbaurichtung des

Verteilers (047) in bezug
auf den Verteilerdeckel
(041) beachten).
Den Einsatz des Verteilers (047) in den Verteilerdeckel (041) nicht

forcieren.
Respect the assembly

sense of the valving
(047) in relation to the
cover (041).
Do not force when installing

the
valving
(047) into the cover
(041).
Montage der Verteilerausfhrung 1C (konstanter

Hubvolumen).
Valving assembly type single displacement motor.
Keine besondere Montagerichtung.
No particular assembly sense.

041
047
Montage der Verteilerausfhrung

2C
(umschaltbarer
Hubvolumen).
Valving assembly type Dual

displacement motor.
Den gewhlten Buchstaben, der

die Drehrichtung anzeigt, gegenber dem Steuerkolben (053) anordnen.
Write the chosen letter indicate

the rotation sense in front of the
displacement change spool (053).
POSITIONIERUNG DES VERTEILERS

G/L Links
VALVING POSITIONING
2031
G/L Left
041
R
047
L
053
6758
R
053
3 2 2 7
30
REPAR MS2-18 D/GB
286
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
D/R Right
D/R Rechts
047
R
041
L
6757
A
053
3 2 2 8
Falls kein Buchstabe vorhanden

ist, die Ausrichtung anhand der beim
Ausbau festgelegten Markierungen
vornehmen.
If there is no letter, do the indexing according to the marks

made during disassembly.
Dazu
die
im
Kapitel
Auswechseln des kompletten Zylinderblocks
(010)
unter
Wiedereinbau beschriebenen Arbeiten ausfhren, Seite 28.
chapter "replacement of the cylinders block" section "reassembly"
page 28.
Motoren SE02 und S05
Situation of SE02 and S05 motors
SE02 Motor :
SE02 motor :
D/R Rechts
D/R Right
G/L Links
G/L Left
6959
6 9 5 9
S05 Motor :
S05 motor
G/L Links
G/L Left
D/R Rechts
D/R Right
053
6 9 4 8
6948
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
31
287

0606(WR
POCLAIN HYDRAULICS
Auswechseln der Deckeldichtung (045)
Replacement of the O-ring

(045) of the end cover
Demontage
Disassembly
Motor auf Lagerteil stellen

(Muttern sind zum Schutz der Gewindebolzen aufgesetzt)
Schrauben (066) herausnehmen.
Place the motor on the bearing

support (fitted with nuts for studs
protection)
Remove the screws (066)
066
6543
Verschlussplatte abnehmen.
Remove the end cover
6544
O-Ring (045) entfernen.

045
057
6545
Wenn Motor mit 2 Hubvolumen, O-Ring (057) entfernen
Discard the O-ring (057) if the

motor has 2-displacement
6546
32
REPAR MS2-18 D/GB
288
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Wiedereinbau
Reassembly
Install
Neuen O-Ring (045) einsetzen.
new
O-ring
(045).
6547
Wenn Motor mit 2 Hubvolumen, neuen O-Ring (057) einsetzen, andernfalls zum nchsten
Schritt bergehen
Install a new O-ring (057) if the

motor has 2-displacement. If not go
to the next section
6548
Verschlussplatte montieren.
Install the end cover
6544
Schrauben (066) einsetzen und

mit entsprechendem Drehmoment
anziehen (siehe Schaubild Seite 38)
Install and tighten the screws

(066) to the right torque (see table
page 38)
6543
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
33
289

0606(WR
POCLAIN HYDRAULICS
Auswechseln des Drehzahlsensors (Option)
Replacing the sensor (optional)
Demontage
Disassembly
Disconnect
(161.3)
Stecker (161.3) abziehen
the
connector
6550
Schraube (165) aufschrauben

und ausbauen
Unscrew and remove the screw

(165)
165
6551
Sensor (161) mit dem Trger

(166) abziehen
Extract the sensor (161) with its

support (166)
166
161
6552
34
REPAR MS2-18 D/GB
290
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Reassembly
Wiedereinbau
Der Dichtung (164) auf

Sauberkeit der Auflageflche dem Verteilerdeckel (041) prfen.
Make sure that the seal

mounting surface (164)
on the valving cover
(041) is clean.
Neuen Haltering (163) und

neue Dichtung (164) auf den Sensor (161) mit seiner Distanzscheibe
(167) schieben.
Install the new brake washer

(163) and the new seal (164) on the
sensor (161) fitted with its adjusting
sticker (167).
Den Sensor in die Halterung

(166) stecken, so da die Dichtung
(164) korrekt in ihrer Aufnahme
sitzt.
Push the sensor assembly into

the support (166) until the seal
(164) is in its housing.
6552
Sensor (041) in die Bohrung

des Verteilerdeckels bis zum Kontakt mit dem Zylinderblock (011)
schieben.
Push the sensor into the valving

cover (041) until it comes in contact
with the cylinders block (011),
2064
Die Kerbe im Steckeranschluss des

Sensors muss radial zur Mitte des
Motors (Richtung Welle) zeigen.
the notch of the sensor should be

oriented towards the center of the
motor.
1 5 m a x i
1 5 m a x i
6558
Schrauben (165) einsetzen und

mit entsprechendem Drehmoment
anziehen (siehe Schaubild Seite
38)
Install and tighten the screw

(165) to the right torque (see table
page 38)
6551
Stecker
schlieen.
(161.3)
wieder
an-
Reconnect
(161.3).
the
connector
6550
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
35
291

0606(WR
POCLAIN HYDRAULICS
Tooling inventory
Werkzeug-Liste
Standard tools
Standard Werkzeug
Innensechskant-Schlssel
Ring-/Maulschlssel fr
Sechskantschraube
Hollow head
wrench
5 6 8 10 12 14
Hex head wrench
13 17 19 22 24
Drehmoment-Schlssel
FACOM J 250 A
Drehmoment-Schlssel
FACOM S 250 A Torque wrench
50 bis 240 N.m [35 to 175 lbf.ft]
Drehmoment-Schlssel
FACOM K 250 A Torque wrench
160 bis 800 N.m [120 600 lbf.ft]
Korrosionsschutzfett
Auto-top
2000 Anti-oxidizing
grease
origine AGIP
Leuchtend grne Farbe / fluorescent green color
Zange fr Innenringe
Abzieher
FACOM 499.32
FACOM U 20 B
Sechskantschlssel fr
Innensechskantschraube
Torque wrench
6 bis 30 N.m [4.4 to 22.1 lbf.ft]
Internal snap ring

pliers
Extractor
6553
Hex head wrench
13 17 19 22 24
Drehmoment-Schlssel
FACOM J 250 A
Drehmoment-Schlssel
FACOM S 250 A Torque wrench
50 240 N.m [35 to 175 lbf.ft]
Drehmoment-Schlssel
FACOM K 250 A Torque wrench
160 800 N.m [120 600 lbf.ft]
36
Torque wrench
REPAR MS2-18 D/GB
292
%20$*
6 30 N.m [4.4 to 22.1 lbf.ft]
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Special tools
Spezialwerkzeuge
Mandrel for reassembling the

brake cover or to compress the
spring washer.
Montagewerkzeug
zum
Anheben
der
Schutzkappe oder zum
Komprimieren der Tellerfeder.
D
0759
F02
F03
F04
mm
[inch]
mm
[inch]
110
[4.3]
100
[4.0]
mm [inch]
125
[4.9]
mm
135
[inch]
[inch]
mm
mm
[inch]
mm
[inch]
[5.3]
M12
F05
125
[4.92]
115
[4.52] 151 [5.94]
159
[6.25]
125
[4.92]
115
[4.52] 151 [5.94]
159
[6.25]
50
[1.96]
10
[0.39]
20
[0.78]
50
[1.96]
10
[0.39]
20
[0.78]
50
[1.96]
20
[0.78]
30
[1.18]
F07
F08
F09
F11
F12
M16
F18
190
[7.48]
180
[7.08] 205 [8.07]
215
[8.46]
F19
[0.39]
10
[2.75]
70
Rohr zum Festsetzen

des Motors
Tube to immobilize the motor
2 5
[0 .9 8 " d ia ]
F21
1 6
[0 .6 2 " d ia ]
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2
H
x 1 2 0
M 1 6 x 1 2 0
c l. 1 0 .9
M 1 2
H M 1 6
Z 1 2 N
Werkzeuge zur mechanischen

Bremslsung.
800378128J
008 912 53
Tools for mechanical

brake
release
REPAR MS2-18 D/GB
%20$*
A = 2 0 0
A = 2 8 0
F 0 2
F 0 3
F 0 4
F 0 5
F 0 7
F 0 8
F 0 9
F 1 1
F 1 2
F 1 8
F 1 9
F 2 1
6 0 x 3 0
1 6 .5
[0 .6 4 ]
5 0 x 5
37
293

0606(WR
POCLAIN HYDRAULICS
Anziehdrehmomente
Nm 10%
Tightening torques
in [lbf.ft] 10%
(Gem Norm DIN 912)
(According to the standard DIN 912)
Gre Size
8.8
10.9
12.9
8.8
10.9
12.9
M6
M8
M10
M12
M14
M16
M18
M20
10
25
49
86
135
210
290
410
14
35
69
120
190
295
405
580
17
41
83
145
230
355
485
690
7.5
18.4
36
63.4
100
155
214
302
10
26
51
88.4
140
218
299
428
12.5
30
61
107
170
262
358
509
38
REPAR MS2-18 D/GB
294
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Ersatzteile
Nummer
Bezeichnung
010
Kompletter Zylinderblock
012
Kompletter Kolben Cl. 0
013
Kompletter Kolben Cl. 1
015
Reparatursatz
}
}
026
040
065
070
Kompletter Nockenring
027 O-Ring
041
042
043
044
045
047
048
050
051
052
053
054
055
056
057
059
Komplettes Verteilerdeckel
Verteilerdeckel
Schraube
Dichtungsring
Schraube
O-Ring
Verteiler
Dichtungssatz
Stopfen
O-Ring
Feder
Umschaltkolben
Scheibe
Sicherungsring
Feder
O-Ring
Stift
Kompletter Verschlussplatte
066 Schraube
067 Dichtring
071
072
073
074
075
076
077
078
079
081
087
090
091
096
097
098
099
154
155
156
800378128J
008 912 53
Komplettes Lagerteil
Lagerteil
Innerer Lippendichtring
Rollenlager
Rollenlager
Scheibensatz
Sttzring
Sicherungsring
uerer Dichtring
Abweiser
Dichtungstrger
Passfeder
Welle
Radbolzensatz
Bremstrommel
Schraube
Bremsseil
Sicherungsring
Komplette Bremsbacke
Kompletter Radzylinder
Gegenhalter
Spare parts list
Item
Description
010
Cylinders-block assembly
012
Piston Cl 0 assembly
013
Piston Cl 1 assembly
015
Repair kit
026
040
065
070
Cam assembly
027 O-ring
041
042
043
044
045
047
048
050
051
052
053
054
055
056
057
059
End cover assembly

066 Screw
067 Sealing ring
071
072
073
074
075
076
077
078
079
081
087
090
091
096
097
098
099
154
155
156
REPAR MS2-18 D/GB
%20$*
Valving cover assembly

Valving cover part
Screw
Seal washer
Screw
O-ring
Valving
Seal kit
Plug
O-ring
Spring
Valve spool
Washer
Snap ring
Spring
O-ring
Pin
Bearing support assembly

Bearing support part
Radial lip seal
Roller bearing
Roller bearing
Set of shims
Thrust ring
Snap ring
Lip seal
Deflector
Seal support
Key
Shaft
Set of studs
Drum brake
Screw
Brake cable
Snap ring
Brake shoe sub-assembly
Brake cylinder sub-assembly
Brake adjustment
39
295

0606(WR
POCLAIN HYDRAULICS
Nummer
Bezeichnung
100
Komplette Bremse
101 Bremsgehuse
102 Schraube
106 O-Ring
107 Kolben
108 Tellerfeder
109 Sicherungsring
110 Welle
111 Dichtsatz Bremswelle
112 Schraube
113 Dichtungsring
135 Satz Bremslamellen
141 Schutzkappe
142 Stopfen
143 O-Ring
150
160
Als Satz lieferbare Baugruppe
Drehzahlsensor-Vorbereitung
152 Scheibe
153 Scheibe
161
162
163
164
40
Kompletter Sensor
Sensor
Mutter
Scheibe
Dichtung
Item
100
150
160
Sub-assembly sold assembled
101
102
106
107
108
109
110
111
112
113
135
141
142
143
296
%20$*
Speed sensor predisposition

152 Washer
153 Washer
161
162
163
164
REPAR MS2-18 D/GB
Description
Brake assembly
Brake body
Screw
O-ring
Brake piston
Spring washer
Snap ring
Brake shaft
Seal
Screw
Seal washer
Brake kit
Cover
Plug
O-ring
Speed sensor assembly

Speed sensor part
Nut
Washer
Seal
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
41
297

0606(WR
POCLAIN HYDRAULICS
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.
Single displacement motors MS, MSE 02-05-08-11-18.
0987
42
REPAR MS2-18 D/GB
298
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
0988
43
299

0606(WR
POCLAIN HYDRAULICS
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.
Dual displacement motors MS, MSE 02-05-08-11-18.
0990
44
REPAR MS2-18 D/GB
300
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
0989
45
301

0606(WR
POCLAIN HYDRAULICS
46
REPAR MS2-18 D/GB
302
%20$*
800378128J
008 912 53

0606(WR
POCLAIN HYDRAULICS
800378128J
008 912 53
REPAR MS2-18 D/GB
%20$*
47
303

0606(WR
China
Espaa & Portugal
POCLAIN HYDRAULICS BEIJING rep. office

Unit A0808, Hui Bin Officies
No.8 Beichendong St.
BEIJING 100101
CHINA
Tel.: 86 10 6499 3988
Fax: 86 10 6499 3979
e-mail: info-china@poclain-hydraulics.com
POCLAIN HYDRAULICS SPAIN S.L.

Gran Via Carlos III no84 1o 3a
08028 BARCELONA
ESPAA
Tel.: 349 3 409 54 54
Fax: 349 3 490 21 79
e-mail: info-espana@poclain-hydraulics.com
HVNi 5HSXEOLND
France
POCLAIN HYDRAULICS SRO

Krova 186
61900 BRNO
(6. 5(38%/,.$
Tel.: 420 5 43217830

Fax: 420 5 43217818
e-mail: info-ceskarepublika@poclain-hydraulics.com
POCLAIN HYDRAULICS France SAS

B.P. 106
60411 VERBERIE CEDEX
FRANCE
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 91
e-mail: info-france@poclain-hydraulics.com
Deutschland
Japan
POCLAIN HYDRAULICS GMBH

Bergstrasse 106
64319 PFUNGSTADT
DEUTSCHLAND
Tel.: 49 6157 9474 0
Fax: 49 6157 9474 74
e-mail: info-deutschland@poclain-hydraulics.com
POCLAIN HYDRAULICS KK
5-4-6 Kugenumashinme
FUJISAWA 251
JAPAN
Tel: 81 466 50 4400
Fax: 81 466 50 4422
e-mail: info-japan@poclain-hydraulics.com
Italia
United Kingdom
POCLAIN HYDRAULICS SRL

Via Svizzera 4/A
41012 CARPI (MODENA)
ITALIA
Tel.: 390 59 64 22 44
Fax: 390 59 64 20 44
e-mail: info-italia@poclain-hydraulics.com
POCLAIN HYDRAULICS LTD

Nene Valley Business Park
Oundle
PETERBOROUGH, Cambs PE8 4HN
ENGLAND
Tel.: 44 1832 273773
Fax: 44 1832 274990
e-mail: info-uk@poclain-hydraulics.com
Nederland
USA
POCLAIN HYDRAULICS BENELUX BV

Penningweg 32C
4879 AM ETTEN-LEUR
NEDERLAND
POCLAIN HYDRAULICS INC.

7900 Durand Avenue
P.O. BOX 801
STURTEVANT, WI 53177
USA
Tel.: 1 262 554 6739
Fax: 1 262 554 4860
e-mail: info-america@poclain-hydraulics.com
Tel.: 31 76 5021152
Fax: 31 76 5012279
e-mail: info-netherlands@poclain-hydraulics.com
POCLAIN HYDRAULICS INDUSTRIE

B.P. 106
60411 VERBERIE CEDEX - France
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 99
e-mail: info@poclain-hydraulics.com
www.poclain-hydraulics.com
304
S.A.S. au capital de 85 124 000 Francs

Sige social: Route de Saint Sauveur
VERBERIE (OISE)
R.C.S. Senlis B 414 781 823
Siret 414 781 823 00011
%20$*
008 912 53
7.4
008 912 53
Vibration motor A2FM 32
%20$*
305

306
9LEUDWLRQPRWRU$)0
%20$*
008 912 53

9LEUDWLRQPRWRU$)0
Instructions for repair

A2FM32
058 010 53
Vibration motor
008 196 03
008 912 53
%20$*
01/1993
307

308
9LEUDWLRQPRWRU$)0
%20$*
008 912 53

9LEUDWLRQPRWRU$)0
Table of Contents
008 196 03
008 912 53
6.00
6.01
Repair survey vibration motor
6.02
Special tools
6.03
General notes for repairs
6.04
Sealing the vibration motor
6.05
Repairing the vibration motor drive
BOMAG
%20$*
1
309

9LEUDWLRQPRWRU$)0
Repair survey vibration motor
6.01
Fig. 1
4 Drive
5 Locking ring
6 Drive shaft
1 Housing
2 Connecting plate
3 Valve plate
6.01 Repair survey vibration motor

Installation weight:
approx. 11 kg
Opening the motor will result in the loss

of all warranty and policy adjustment
claims!
The description of the repair procedures is in

accordance with economical and technical
aspects. We do not recommend any further
repairs.
2
310
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
Special tools
6.02
6.02 Special tools
1. Puller 079 944 02
Fig. 1
008 196 03
008 912 53
BOMAG
%20$*
3
311

9LEUDWLRQPRWRU$)0
General notes for repairs
6.03
6.03 General notes for repairs
Please observe the following notes when

carrying out repairs on hydraulic components!
1. Close all openings on hydraulic components.
Fig. 1
2. Replace all seals and gaskets.
Fig. 2
3. Check all sealing and sliding surfaces for signs
of wear.
Fig. 3
4. Fill the hydraulic components with hydraulic oil
before taking them into operation.
Fig. 4
4
312
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.04
6.04 Sealing the vibration motor
1. Mark the position of the connecting plate to the
housing and unscrew the socket head cap
screws (Fig. 1).
Fig. 1
2. Swivel the connecting plate 1 (Fig. 2) around
the timing pin and lift it off.
Fig. 2
3. Cover the drive shaft with adhesive tape to
prevent the new radial seal from being damaged (Fig. 3).
Fig. 3
Fig. 4
008 196 03
008 912 53
BOMAG
%20$*
5
313

9LEUDWLRQPRWRU$)0
6.04
5. Force the locking ring out (Fig. 5).
Fig. 5
6. Remove the radial seal 1 (Fig. 6) and the
O-ring (2).
Fig. 6
7. Check the drive shaft for running grooves
(Fig. 7).
Fig. 7
8. If the running groove is very deep place an
appropriate shim 1 (Fig. 8) in front of the radial
seal.
Fig. 8
6
314
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.04
9. Press the new radial seal in dry by using a
suitable sleeve (Fig. 9).
Fig. 9
10. Insert the new O-ring 1 (Fig. 10) with some
grease and fill the new radial seal (2) with
grease.
Fig. 10
11. Knock the locking ring in by tapping it lightly
with a hammer (Fig. 11).
Fig. 11
12. Install the circlip (Fig. 12).
Fig. 12
008 196 03
008 912 53
BOMAG
%20$*
7
315

9LEUDWLRQPRWRU$)0
6.04
13. Make sure that the circlip is sitting correctly in

the groove (Fig. 13).
Fig. 13
14. Insert new O-ring 1 (Fig. 14) with some grease.
Fig. 14
15. Make sure that the timing pin 1 (Fig. 15) is in
assembling position and attach the connecting
plate.
Fig. 15
16. Observe the marks and fasten the socket head
cap screws crosswise with 25 Nm (Fig. 16).
Fig. 16
8
316
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.04
17. Unscrew the plug 1 (Fig. 17) and insert a new
O-ring (2) with some grease.
Fig. 17
008 196 03
008 912 53
BOMAG
%20$*
9
317

9LEUDWLRQPRWRU$)0
6.05
6.05 Repairing the vibration motor drive

Dismantling the drive
1. Mark the position of the connecting plate to the
housing and unscrew the socket head cap
screws (Fig. 1).
Fig. 1
2. Swivel the connecting plate 1 (Fig.2) around
the timing pin and lift it off.
Fig. 2
3. Remove the O-ring 1 (Fig.3)
4. Remove the valve plate (2).
Fig. 3
Fig. 4
10
318
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.05
6. Force the locking ring out (Fig. 5).
Fig. 5
7. Remove the radial seal 1 (Fig. 6) and the
O-ring (2).
Fig. 6
8. Remove the shims 1 (Fig. 7).
Fig. 7
9. Dismantle the drive by using the puller as
shown in Fig. 8.
Guide the cylinder in by hand.
Fig. 8
008 196 03
008 912 53
BOMAG
%20$*
11
319

9LEUDWLRQPRWRU$)0
6.05
10. Check the housing for signs of scoring (Fig. 9).
Fig. 9
Assembling the drive
The drive 1 (Fig. 10) can only be renewed

completely as the hydraulical and the mechanical parts are adjusted to each other.
Fig. 10
1. Insert the spring cup 1 (Fig. 11) and the Belleville springs (2) into the cylinder (3) by using a
piece of wire.
Fig. 11
2. Slide all pistons into the cylinder by moving
them slightly from side to side (Fig. 12).
Fig. 12
12
320
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.05
3. Stand the new drive into a suitable bore and
swash it to maximum displacement (Fig. 13).
Fig. 13
4. Heat the housing up to a temperatur of approx.
80 C (Fig. 14).
Fig. 14
5. Slide the warm housing onto the drive as far as
it will go (Fig. 15).
Danger of injury!
Fig. 15
Let the housing cool down, before further

assembly to avoid damages to the O-ring.
6. Insert the shims 1 (Fig. 16).
Fig. 16
008 196 03
008 912 53
BOMAG
%20$*
13
321

9LEUDWLRQPRWRU$)0
6.05
7. Press the new radial seal in dry by using a

suitable sleeve (Fig. 17).
Fig. 17
8. Insert the new O-ring 1 (Fig. 18) with some
grease and fill the new radial seal (2) with
grease.
9. Cover the drive shaft with adhesive tape to
prevent the new radial seal from being damaged.
Fig. 18
10. Knock the locking ring in by tapping it lightly
with a hammer (Fig. 19).
Fig. 19
11. Install the circlip (Fig. 20).
Fig. 20
14
322
BOMAG
%20$*
008 196 03
008 912 53

9LEUDWLRQPRWRU$)0
6.05
12. Make sure that the circlip is sitting correctly in
the groove (Fig. 21).
Fig. 21
13. Pull the drive against the locking ring by using
the puller (Fig. 22).
When the drive is touching, the locking ring is

free of clearance.
Fig. 22
14. Insert the O-ring (Fig. 23) with some grease
into the the groove.
15. Stick the valve plate (2) onto the drive by using
oil.
Fig. 23
16. Make sure that the timing pin 1 (Fig. 24) is in
assembling position and put on the connecting
plate.
Fig. 24
008 196 03
008 912 53
BOMAG
%20$*
15
323

9LEUDWLRQPRWRU$)0
6.05
17. Observe the marks and tighten the socket

head cap screws crosswise with 25 Nm (Fig.
25).
Fig. 25
18. Screw the socket head cap screw into the drive
shaft and check if the drive shaft can be turned
by using an Allen key (Fig. 26).
The vibration motor has to be bled and

filled with hydraulic oil before taking it into
service.
Fig. 26
16
324
BOMAG
%20$*
008 196 03
008 912 53

Bomag BW180AD

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Instructions for repair

Tandem Vibratory Roller

1.2 Safety regulations

1.3 General repair instructions

1.4 Tightening torques

1.5 Connection overview

Tests and adjustments

2.2 Special tools

2.3 Checking the rotation speeds

2.4 Pressure tests in the travel circuit

2.5 Checking / adjusting the neutral positions of the travel pump

2.7 Pressure measurements in the vibration circuit

2.10 Checking the leakage rate of the vibration motor

2.11 Pressure test in steering circuit

2.12 Operation of display module for ESX-control

2.13 Driving against the closed brake

2.14 Adjusting the machine type

2.15 Calibration of the angle transducers

2.16 Adjusting the angle transducers

2.17 Automatic detection of step currents for the steering valves

2.18 Adjusting the type of travel range switch

2.19 Resetting the step currents in the travel system

2.20 Automatic detection of step currents in the travel system

2.21 Showing stored faults

2.22 Deleting stored faults

3.2 Flushing shematic for front drum drive

3.3 Flushing schematic for rear drum drive system

3.4 Flashing the travel circuit

3.5 Flushing schematic for vibration drive

3.6 Flushing the vibration circuit

4.2 Trouble shooting diagram

5.2 Repair overview for drum

5.3 Removing and installing the drum

5.6 Repairing the vibrator unit on the drum drive unit

6.1 Removing, repairing and installing the pivot steering

6.2 Repairing the oscillation joint

7.4 Vibration motor A2FM 32

Tests and adjustments

This instruction manual contains only assembly

Please observe strictly the safety regulations in

Tools, lifting gear, lifting tackle, supports and other

Use only safe and approved lifting gear of sifficient

Be careful with cleansing agents. Do not use easily

When performing welding work strictly comply with

Special safety regulations

Use only genuine BOMAG spare parts for repair

We wish to make explicitly clear that we have not

Unauthorized changes to the machine are prohibited for safety reasons.

If tests on the articulated joint need to be performed

Do not perform cleaning work while the engine is

If tests must be performed with the engine running

Refuel only with the engine shut down. Ensure strict

Keep used filters in a separate waste container and

Do not refuel in closed rooms.

Do not heat up oil higher than 160 C because it

Wipe off spilled oil and fuel.

Before starting repair work stand the machine on

Always secure the machine against unintended rolling.

Secure the engine reliably against unintentional

Mark a machine that is defective or being repaired

Use protective clothes like hard hat, safety boots

Keep unauthorized persons away from the machine

Do not smoke when refuelling or when checking the