Instructions for repair

BW177 D/DH/PDH-50
SN: 901582301001 > SN: 901582311001 >
SN: 901582321001 >

Single Drum Vibratory Roller

Catalog Number
0852821 5/12
TABLE OF CONTENTS
SYMBOLS USED IN THIS MANUAL ............................................................................................................................... 9
SERVICE AND REPAIR PRECAUTIONS ........................................................................................................................ 11
Poisonous Substances................................................................................................................................................ 15
Engine.......................................................................................................................................................................... 15
Air Conditioning System ..................................................................................................................................... 15
Battery .................................................................................................................................................................. 16
Special safety notes.................................................................................................................................................... 16
Electrics ................................................................................................................................................................ 17
Hydraulic system ................................................................................................................................................. 18
Air conditioning system ...................................................................................................................................... 19
Fuel hoses............................................................................................................................................................. 21
Gaskets and mating surfaces .............................................................................................................................. 21
Feather keys and keyways .................................................................................................................................. 22
Ball and roller bearings ....................................................................................................................................... 23
Screws and nuts ................................................................................................................................................... 24
Tightening torque ............................................................................................................................................... 24
Torques for bolts with metric unified threads .................................................................................................. 27
Torques for bolts with metric unified fine threads ........................................................................................... 28
Torques for screws treated with anti-seizure paste ......................................................................................... 29
The values specified in the table apply for screws: .......................................................................................... 30
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread ............................................................................................................................................. 31
Tightening torques for screws with UNF thread ............................................................................................... 31
Specifications.............................................................................................................................................................. 32
General notes on maintenance .......................................................................................................................... 35
Fuels and lubricants ............................................................................................................................................ 36
Engine oil.............................................................................................................................................................. 36
Fuels...................................................................................................................................................................... 37
Hydraulic oil ......................................................................................................................................................... 39
Running-in instructions ...................................................................................................................................... 39
Maintenance schedule ............................................................................................................................................... 41
Hydraulic pump and drive component identification............................................................................................. 43
Test and adjustments flushing .................................................................................................................................. 45
Special Tools ........................................................................................................................................................ 48
Checking the rotary speeds ................................................................................................................................ 53
Checking I adjusting the mechanical neutral position of the travel pump .................................................... 54
Pressure tests in the travel circuit ...................................................................................................................... 56
Measurement with quickly operated travel lever ............................................................................................ 57
Adjusting the vibrator shaft speed .................................................................................................................... 58
Pressure tests in the vibration circuit ................................................................................................................ 59
Checking the leak oil rate of the vibration motor............................................................................................. 60
Pressure test in the steering circuit.................................................................................................................... 62
Special tools for flushing ........................................................................................................................................... 64
Special tools for flushing .................................................................................................................................... 64
Flushing - general ................................................................................................................................................ 66
Hose routing for flushing .................................................................................................................................... 68
Flushing the travel circuit ................................................................................................................................... 70
Cleaning the hydraulic oil tank .......................................................................................................................... 70
Filter installation to flush the travel circuit ....................................................................................................... 70
Bleeding the travel circuit................................................................................................................................... 72
Flushing the hoses in the travel circuit .............................................................................................................. 74
Flushing the drum drive motor .......................................................................................................................... 75
Flushing the travel motor ................................................................................................................................... 76
Function test ........................................................................................................................................................ 77
Flushing schematic, vibration drive................................................................................................................... 78
Flushing the vibration circuit ............................................................................................................................. 79
Flushing the entire system ................................................................................................................................. 79
Flushing the vibration circuit .................................................................................................................................... 80
Cleaning the hydraulic oil tank .......................................................................................................................... 80
Filter installation to flush the vibration circuit ................................................................................................. 80
Bleeding the vibration circuit ............................................................................................................................. 82
Flushing the hydraulic hoses .............................................................................................................................. 83
Flushing the vibration system ............................................................................................................................ 83
Function test ........................................................................................................................................................ 84
Maintenance of the flushing kit ......................................................................................................................... 84
Trouble shooting ........................................................................................................................................................ 85
General ................................................................................................................................................................. 88
Trouble shooting charts ............................................................................................................................................. 90
Check the neutral position.................................................................................................................................. 91
Check the mechanical O-position....................................................................................................................... 91
Adjust the mechanical 0-position ...................................................................................................................... 92
Check the servo control ...................................................................................................................................... 92
The machine does not drive ...................................................................................................................................... 93
Check the travel control cable ............................................................................................................................ 93
Check high and charge pressure ........................................................................................................................ 93
Check the magnetic coil of the brake valve....................................................................................................... 93
Check the brake releasing pressure ................................................................................................................... 94
Check the steering/charge pump ....................................................................................................................... 95
Check the charge pressure relief valve .............................................................................................................. 96
Check the flushing valve for the axle drive motor ............................................................................................ 96
Check the individual components ..................................................................................................................... 97
Check the drum drive motor............................................................................................................................... 97
Check axle drive motor / travel pump ............................................................................................................... 97
Check the servo control ...................................................................................................................................... 98
Insufficient travel power, max. speed not reached ................................................................................................. 99
Check the engine speed ...................................................................................................................................... 99
Check trouble travel cable .................................................................................................................................. 99
Check the charge pressure................................................................................................................................100
Check the steering/charge pump ..................................................................................................................... 101
Check the leakage of the brake ........................................................................................................................ 101
Check the charge pressure relief valve ............................................................................................................ 102
Check the flushing valve for the axle drive motor .......................................................................................... 102
Check the individual components ................................................................................................................... 103
Check the drum drive motor............................................................................................................................. 103
Check axle drive motor / travel pump ............................................................................................................. 103
Check the servo control ....................................................................................................................................104
Hydraulic oil overheating ........................................................................................................................................ 105
Check the thermostat valve .............................................................................................................................. 105
Check the multi-function valves....................................................................................................................... 105
No vibration ..............................................................................................................................................................106
Check the magnetic coil of the vibration valve ...............................................................................................106
Check the pilot pressure ...................................................................................................................................106
Check the vibration pump ................................................................................................................................ 107
Check the vibrator shaft bearings .................................................................................................................... 107
Check the engine speed ....................................................................................................................................108
Check the vibration pump ................................................................................................................................108
Vibrator shaft speed too low ...................................................................................................................................108
Check flushing valve and flushing spool ......................................................................................................... 109
Check the steering / charge pump ................................................................................................................... 109
Check the charge pressure relief valve ............................................................................................................ 110
Check the leak oil rate of the vibration motor ................................................................................................ 110
Check the vibration shaft bearings .................................................................................................................. 111
Check the multi-function valve ........................................................................................................................ 111
Check the individual components ................................................................................................................... 111
Check the way-valve.......................................................................................................................................... 112
No steering function / steering sticky / end stops not reached ............................................................................ 113
Check the steering pressure ............................................................................................................................. 113
Check the steering cylinders ............................................................................................................................ 113
Check the steering/charge pump ..................................................................................................................... 114
Drum .......................................................................................................................................................................... 115
Special tools ....................................................................................................................................................... 118
Removing the drum........................................................................................................................................... 120
Removing and installing the drum ......................................................................................................................... 120
Installing the drum ............................................................................................................................................ 122
Repair overview drum .............................................................................................................................................. 124
Repairing the drum .................................................................................................................................................. 126
Disassembling the bearing cover............................................................................................................................ 127
Removing the vibrator shaft ............................................................................................................................ 128
Dismantling the vibrator shaft ......................................................................................................................... 129
Removing the cover .......................................................................................................................................... 131
Installing the cover ............................................................................................................................................ 132
Assembling the vibrator shaft .......................................................................................................................... 132
Assembling the vibrator shaft .......................................................................................................................... 135
Assembling the bearing cover.......................................................................................................................... 139
Dismantling, assembling the change-over weight................................................................................................ 141
Dismantling the change-over weight. ............................................................................................................. 141
Assembling the change-over weight ............................................................................................................... 142
Changing the rubber buffers ............................................................................................................................ 143
Oscillating articulated joint ..................................................................................................................................... 145
Special tools ....................................................................................................................................................... 148
Removing and installing the oscillating articulated joint.............................................................................. 149
Overview Articulated Joint ...................................................................................................................................... 151
Dismantling the oscillating articulated joint .................................................................................................. 152
Assembling the oscillating articulated joint ................................................................................................... 156
Service Training ........................................................................................................................................................ 165
Diesel engine monitoring: ................................................................................................................................ 166
Travel pump ....................................................................................................................................................... 169
Cross-sectional view of travel pump ................................................................................................................ 171
View of the rotating group ............................................................................................................................... 172
Description of function ..................................................................................................................................... 173
Tandem pump .................................................................................................................................................... 175
Tandem pump, connections an adjustment points ........................................................................................ 176
Servo control...................................................................................................................................................... 178
Multi-function valves ........................................................................................................................................ 180
Flushing valve .................................................................................................................................................... 183
Axle drive motor ................................................................................................................................................184
Rear axle ............................................................................................................................................................. 186
Front drum drive motor: Radial piston motor MSE 18 2 CX ........................................................................... 187
Travel circuit: Drum drive with radial piston motor ....................................................................................... 190
Brake control: Travel motor in axle .................................................................................................................. 191
Travel drive, components and test points ....................................................................................................... 192
Travel pump: right hand side ........................................................................................................................... 193
Front travel motor, without brake (radial piston motor) ............................................................................... 194
Rear travel motor: Axle motor .......................................................................................................................... 195
Rear travel motor: Axle motor .......................................................................................................................... 196
Travel lever console........................................................................................................................................... 197
Travel lever ........................................................................................................................................................ 198
Trouble shooting ...................................................................................................................................................... 199
Vibration system............................................................................................................................................... 200
Vibration system................................................................................................................................................202
Function .............................................................................................................................................................203
Vibration pump ................................................................................................................................................ 204
High pressure relief valves .............................................................................................................................. 206
High pressure relief valves ...............................................................................................................................207
High pressure relief valves ............................................................................................................................... 210
Vibration system: Components and test ports ...................................................................................................... 211
Vibration pump ................................................................................................................................................. 211
Vibration pump ................................................................................................................................................. 212
Vibration motor ................................................................................................................................................. 213
Trouble shooting ............................................................................................................................................... 214
Trouble shooting ............................................................................................................................................... 215
Steering pump ................................................................................................................................................... 216
Working principle of the gear pumps .............................................................................................................. 217
Steering valve .................................................................................................................................................... 218
Articulated joint.................................................................................................................................................220
Steering: Components and test ports ..............................................................................................................222
Steering pump ...................................................................................................................................................222
Vibration and noise damper .............................................................................................................................223
Steering valve ....................................................................................................................................................224
Trouble shooting ......................................................................................................................................................225
Electrics: Single drum rollers D-50 ..........................................................................................................................226
Function test: .....................................................................................................................................................226
Instrument cluster .............................................................................................................................................227
Electric control cabinet with vibration module ..............................................................................................227
Plug assignment with operating hour meter ..................................................................................................229
Electrics .....................................................................................................................................................................323
BW177D-50 ........................................................................................................................................................323
BW177DH/PDH-50 ............................................................................................................................................ 368
Air Conditioning ....................................................................................................................................................... 417
Heat Temperature Control* ..................................................................................................................................... 418
g = Rotary switch for cabin heater (temperature selector switch)* ..................................................................... 418
Sauer Danfoss Series 90 Axial Piston Pumps and Motors .................................................................................... 465
Sauer Danfoss Series 42 Axial Piston Closed Circuit Pump ................................................................................... 553
Poclain MS Hydraulic Motors................................................................................................................................... 621
Sauer Danfoss Series 51 Bent Axis Variable Motors .............................................................................................. 701
Dana 192 Axle ........................................................................................................................................................... 781
Detroit Locker NoSpin .............................................................................................................................................. 817
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

8 5/2012
SYMBOLS USED IN THIS MANUAL

The following symbols have been used in this manual to help communicate the intent of the
instructions. When one of these symbols appears, it conveys the meaning as defined in the
following descriptions:

Serious personal injury, death and/or Minor personal injury can result, or a
extensive property damage can result part, an assembly, or the engine can be
if the DANGER instructions are not damaged if the CAUTION instructions
followed. are not followed.

Serious personal injury and/or

extensive property damage can result
NOTE: Gives additional information, and/or
if the WARNING instructions are not clarification details, which are used in
followed. conjunction with previously presented
information.

CALIFORNIA
Proposition 65
Diesel Exhaust Warning
WARNING: Diesel engine exhaust and
some of its constituents are known to the
state of California to cause cancer, birth
defects and other reproductive harm.

CALIFORNIA
Proposition 65
Battery Warning
WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the State
of California to cause cancer, birth defects
and other reproductive harm.

Wash hands after handling.

BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

10 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

SERVICE AND REPAIR PRECAUTIONS

ALWAYS inspect all slings, chains, or cables when lifting components. Be sure that they are properly tied,
fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the
weight to be lifted.

NEVER attempt to lift heavy parts by hand when a lifting device should be used.

ALWAYS wear safety glasses when performing any maintenance or repair work on the machine.

NEVER attempt to remove or repair any component on the machine while the engine is running.

NEVER leave the machine and/or heavy parts in an unstable position during repair.

ALWAYS support the machine with sound blocking.

ALWAYS keep the machine and work area clear of lubricants and dirt.

ALWAYS use the correct tools for the repair procedures being done on the machine.

ALWAYS keep tools in a good and clean condition.

ALWAYS use approved parts that are designed for the machine being repaired. This helps to ensure
maximum service life of the machine.

ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove components.

ALWAYS attach a sign in the machine operator’s area, stating “DO NOT OPERATE” when the machine is
being repaired.

ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and Service
Manual and found on the machine decals.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

These safety regulations must be read’ and applied • Always mark a defective machine by attaching a
by every person involved in the repair of the machine. respective note to the steering wheel.
The applicable accident prevention regulations
• During work secure the articulated joint with the
and the safety regulations in the operating and
articulation lock.
maintenance instructions must also be observed.
• Use your protective outfit, such as hard hat and
Repair work must only be performed by trained protective boots.
personnel or by the after sales service of BOMAG.
• Keep unauthorized persons away from the
machine while the repair work is going on.
Workshop equipment and facilities as well as the use
and waste disposal of fuels and lubricants, cleaning • Tools, lifting gear, lifting tackle, trestles and other
agents and solvent as well as gases and chemicals auxiliary equipment must be fully functional and
are subject to legal regulations, which are intended in safe condition.
to provide a minimum on safety. It is obviously your
• Use only safe and approved lifting gear of sufficient
own responsibility to know and adhere to these
load bearing capacity to removal and install parts
regulations.
or components from and to the machine.
This manual contains headers like “Note”, “Attention”, • Be careful with cleansing agents. Gasoline or
“Danger” and “Environment”, which must be strictly other easily inflammable substances must not be
complied with in order to inform about and avoid used for cleaning purposes.
dangers to persons, property and the environment.
• Cleaning and repair work on the fuel tank is
dangerous. When repairing or cleaning the fuel
Note: The repair instructions contain safety related tank do not smoke in the immediate vicinity,
headers such as ‘Note’, ‘Caution’, ‘Warning’,
avoid ignition sparks and do not use open fire.
‘Danger’, which must be strictly observed.
• Always observe the welding instructions when
Note: Paragraphs marked like this contain technical performing welding work.
information for the optimal economical use Transport work with cranes and lifting tackle
of the machine.
Note: Cranes must only be operated by
Paragraphs marked like this highlight instructed persons who had been trained
possible dangers for machines or parts in handling cranes.
of the machine.
• Follow the operating instructions of the
Paragraphs marked like this highlight manufacturer when working with cranes.
possible dangers for persons.
• Follow the operating instructions of the operator
when working with cranes.
Paragraphs marked like this point out
practices for safe and environmental • Always comply with the applicable accident
disposal of fuels and lubricants as well prevention instructions when working with
as replacement parts. cranes and lifting tackle.
Precautions and codes of conduct for welding
Environment: Observe the regulations for the work
protection of the environment.
Welding work must only be carried out by properly
General trained personnel.

• For repair work stand the machine on level and

firm ground an shut down.
• Secure the machine against unintentional rolling.
• Secure the engine .reliably against unintentional
starting.

12 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Electric shock! Maintenance; waste disposal

Sparks, fire hazard, burning of skin! • Replace damaged insulating jaws and welding
Infrared or ultraviolet radiation (arc), rod holders immediately.
flashing of eyes! • Replace the welding wire reels only in de-energized
Health hazard caused by welding state.
work on highly alloyed work pieces, What to do in case of accidents; First Aid
metal coatings, paint coatings, plastic
coatings, oil containing dirt deposits, • Keep calm.
grease or solvent residues, etc.! • Call first air helpers.
• Check welding equipment and cables for damage • Report the accident.
before use (also the validity of inspection
• In case of an electric accident: Interrupt the
stickers).
power supply and remove the injured person
• Ensure good conductivity between earth cable from the electric circuit. If breathing and heart
and work piece. have stopped apply reactivation measures and
• Start the extraction fan before starting work and call for an emergency doctor.Old oils
guide with the progressing work as required. Prolonged and repetitive contact with mineral oils
• Always isolate the burner when laying it down will remove the natural greases from the skin and
(remove possible electrode residues). causes dryness, irritation and dermatitis. Moreover,
used engine oils contain potentially hazardous
• Protect cables from being damaged, use cables contaminants, which could cause skin cancer.
with insulated couplings. Appropriate skin protection agents and washing
• Ensure sufficient fire protection, keep a fire facilities must therefore be provided.
extinguisher at hand. • Wear protective clothes and safety gloves, if
• Welding work in areas where there is a risk of possible.
fire or explosion, must only be carried out with • If there is a risk of eye contact you should protect
welding permission. your eyes appropriately, e.g. chemistry goggles
• Remove any combustible materials from the or full face visor; a facility suitable for rinsing the
welding area or cover such items appropriately. eyes should also be available.
• Name a fire watch during and after welding • Avoid longer and repetitive contacts with oils. In
work. case of open incisions and injuries seek medical
advice immediately.
• Place welding rod holders and inert gas welding
guns only on properly insulated bases. • Apply protective cream before starting work, so
that oil can be easier removed from the skin.
• Place the inert gas bottles in a safe place and
• Wash affected skin areas with water and soap
secure them against falling over.
(skin cleansers and nail brushes will help). Lanolin
• Use a protective screen or hand shield with containing agents will replace natural skin oils
welding filter, wear welding gloves and clothes. that were lost.
• Switch the welding unit off before connecting • Do not use gasoline, kerosene, diesel, thinner or
welding cables. solvents to wash the skin.
• Check electrode holders and electric cables at • Do not put oil soaked cloths into your pockets.
regular intervals. • Avoid clothes getting soiled by oil.
Behavior in case of faults • Overalls must be washed at regular
• In case of deficiencies switch off the welding unit intervals. Dispose of non-washable clothes
and inform supervising persons. environmentally.
• In case of an extractor fan failure or any other • If possible degrease components before
fault inform the supervising persons. handling.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Environment: It is strictly prohibited to drain off Fuel vaporous not only are easily
oil into the soil, the sewer system inflammable, but also highly explosive
or into natural waters. Old oil must inside closed rooms and toxic; dilution
be disposed of according to appli- with air creates an easily inflammable
cable environmental regulations. mixture. The vaporous are heavier
If in doubt you should consult than air and therefore sink down to
your local authorities. the ground. Inside a workshop they
Hydraulics may easily become distributed by
• Always relieve the pressure in the hydraulic draft. Even the smallest portion of
system before disconnecting any lines. Hydraulic spilled fuel is therefore potentially
oil escaping under pressure can penetrate the dangerous.
skin and cause severe injury.
• Always make sure that all screw fittings have • Fire extinguishers charged with FOAM, CO2 GAS
been tightened properly and that hoses and or POWDER must be available wherever fuel is
pipes are in mint condition before pressurizing stored, filled in, drained off, or where work on fuel
the system again. systems is performed.
• Hydraulic oil leaking out of a small opening • The vehicle battery must always be disconnected,
can hardly be noticed, therefore please use a BEFORE work in the fuel system is started. Do not
piece of cardboard or wood when checking for disconnect the battery while working on the fuel
leaks. When injured by hydraulic oil escaping system. Sparks could cause explosion of the fuel
under pressure consult a physician immediately, fumes.
as otherwise this may cause severe infections. • Wherever fuel is stored, filled, drained off or
• Do not step in front of or behind the drums, where work on fuel systems is carried out, all
wheels or crawler tracks when performing potential ignition sources must be extinguished
adjustment work in the hydraulic system while or removed. Search lights must be fire proof
the engine is running. Block drums, wheels or and well protected against possible contact with
crawler tracks with wedges. Reattach all guards running out fuel.
and safety installations after all work has been Hot Fuels
completed.
• Please apply the following measures before
Environment: It is strictly prohibited to drain off draining of fuel to prepare for repair work:
oil into the soil, the sewer system or
into natural waters. Old oil must be • Allow the fuel to cool down, to prevent any
disposed of according to applicable contact with a hot fluid.
environmental regulations. If in • Vent the system, by removing the filler cap in a
doubt you should consult your well ventilated area. Screw the filler cap back on,
local authorities. until the tank is finally emptied.
Fuels Synthetic Rubber
Repair work shall only performed by • If the material is in such a state it must only
appropriately trained personnel or by be touched with special protective gloves. The
the after sales service of BOMAG. protective gloves must be disposed of according
to applicable environmental regulations
Follow the valid accident prevention immediately after use.
instructions when handling fuels.
• If the material has contacted the skin despite
these measures, take off the soiled clothes and
The following notes refer to general
seek medical advice immediately. In the meantime
safety precautions for danger free
cool and wash the affected area of skin over a
handling of fuel.
sufficient time with cold water or lime water.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Poisonous Substances Air Conditioning System

Some of the fluids and substances used are toxic and Work on air conditioning systems must
must under no circumstances be consumed. only be carried out by persons who can
Skin contact, especially with open wounds, must be provide sufficient evidence of their
avoided. ability (proof of professionalism) and
These fluids and substances are, amongst others, anti- only with the appropriate technical
freeze agents, hydraulic oils, fuels, washing additives, equipment.
refrigerants, lubricants and various bonding agents.
• Always wear goggles and protective clothing
Engine when performing maintenance and repair
Do not work on the fuel system while work on air conditioning systems. Refrigerant
the engine is running. (Danger to life!) withdraws heat from the environment when
evaporating, which can cause injury by freezing
Once the engine has stopped wait
when in contact with skin (boiling point of R134a
approx. 1 minutes for the system to
-26,5 °C at normal pressure).
depressurize. The systems are under
high pressure. (Danger to life!) • Perform maintenance and repair work on air
conditioning systems only in well ventilated
Keep out of the danger zone during
rooms! Escaping refrigerant vapours will mix with
the initial test rung. Danger caused by
the ambient air and displace the oxygen required
high pressure in case of leaks. (Danger
for breathing (danger of suffocating).
to life!)
• Smoking is prohibited when performing
When performing work on the fuel
maintenance and repair work on air conditioning
system make sure that the engine
systems! Toxic breakdown products may be
cannot be started unintentionally
generated if refrigerant comes into contact with
during repair work. (Danger to life!)
heat.
• Maintenance and cleaning work on the engine
• Refrigerant should always be extracted by
must only be performed with the engine stopped
flushing with nitrogen before starting welding
and cooled down. Make sure that the electric
or soldering work near components of the air
system is switched off and sufficiently secured
conditioning system. The development of heat
against being switched on again (e.g. pull off
may cause the refrigerant to develop toxic and
ignition key, attach a warning label)
highly corrosive breakdown products.
• Observe the accident prevention regulations for
• Pungent smell! The toxic substances, which are
electric systems (e.g. -VDE-0100/-0101/-0104/-
responsible for the pungent smell, must not be
0105 Electric precautions against dangerous
inhaled, since this may cause damage to the
contact voltages).
respiratory system, the lung and other organs.
• Cover all electric components properly before Extract toxic breakdown products with a suitable
wet cleaning. extraction system (workshop extraction system).
• When blowing out components with compressed
air and when flushing with nitrogen the gas
mixture escaping from the components must
be extracted via suitable extraction facilities
(workshop extraction systems).
Handling pressure vessels
• Since the fluid container is pressurized, the
manufacture and testing of these pressure vessels
is governed by the pressure vessel directive.
The pressure vessels must be repetitively

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

tested by an expert as specified in TRB 532 • Do not lean over the battery while it is under load,
Inspection by Experts, Repetitive Tests. In this being charged or tested (danger of explosion).
case periodically recurring inspections consist of • Keep ignition sources away from the battery.
external examinations, normally on containers in Burning cigarettes, flames or sparks can cause
operation. In combination with the inspection, the explosion of the battery
refrigerant collector must be visually examined
two times per year. Special attention must thereby • Use battery chargers etc. only in strict compliance
be paid to signs of corrosion and mechanical with the operating instructions.
damage. If the container is in no good condition, • After an accident with acid flush the skin with
it should be replaced for safety reasons, in order a sufficient amount of water and seek medical
to protect the operator or third parties against advice.
the dangers when handling or operating pressure
• Do not allow children access to batteries.
vessels.
• When mixing battery fluid always pour acid into
• Secure pressure vessels against tipping over or
water, never vice-versa.
rolling away.
Special safety notes
• Do not throw pressure vessels! Pressure vessels
• Use only genuine BOMAG spare parts for repair
may thereby be deformed to such an extent,
and maintenance work. Genuine spare parts and
that they will crack. The sudden evaporation and
original accessories were specially developed,
escape of refrigerant releases excessive forces. This
tested and approved for the machine.
applies also when snapping off valves on bottles.
Bottles must therefore only be transported with • The installation and use of non-genuine spare parts
the safety caps properly installed. or non-genuine accessories may therefore have
an adverse effect on the specific characteristics of
• Refrigerant bottles must never be placed near
the machine and thereby impair the active and/or
heating radiators. Higher temperatures will
passive driving safety. The manufacturer explicitly
cause higher pressures, whereby the permissible
excludes any liability for damage caused by the
pressure of the vessel may be exceeded.
use of non-original parts or accessories.
• Do not heat up refrigerant bottles with an open
• Unauthorized changes to the machine are
flame. Excessive temperatures can damage
prohibited for safety reasons.
the material and cause the decomposition of
refrigerant. • Do not perform any cleaning work while the
engine is running.
• Do not overfill refrigerant bottles, since any
temperature increase will cause enormous • If tests on the articulated joint need to be
pressures. performed with the engine running, do not stand
in the articulation area of the machine (danger of
Environment It is strictly prohibited to release
crushing!).
refrigerant into the atmosphere
during operation, maintenance • If tests must be performed with the engine
and repair work and when taking running do not touch rotating parts of the engine
air conditioning systems into or out (danger of injury!).
of service. • Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
Battery highly dangerous!
• Always wear goggles and protective clothing to • Refuel only with the engine shut down. Ensure
service or clean batteries! Battery acid can cause strict cleanliness and do not spill any fuel.
severe injury by cauterization when coming in
• Always ensure an adequate supply of fresh air
contact with skin.
when refuelling in closed rooms.
• Work only well ventilated rooms (formation of
• Dispose of used filters in accordance with
oxyhydrogen gas).
applicable environmental regulations.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

• When performing repair and maintenance control unit or inspected the wiring, this should
work collect oils and fuels in suitable containers be done before changing any parts.
and dispose of in compliance with applicable • Check for good cable and ground contacts,
environmental regulations. therefore keep all mechanical transition points
• Do not heat up oils higher than 160 °C because between electric conductors (terminals, plugs)
they may ignite. free of oxide and dirt, as far as this is possible.
• Wipe off spilled or overflown oil using suitable • Always use the machine related wiring diagram
cleaning means and dispose of in accordance for testing. If one or more faults were detected,
with applicable environmental regulations. these should be corrected immediately.
• Dispose of old batteries according to applicable • Do not disconnect or connect battery or generator
environmental regulations. while the engine is running.
• There is a danger of scalding when draining off • Do not operate the main battery switch under
engine or hydraulic oil at operating temperature! load.
Allow engine and hydraulic system to cool down • Do not use jump leads after the battery has been
to a sufficient level. removed.
• Do not exceed the max. permissible tire pressure. • Sensors and electric actuators on control units
General must never be connected individually or between
• Before removing or disassembling parts, external power sources for the purpose of testing,
assemblies, components or hoses mark these but only in connection with the control unit in
parts for easier assembly. question.

• Before assembling and installing parts, assemblies • It is not permitted to pull plugs off while the
or components oil or grease all movable parts or voltage supply is switched on (terminal 15 “ON”)!
surfaces as required and in compliance with the Switch the voltage supply “OFF” first and pull out
compatibility of materials. the plug.

Electrics • Even with an existing polarity reversal protection

incorrect polarity must be strictly avoided.
General Incorrect polarity can cause damage to control
units!
Due to the fast technical development electric and
electronic vehicle systems become more intelligent • Plug-in connectors on control units are only
and more comprehensive day by day, and can hardly dust and water tight if the mating connector is
be dispensed with in hydraulic and mechanical vehicle plugged on! Control units must be protected
systems. against spray water, until the mating connector is
finally plugged on!
Diagnostics according to plan
• Unauthorized opening of control electronics
Well structured trouble shooting procedures can save
(Microcontroller MC), modifications or repairs in
time and money.
the wiring can cause severe malfunctions.
Random tests have revealed that purely electronic
• Do not use any radio equipment or mobile phones
components or control units only very rarely are the
in the vehicle cab without a proper aerial or in the
actual cause of failures:
vicinity of the control electronics!
General:
Electrics and welding
• Before changing any expensive components,
• Surge voltages in the electric system of the vehicle
such as control units, you should run a systematic
must be strictly avoided when welding. Always
trouble shooting session to eliminate any other
fasten the earth clamp of the welding unit in the
possible fault sources. Knowledge in basic
immediate vicinity of the welding location.
electrics is required for this purpose. If a fault was
diagnosed without having pulled the plug of the

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Switch off the main battery switch, Hydraulic system

disconnect the generator and pull the
plug out on the control unit before Repair work on hydraulic elements
starting welding work. shall only performed by appropriately
trained personnel or by the after sales
Battery service of BOMAG.

Rules for the handling of batteries Please note

When removing a battery always disconnect the Note: Cleanliness is of utmost importance. Dirt and
minus pole before the plus pole. When installing the other contaminations must strictly be kept
battery connect the minus pole after the plus pole to out of the system.
avoid short circuits.
Fasten the terminal clamps with a little force as • Connections and screw fittings, filler neck covers
possible. and their immediate surrounding areas must be
cleaned before removal.
Always keep battery poles and terminal clams clean
to avoid high transition resistances when starting and • Before loosening hoses, pipe lines etc. relieve all
the related development of heat. pressure from the system.
Make sure the battery is properly fastened in the • During repair work keep all openings closed with
vehicle. clean plastic plugs and caps.
• Never run pumps, motors and engines without oil
or hydraulic 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
let such substances come in contact with rubber
parts.
• 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.
• Avoid the formation of rust on fine machined
caused by hand sweat.
• Use new O-rings or seal rings for reassembly.
• Use only hydraulic oil as sliding agent when
reassembling. Do not use any grease!
• Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high
pressure.
• Check the hydraulic oil level before and after the
work.
• Fill in only clean oil as specified in the maintenance
instructions.
• Check the hydraulic system for leaks, if necessary
find and rectify the cause.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

• Before taking new hydraulic components into Air conditioning system

operation fill these with hydraulic oil as specified Work on air conditioning systems must only be
in the operating and maintenance instructions. carried out by persons who:
• After changing a hydraulic component thoroughly • have proven to have sufficient expert
flush, refill and bleed the complete hydraulic knowledge,
system.
• have the necessary equipment to undertake such
• Perform measurements at operating temperature tasks,
of the hydraulic oil (approx. 40 ¯ C).
• are reliable and
• After changing a component perform a high and
charge pressure test, if necessary check the speed • are not any directives regarding their activities
of the exciter shaft. when carrying out inspection and maintenance
work acc. to § 4 section 2 of the chemical/ozone
• The operating pressure of the exciter shaft to layer regulation.
a great extent depends on the base under the
vibrating drum. On hard ground place the drums The inspection and maintenance tasks, including leak
on a suitable base and check the drum pressure. tests and possible repair activities, must be recorded in
Do not activate the vibration on a hard, concreted the operating instructions together with information
base, danger of bearing damage. about the refrigerant quantities used and regained,
whereby the operator is obliged to keep these records
• After the completion of all tests perform a test over a period of at least five years.
run and then check all connections and fittings
for leaks with the engine still stopped and the Note: Cleanliness is of utmost importance. Dirt and
hydraulic system depressurized. other contaminations must strictly be kept
out of the system.
Before commissioning
• Fill the housings of hydraulic pumps and • Tools used on refrigeration circuits must be of
motors with hydraulic oil. Use only hydraulic oils excellent condition, thus to avoid the damage of
according to the specification in the maintenance any connections.
instructions. • During repairs on refrigerant lines and
• After changing a component flush the hydraulic components, these must be kept closed, as far
system as described in the flushing instructions. as this is possible, to prevent the system from
being contaminated by air, moisture and dirt.
Taking into operation The operational safety of the system can only
• Bleed the hydraulic circuits. be assured as long as all components in the
• Start up the hydraulic system without load. refrigerant circuit are kept internally clean and
dry.
• Check the hydraulic oil level in the tank, if
necessary top up with hydraulic oil as specified • Connections, screw fittings and their immediate
in the operating and maintenance instructions or surrounding areas must be cleaned before
drain oil off into a suitable container. removal.

After taking into operation • Before loosening hoses, pipe lines etc. relieve all
pressure from the system.
• Check fittings and flanges for leaks.
• During repair work keep all openings closed with
• After each repair check all adjustment data, system clean plastic plugs and caps.
pressures, rotational speeds and nominal values
in the hydraulic system, adjust if necessary. • All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean
• Do not adjust pressure relief valves and control compressed air or dried with a lint-free cloth.
valves to values above their specified values.
• Before opening all components should have
warmed up to ambient temperature, to avoid
that damp air is drawn into the component by the
difference in temperatures.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

• Damaged or leaking parts of the air conditioning refill. Moisture bonded in the compressor oil /
must not be repaired by welding or soldering, but refrigeration oil (PAG oil) can only be removed
must generally be replaced. from the system by changing the oil.
• Do not fill up refrigerant, but extract existing • Compressor valves must only be opened after the
refrigerant and refill the system. system has been properly sealed.
• Different types of refrigerant must not be • The use of leak detection spray is not permitted.
mixed. Only the refrigerant specified for the If such substances are used the WARRANTY will
corresponding air conditioning system must be become null and void.
used. • If the air conditioning system had been opened
• Refrigerant circuits with refrigerant type R134a for repair work, a new drier should be installed in
must only be operated with the compressor oil / the refrigerant circuit.
refrigeration oil approved for the compressor. • After completion of repair work screw locking
• Used compressor oil/refrigeration oil must be caps (with seals) on all valve connections service
disposed of in strict compliance with applicable connections.
environmental regulations. • Before start up of the air conditioning system
• Due to its chemical properties compressor oil after a new filling: - Turn the compressor approx.
/ refrigeration oil must never be disposed of 10 revolutions by hand using the clutch or V-belt
together with engine or transmission oil. pulley of the magnetic clutch. - Start the engine
• Compressor oil / refrigeration oil is highly with the compressor/ control valve switched off.
hydroscopic. Oil cans must strictly be kept closed - Once the idle speed of the engine has stabilized
until use. Oil rests should not be used, if the can switch on the compressor and run it for at least
had been opened over a longer period of time. 10 minutes at idle speed and maximum cooling
power.
• All O-rings/seal rings as well as pipe/ hose fittings
must be oiled with compressor/refrigeration oil • Never run the compressor with an insufficient
before assembly. amount of refrigerant.

• When replacing a heat exchanger, e.g. evaporator

or condenser, any compressor oil/refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
• A too high compressor oil / refrigeration oil level
adversely affects the cooling performance and
a too low oil level has a negative effect on the
lifetime of the compressor.
• Use new O-rings or seal rings for reassembly.
• Always used 2 spanners to work on pipes/hoses
to avoid damages .
• Tighten screw fittings with the specified torque.
• Check all pipes/hoses, screw fittings or
components for damage, replace if necessary.
• Do not leave the refrigerant circuit unnecessarily
open to the atmosphere.
• In case of a repair on the refrigeration system
you should first evacuate the air conditioning
system for at least 45 minutes to remove any
moisture from the system, before you start to

20 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Fuel hoses Gaskets and mating surfaces

Leaking sealing faces can mostly be traced back to

incorrect assembly of seals and gaskets.
• Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes,
corrosion or other damage.
• Inappropriately stored or handled seals (e.g.
hanging from hooks or nails) must under no
circumstances be used.
• Assemble seals and gaskets only with sealing
compound, grease or oil, if this is specifically
Fig. 1 specified in the repair instructions.
All fuel hoses have two layers of • If necessary remove any old sealing compound
material, a reinforced rubber coating before assembling. For this purpose do not
outside and an internal Viton hose. If use any tools that could damage the sealing
a fuel hose has come loose one must surfaces.
make absolutely sure that the internal • Sealing compound must be applied thin and
Viton layer has not been separated evenly on the corresponding surfaces; take
from the reinforced outer layer. In case care that the compound does not enter into oil
of a separation the hose needs to be galleries or blind threaded bores.
replaced.
• Examine the contact faces for scratches and burrs,
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
• Blow out lines, ducts and gaps with compressed
air, replace any O-rings and seals that have been
dislodged by the compressed air.
Assembly of radial seals

Fig.2
• Lubricate the sealing lips (2) (Fig. 2) with clean
grease; in case of double seals fill the space
between the sealing lips with a generous amount
of grease.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

• Slide the seal over the shaft, with the lip facing Feather keys and keyways
towards the fluid to be sealed.
Feather keys may only be reused if
Note: If possible, use an assembly sleeve (1 (Fig. 2)), they are free of damage.
to protect the lip from being damaged by
sharp edges, threads or splines. If no assembly
sleeve is available, you should use a plastic
tube or adhesive tape to prevent the sealing
lip from being damaged.

• Lubricate the outer rim (arrow 3 (Fig. 2)) of the

seal and press it flat on the housing seat.

Fig. 4
• Clean and thoroughly examine the feather key.
Fig. 3
• Deburr and thoroughly clean the edges of the
• Lubricate the outer rim (arrow 3 (Fig. 2)) of the
keyway with a fine file before reassembling.
seal and press it flat on the housing seat.
Note: If possible, use a “bell” (1 (Fig. 3)), to make
sure that the seal will not skew. In some cases
it may be advisable to assemble the seal into
the housing first, before sliding it over the
shaft. Under no circumstances should the full
weight of the shaft rest on the seal.

If you have no proper service tools at hand,

use a suitable drift punch with a diameter
which is about 0,4 mm smaller than the outer
diameter of the seal. Use VERY LIGHT blows
with the hammer if no press is available.

22 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Ball and roller bearings recommended type of grease before assembly or

reassembly.
Ball and roller bearings may only be
reused if they are free of damage and • On greased bearings (e.g. wheel bearings) fill the
do not show any signs of wear. space between ball or roller bearing and outer
seal with the recommended type of grease before
assembling the seal.
• Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
• Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing.
• Always mark the individual parts of separable
ball or roller bearings (e.g. taper roller bearings)
to enable correct reassembling. Never assemble
the rollers to an outer race that has already been
used, replace the complete ball or roller bearing
instead.

Fig. 6
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
Fig. 5
(Fig. 6).
• If a ball or roller bearing of a bearing pair shows
defects, both ball or roller bearings need to be When fitting the bearing into the housing load must
replaced. only be applied to the outer race (2).
• Remove any lubricant residues from the ball or
roller bearing to be examined by washing it with
gasoline or any other appropriate degreasing
agent. Ensure strict cleanliness.
• Check balls or rollers, running surfaces, outer
faces of outer races and inner faces of inner races
for visible damage. Replace the ball or roller
bearing if necessary.
• Check the ball or roller bearing for clearance and
resistance between the inner and outer races,
replace if necessary.
• Lubricate the ball or roller bearing with the

5/2012 23
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Screws and nuts • Strength classes, metric screws

Tightening torque The strength classes (from 3.6 to 12.9) are specified for
all strength classes from a nominal diameter of 5mm.
Tighten nuts or screws with the The corresponding identification can be found where
tightening torques specified in the allowed for by the shape of the screw.
following tables of tightening torques.
Tightening torques deviating from
the ones in the table are specially
mentioned in the repair instructions.

Damaged screws must under no

circumstances be used any longer.
Recutting threads with thread cutters
or taps adversely affects the strength
and leak tightness of the screw joint.
Damaged or corroded thread pitches
can cause incorrect torque value
readings.

Self-locking nuts must generally be

replaced after disassembly.

The use of screws with too high

strength can cause damage! Fig. 7 Identification of screws
Example: A screw is identified with 12.9.
• Nut of a higher strength can generally be used
instead of nuts of a lower strength classification. The first number corresponds with 1/100 of the
nominal tensile strength (minimum tensile strength)
• When checking or retightening screw joints to
in N/mm2.
the specified tightening torque you should first
relieve by a quarter turn and then tighten to the • The nominal tensile strength is 12 X 100 N/mm2
correct torque. = 1200 N/mm2.
• Before tightening you should lightly oil the The second number specifies 10-times the ration
thread, in order to ensure low friction movement. between lower yield point and nominal tensile
The same applies for self-locking nuts. strength (yield point ratio).
• Make sure that no oil or grease will enter into blind Note: When exceeding the lower yield point, the
tapped bores. The hydraulic power generated material will return to its original shape when
when turning in the screw could cause breakage being relieved (plastic deformation).
of the effected part.
When exceeding the upper yield point the
material will not restore its original shape after
being relieved.

• The lower tensile strength is 9/10 X 1200 N/

mm2 = 1080 N/mm2.
Note: However, these values are by no means
identical with the tightening torques,
which are to be set on a torque wrench.
The corresponding calculation requires a
higher effort and, in the end, depends on the
materials to be bolted together.

24 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Strength classes of metric nuts Identification in clock system

Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5, 6,
8, 10, 12)
Fig. 9 Identification of nuts in clock system
For small nuts (Fig. 9) the clock system can be used for
identification.
• The 12 o’clock position is identified by a dot or the
manufacturer’s symbol.
Fig. 8 Identification of nuts • The strength class is identified by a dash (b).
In a connection with a screw, these nuts 1 (Fig. 8) must Identification of UNF-threads
be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).

Strength class of nut Strength class of

associated screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8 5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
Fig. 10
Nuts for screw joints with limited load factor (04, 05) Screws
The preceding “0” indicates that, due to their low The screw head is marked with a stamped in, round
height, nuts 2 (Fig. 8) in this group are only able to cavity 3 (Fig. 10).
withstand the force of a screw to a limited extent.
Nuts
Nut height below 0,8 d (d = nominal dimension).
An uninterrupted series of stamped in circles parallel
Nuts for screw joints without specified load factor to the axis of the nut on a hexagon area (2).
(11H, 14H, 17H, 22H)
Studs and brake rods
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 8), for which no load values At the outmost end a short end of the component is
can be specified, e.g. because of their shape and reduced to its core diameter (1).
dimensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Cotter pins

Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the
illustration, unless specified differently.

26 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Torques for bolts with metric unified threads

BOLT TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

M4 2 ft. lbs./3 N•m 3 ft. lbs./5 N•m 4 ft. lbs./5 N•m
M5 4 ft. lbs./6 N•m 7 ft. lbs./10 N•m 7 ft. lbs./10 N•m
M6 7 ft. lbs./10 N•m 11 ft. lbs./15 N•m 13 ft. lbs./18 N•m
M8 18 ft. lbs./25 N•m 26 ft. lbs./35 N•m 33 ft. lbs./45 N•m
M10 37 ft. lbs./50 N•m 55 ft. lbs./75 N•m 61 ft. lbs./83 N•m
M12 65 ft. lbs./88 N•m 91 ft. lbs./123 N•m 108 ft. lbs./147 N•m
M14 101 ft. lbs./137 N•m 145 ft. lbs./196 N•m 173 ft. lbs./235 N•m
M16 156 ft. lbs./211 N•m 221 ft. lbs./300 N•m 264 ft. lbs./358 N•m
M18 213 ft. lbs./290 N•m 303 ft. lbs./412 N•m 361 ft. lbs./490 N•m
M20 304 ft. lbs./412 N•m 426 ft. lbs./578 N•m 513 ft. lbs./696 N•m
M22 413 ft. lbs./560 N•m 559 ft. lbs./785 N•m 695 ft. lbs./942 N•m
M24 524 ft. lbs./711 N•m 738 ft. lbs./1000 N•m 885 ft. lbs./1200 N•m
M27 774 ft. lbs./1050 N•m 1092 ft. lbs./1480 N•m 1308 ft. lbs./1774 N•m
M30 1047 ft. lbs./1420 N•m 1482 ft. lbs./2010 N•m 1770 ft. lbs./2400 N•m

WARNING: Tables 2-14 and 2-15 list torque values for standard hardware and are intended as a guide for
average application involving typical stresses and machined surfaces.
Values are based on physical limitations of clean, plated and lubricated hardware. In all cases,
when an individual torque value is specified, it should be followed instead of values given in
this table. Replace original equipment with hardware of equal grade.

NOTE: The above table represents the strength class for capscrews with untreated, non-lubricated
surfaces. The quality designation of the capscrews is marked on the screw head.
The values result in a 90% utilization of the capscrews, yield point at a coefficient of friction of µ
total = 0.14.
Use a torque wrench to tighten capscrews to the CORRECT above-given torques; do NOT apply
when using lubricants.

5/2012 27
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Torques for bolts with metric unified fine threads

BOLT TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

M8 x 1 19 (26) 27 (37) 35 (48)
M10 x 1.25 38 (52) 56 (76) 65 (88)
M12 x 1.25 72 (98) 101 (137) 119 (126)
M12 x 1.5 69 (93) 94 (127) 112 (152)
M14 x 1.5 112 (152) 159 (216) 188 (255)
M16 x 1.5 166 (225) 235 (318) 282 (383)
M18 x 1.5 239 (324) 344 (466) 409 (554)
M20 x 1.5 340 (461) 463 (628) 572 (775)
M22 x 1.5 456 (618) 636 (863) 780 (1058)
M24 x 2 575 (780) 808 (1096) 954 (1294)
M27 x 2 846 (1147) 1164 (1578) 1416 (1920)
M30 x 2 1156 (1568) 1662 (2254) 1988 (2695

The torque values allow a bolt yield strength up to 90%, assuming a friction coefficient of 0.14 total.
Torque values are observed by using torque wrenches.

Torques deviating from these tables are mentioned separately in the descriptions. The indicated
torque values are not applicable when MoS2 lubricants are uses.

* Strength classification for bolts with untreated and unlubricated surfaces.

Bolt quality classification can be read on the bolt heads.

28 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Torques for screws treated with anti-seizure paste OKS 2401 (copper paste)

BOLT TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

M16 124.6 ft. lbs./169 N•m 177 ft. lbs./240 N•m 211.6 ft. lbs./287 N•m
M16 x 1.5 132.7 ft. lbs./180 N•m 188.0 ft. lbs./255 N•m 226.4 ft. lbs./307 N•m
M18 171.1 ft. lbs./232 N•m 243.4 ft. lbs./330 N•m 289.1 ft. lbs./392 N•m
M18 x 1.5 191.7 ft. lbs./260 N•m 275.1 ft. lbs./373 N•m 327.4 ft. lbs./444 N•m
M20 243.3 ft. lbs./330 N•m 341.4 ft. lbs./463 N•m 410.8 ft. lbs./557 N•m
M20 x 1.5 272.1 ft. lbs./369 N•m 370.2 ft. lbs./502 N•m 457.2 ft. lbs./620 N•m
M22 330.4 ft. lbs./448 N•m 463.1 ft. lbs./628 N•m 556.1 ft. lbs./754 N•m
M22 x 1.5 365.0 ft. lbs./495 N•m 509.6 ft. lbs./691 N•m 624.7 ft. lbs./847 N•m
M24 419.6 ft. lbs./569 N•m 590.0 ft. lbs./800 N•m 708.0 ft. lbs./960 N•m
M24 x 2 460.2 ft. lbs./624 N•m 648.3 ft. lbs./879 N•m 764.1 ft. lbs./1036 N•m
M27 619.5 ft. lbs./840 N•m 873.2 ft. lbs./1184 N•m 1121.0 ft. lbs./1520 N•m
M27 x 2 677.0 ft. lbs./918 N•m 931.5 ft. lbs./1263 N•m 1132.8 ft. lbs./1536 N•m
M30 837.8 ft. lbs./1136 N•m 1185.9 ft. lbs./1608 N•m 1416.1 ft. lbs./1920 N•m
M30 x 2 925.6 ft. lbs./1255 N•m 1330.5 ft. lbs./1804 N•m 1590.1 ft. lbs./2156 N•m
3/4” - 10 UNC 203.5 ft. lbs./276 N•m 203.6 ft. lbs./388 N•m 342.2 ft. lbs./464 N•m
3/4” - 16 UNC 227.2 ft. lbs./308 N•m 318.6 ft. lbs./432 N•m 383.5 ft. lbs./520 N•m

1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to
high temperatures and corrosive effects. Prevents seizure and corrosion.

TIGHTENING TORQUE
FT. LBS. /N•m

THREAD DIAMETER 10.9

M12X1.5 73.7 ft. lbs./100 N•m
M14X1.5 110.6 ft. lbs./150 N•m
M18X1.5 221.2-258.1 ft. lbs./300-350 N•m
M20X1.5 295.0-368.7 ft. lbs./400-500 N•m
M22X1.5 368.7-442.5 ft. lbs./500-600 N•m
1 Coefficient of friction µ tot. = 0,14
2 These values result in a 90% utilization of the yield point

5/2012 29
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

The values specified in the table apply for screws:

• black oiled
• with surface protection A4C
• with surface protection DACROMET
Note: The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix.
DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread

SCREW TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

1/4”-20 8.1 ft. lbs./11 N•m 11.0 ft. lbs./15 N•m 14.0 ft. lbs./19 N•m
5/16”-18 16.9 ft. lbs./23 N•m 23.6 ft. lbs./32 N•m 28.7 ft. lbs./39 N•m
3/8”-16 28.7 ft. lbs./39 N•m 40.5 ft. lbs./55 N•m 48.6 ft. lbs./66 N•m
7/16”-14 45.7 ft. lbs./62 N•m 64.1 ft. lbs./87 N•m 77.4 ft. lbs./105 N•m
1/2”-13 70.8 ft. lbs./96 N•m 99.5 ft. lbs./135 N•m 118.0 ft. lbs./160 N•m
9/16”-12 103.2 ft. lbs./140 N•m 147.5 ft. lbs./200 N•m 173.3 ft. lbs./235 N•m
5/8”-11 143.8 ft. lbs./195 N•m 202.8 ft. lbs./275 N•m 243.3 ft. lbs./330 N•m
3/4”-10 254.4 ft. lbs./345 N•m 357.7 ft. lbs./485 N•m 427.7 ft. lbs./580 N•m
7/8”-9 413.0 ft. lbs./560 N•m 567.9 ft. lbs./770 N•m 693.3 ft. lbs./940 N•m
1”-8 626.9 ft. lbs./850 N•m 885.0 ft. lbs./1200 N•m 1069.4 ft. lbs./1450 N•m
1 1/8”-7 885.0 ft. lbs./1200 N•m 1253.8 ft. lbs./1700 N•m 1475.1 ft. lbs./2000 N•m
1 1/4”-7 1253.8 ft. lbs./1700 N•m 1770.1 ft. lbs./2400 N•m 2138.9 ft. lbs./2900 N•m
1 3/8”-6 1622.6 ft. lbs./2200 N•m 2286.4 ft. lbs./3100 N•m 2728.9 ft. lbs./3700 N•m
1 1/2”-6 2212.6 ft. lbs./3000 N•m 3097.7 ft. lbs./4200 N•m 3761.5 ft. lbs./5100 N•m

1 Coefficient of friction µ tot. = 0,14

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Tightening torques for screws with UNF thread, 1

UNF Unified National Fine Thread Series, American
Unified Fine Thread

SCREW TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

1/4”-28 9.5 ft. lbs./13 N•m 13.2 ft. lbs./18 N•m 16.2 ft. lbs./22 N•m
5/16”-24 18.4 ft. lbs./25 N•m 25.8 ft. lbs./35 N•m 30.9 ft. lbs./42 N•m
3/8”-24 33.1 ft. lbs./45 N•m 46.4 ft. lbs./63 N•m 56.0 ft. lbs./76 N•m
7/16”-20 51.6 ft. lbs./70 N•m 73.7 ft. lbs./100 N•m 88.5 ft. lbs./120 N•m
1/2”-20 81.1 ft. lbs./110 N•m 114.3 ft. lbs./155 N•m 136.4 ft. lbs./185 N•m
9/16”-18 114.3 ft. lbs./155 N•m 162.2 ft. lbs./220 N•m 191.7 ft. lbs./260 N•m
5/8”-18 162.2 ft. lbs./220 N•m 228.6 ft. lbs./310 N•m 272.8 ft. lbs./370 N•m
3/4”-16 283.9 ft. lbs./385 N•m 398.2 ft. lbs./540 N•m 479.4 ft. lbs./650 N•m
7/8”-14 457.2 ft. lbs./620 N•m 641.6 ft. lbs./870 N•m 774.4 ft. lbs./1050 N•m

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

SCREW TIGHTENING TORQUE

DIMENSIONS FT. LBS. /N•m

8.8 10.9 12.9

1”-12 685.9 ft. lbs./930 N•m 958.8 ft. lbs./1300 N•m 1180.0 ft. lbs./1600 N•m
1 1/8”-12 995.7 ft. lbs./1350 N•m 1401.3 ft. lbs./1900 N•m 1696.3 ft. lbs./2300 N•m
1 1/4”-12 1401.3 ft. lbs./1900 N•m 1991.4 ft. lbs./2700 N•m 2360.1 ft. lbs./3200 N•m
1 3/8”-12 1917.6 ft. lbs./2600 N•m 2728.9 ft. lbs./3700 N•m 3245.2 ft. lbs./4400 N•m
1 1/2”-12 2433.9 ft. lbs./3300 N•m 3392.7 ft. lbs./4600 N•m 4130.3 ft. lbs./5600 N•m
1 Coefficient of friction µ tot. = 0,14

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Dimensions in inches (mm)

A B D H H2 K L O1 O2 S W
BW 177D-50 98.4 (2500) 71.5 (1816) 48.3 (1228) 87.6 (2225) 112.6 (2860) 14.7 (375) 193.5 (4913) 2.6 (65) 2.6 (65) 1.0 (25) 66.4 (1686)
BW 177DH-50 98.4 (2492) 71.5 (1816) 48.3 (1228) 87.6 (2225) 112.6 (2860) 14.7 (375) 193.5 (4913) 2.6 (65) 2.6 (65) 1.0 (25) 66.4 (1686)
BW 177PDH-50 98.4 (2500) 71.5 (1816) 47.6 (1208) 87.6 (2225) 112.6 (2860) 14.7 (375) 193.5 (4913) 2.6 (65) 2.6 (65) 0.6 (15) 66.4 (1686)
Technical data BOMAG BOMAG BOMAG
BW177D-50 BW177DH-50 BW177PDH-50
Weights
Operating Weight with ROPS/FOPS lbs (kg) 15355 (6965) 15640 (7095) 16115 (7310)
Operating Weight with optional leveling blade lbs (kg) — — — — 17440 (7910)
Axle load, drum* lbs (kg) 9040 (4100) 9070 (4115) 9545 (4330)
Axle load, wheels Lbs (Kg) 6315 (2865) 6570 (2980) 6570 (2980)
Static linear load (drum)* pli (kg/cm) 136.1 (24.3) 136.6 (24.4) — —

Dimensions
Working width in (mm) 66.4 (1686) 66.4 (1686) 66.4 (1686)
Track Radius, inner in (mm) 123.1 (3126) 123.1 (3126) 123.1 (3126)
Dimensions See Sketch See Sketch See Sketch

Driving Characteristics (depending on site conditions)

Speed (1) mph (km/hr) 0-4.3 (0-7) 0-2.5 (0-4) 0-2.5 (0-4)
Speed (2) mph (km/hr) 0-6.8 (0-11) 0-4.0 (0-6.5) 0-4.0 (0-6.5)
Speed (3) mph (kmph) — — 0-8.0 (0-13) 0-8.0 (0-13)
Max. gradeability without/with vib. % 45/45 55/55 55/55

Drive
Engine Manufacturer Cummins Cummins Cummins
Type B3.3T B3.3T B3.3T
Cooling water water water
Number of cylinders 4 4 4
Performance ISO 3046 hp (kW) 74 (55) 74 (55) 74 (55)
Speed rpm 2600 2600 2600
Performance SAE J 1995 hp (kW) 74 (55) 74 (55) 74 (55)
Speed rpm 2600 2600 2600
Fuel diesel diesel diesel
Electric Equipment V 12 12 12
Drive System hydrostatic hydrostatic hydrostatic
Drum Driven Standard Standard Standard

Electric equipment
Operating voltage V 12 12 12
Generator D.C. D.C. D.C.
Voltage/current V/A 14/63 14/63 14/63
Battery - voltage / V/Ah 12/100 12/100 12/100
capacity
Starter - voltage / V/kW 12/2,9 12/2,9 12/2,9
power

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR
Technical data BOMAG BOMAG BOMAG
BW177D-50 BW177DH-50 BW177PDH-50
Travel pump
Type Sauer 90R055 Sauer90R055 Sauer 90R055
System Axial piston - Axial piston - Axial piston -
swash plate swash plate swash plate
Displacement cm3 55 55 55
Travel pressure bar max. 435 ±15 max. 400 ±15 400 ±15
Charge pressure limitation bar 25 ±1 25±1 25 ±1

Drum drive motor

Type Poclain Sauer/Danfoss Sauer/Danfoss
MSE8 1CX 51C060 51C060
System Radial piston motor Axial piston bent Axial piston bent
Displacement cm3/U 1259 60 60
Transmission ratio 53.95 53.95

Axle drive motor

Type Sauer 51D80 Sauer 51D80 Sauer 51D80
System Axial piston - bent Axial piston - bent Axial piston - bent
axle axle axle
Displacement cm3/U 80 80 80

Vibration pump
Type Sauer 42R28 Sauer 42R28 Sauer 42R28
System Axial piston - Axial piston - Axial piston -
swash plate swash plate swash plate
Displacement cm3 28 28 28
Starting pressure bar 365 ±35 365 ±35 365 ±35
Operating pressure bar approx. 100 approx. 100 approx. 100

Vibration motor
Type Sauer MMF025 Sauer MMF025 Sauer MMF025
System Axial piston - Axial piston - Axial piston -
swash plate swash plate swash plate
Displacement cm3 25 25 25
Max. leak oil rate (without liters/min approx. 0.5 approx.0.5 approx.0.5
flushing)

Drums And Tires

Number of pad feet — — 104
Area of one pad foot in2/(cm2) — — 15.3 (99)
Height of pad feet in/(mm) — — 3.1 (80)
Tire size 14.9-24/6PR 14.9-24/6PR 14.9-24/6PR
Tire Tread Diamond (R3) Diamond (R3) Tractor (R1)

Brakes
Service brake hydrostatic hydrostatic hydrostatic
Parking brake SAHR SAHR SAHR
Brake releasing pressure bar min. 12 min. 12 min. 12

Steering
Steering System oscill., artic. oscill., artic. oscill., artic.
Steering Method Hydrostatic Hydrostatic Hydrostatic
Steering Angle +/- degrees 35 35 35
Oscillating Angle +/- degrees 12 12 12

Steering/charge pump
Type RexRoth AZ-P-F-12- AZ-P-F-12- AZ-P-F-12-
022-LLR20MB 022-LLR20MB 022-LLR20MB
System Gear Gear Gear
Displacement cm3/rev. 22.9 22.9 22.9
Max. steering pressure bar 200 ± 10 200 ± 10 200 ± 10

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR
Steering valve
Manufacturer Danfoss Danfoss Danfoss
Type OSPC 315 ON OSPC 315 ON OSPC 315 ON
System Rotary spool valve Rotary spool valve Rotary spool valve
Technical data BOMAG BOMAG BOMAG
BW177D-50 BW177DH-50 BW177PDH-50
Rear axle
Manufacturer Dana Dana Dana
Type CHC 192/57LD CHC 192/57LD CHC 192/57LD
Differential No-Spin No-Spin No-Spin
Degree of locking % 100 100 100
Reduction ratio 43,7 43,7 43,7

Vibratory system
Drive System Hydrostatic Hydrostatic Hydrostatic
Frequency vpm (Hz) 1800/2400 (30/40) 1800/2400 (30/40) 1800/2400 (30/40)
Amplitude In (mm) 0.071/0.035 (1.8/.09) 0.071/0.035 (1.8/.09) 0.067/0.035 (1.7/0.9)
Centrifugal Force lbs (kN) 30375/27000 30375/27000 30375/27000
(135/120) (135/120) (135/120)
Capacities
Fuel gal (l) 39.5 (150) 39.5 (150) 39.5 (150)

Technical modifications reserved. Machines may be shown with options.

* on PDH model with blade, the axle load, drum will increase to 10,203 lbs and static linear load will be 153.7 pli.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

General notes on maintenance • Fuel left in the fuel drum is not suitable for the
engine and should only be used for cleaning
When servicing the machine pay careful attention to purposes.
all applicable safety instructions.
Notes on the engine performance
Thorough maintenance of the machine ensures
maximum reliability and prolongs the service life of Combustion air and fuel injection rates of the diesel
important components. The work involved is small engine have been carefully adjusted and determine
when compared with the problems which may arise if the engine’s performance and temperature level as
these instructions are not observed. well as the quality of the exhaust gas.

The terms left/right are always related to travel If your machine has to operate permanently in “thin
direction forward. air” (at high altitudes) and with full power, you should
consult the after sales service of BOMAG or the service
• Clean machine and engine thoroughly before department of the engine manufacturer.
starting maintenance work.
Notes on the hydraulic system
• For maintenance work park the machine on level
ground. Cleanliness is of utmost importance when servicing
the hydraulic system. Make sure that no dirt or other
• Maintenance work must generally be carried out contaminating substances fall into the system. Small
with the engine shut down. particles can flute valves, cause pumps to seize and
• Depressurize hydraulic lines before working on block restrictors and pilot bores, thereby causing
them. costly repairs.
• Disconnect the battery and cover it with insulation • If during the daily oil level check the oil level is
material before starting to work on electrical found to have dropped, check all lines, hoses and
components. components for leakages.
• Always attach the articulation lock (transport • Seal external leakages immediately. If necessary
lock) before starting to work in the articulation inform the responsible service station.
area of the machine. • Do not store hydraulic oil drums outdoors or at
Environment During maintenance catch all least under a cover. Water may penetrate through
running oil, coolant and fuel and the bunghole when the weather changes.
do not let it seep into the ground • Always use the filtering and filling unit (BOMAG
or into the sewage system. Catch part-no. 007 610 01) to fill the hydraulic system.
oils, coolant and fuel and dispose This unit is fitted with a fine filter, which cleans
of environmentally. the hydraulic oil and prolongs the service life of
the filter.
Notes on the fuel system
• Clean fittings, filler caps and their immediate
The lifetime of the diesel engine depends decisively surrounding area before removing them, so that
on the cleanliness of the fuel. no dirt can fall in.
• Keep the engine free of dirt and water as this • Do not leave the tank opening unnecessarily
could damage the injection elements of the open, cover it so that no dirt can fall in
engine.
• Zinc lined drums are not suitable for storing fuel.
• The fuel drum should rest for a longer period of
time before drawing off fuel.
• Do not let the suction hose disturb the sludge on
the bottom of the drum.
• Do not draw off fuel from near the bottom of the
fuel drum.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Fuels and lubricants Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
Engine oil engine damage. In order to keep the occurring wear
as low as possible, occasional exceeding of the limits
Quality
should not happen over a longer period of time.
Lubrication oils are classified according to their
With their better temperature and oxidation stability
performance and quality class. Oils according to other
synthetic lubrication oils offer quite a few benefits.
comparable specifications may be used.
Oil change intervals
The exact assignment of the approved oil qualities and
oil change intervals can be taken from the following The longest permissible time a lubrication oil should
section “Lubrication oil change intervals”. remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
Consult your local service station if in doubt.
year, the oil change should be performed at least once
Oil viscosity per year, irrespective of the operating hours reached.
Multi-purpose oils should be generally used.
ACEA* = 500 operating hours
Since lubrication oil changes its viscosity with the E-5
temperature, the ambient temperature at the operating E-7
location of the engine is of utmost importance when
API** = 500 operating hours
choosing the viscosity class (SAE-class) .
CH-4/SJ
Optimal operating conditions can be achieved by CI-4/SK
using the opposite oil viscosity chart (Fig. 108) as a
reference.
These intervals apply only when using
a diesel fuel with maximum 0.5 %
sulphur by weight and for ambient
temperatures higher than -10 °C.

Approved engine oils

Cummins Engine American Petroleum International Comments
Standard Classifications Institute Classification Classifications
(CES) (API)
N/A API CD, API CE, ACEA E-1 OBSOLETE DO NOT USE
API CG-4/SH
CES-20075 API CF-4/SG ACEA E-2, ACEA E-3, Minimum acceptable oil
JAMA DH-1 classification for Midrange
engines.
CES-20071, CES-20076 API CH-4/SJ, API CH-4 Global DHD-1 Acceptable oil
classification for Midrange
engines
CES-20072, CES-20077 API CH-4 ACEA E-5, Global DHD-1 Similiar in performance to
CES-20071 but validated
under European test
standards. Excellent oil for
midrange engines
CES-20078 API CI-4/SK, API CI-4 N/A Excellent oil for midrange
engines
* European Engine Oil Sequences
** American Petroleum Institute

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

For a list of acceptable substitute fuels contact the

engine manufacturer.
Winter fuel
Fire hazard!
Diesel fuels must never be mixed with
gasoline.

For winter operation use only winter diesel fuel, to

avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separation
can also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.

BioDiesel
Due to the extreme quality differences of bio-diesel
fuels available on the market, BOMAG recommends
that the use of biodiesel fuels be done in strict
accordance with engine manufactures guidelines.
Refer to the engine manufactures operation,
Fig. 108 maintenance and service manuals for certified fuel
Fuels usage and specifications.

Quality

You should only use commercially available brand

diesel fuel with a sulphur content below 0.5% (5000
ppm)1 and ensure strict cleanliness when filling in.
Use only winter-grade diesel fuel under low ambient
temperatures. The fuel level should always be topped
up in due time so that the fuel tank is never run dry,
as otherwise filter and injection lines need to be bled.

Cummins Inc. recommends that the cetane number

of diesel fuel be a minimum of 45 for engines that are
expected to operate at temperatures below 0°C [32°F]
and a minimum of 42 for engines that are operated at
temperatures above 0°C [32°F].
Using diesel fuel with lower than recommended
cetane number can cause hard starting, instability,
and excessive white smoke. To maintain satisfactory
operation at low ambient temperatures, it is important
to specify diesel fuel of the correct cetane number.
Cummins Inc. recommends the use of ASTM
number 2D fuel. The use of number 2D diesel fuel
1. Regional, national, or international regulations can require lower
will result in optimum engine performance. At
sulfur content. U.S. EPA and California regulations for model year 2011
operating temperatures below 0°C [32°F], acceptable and later non-road diesel engines require use of low sulfur diesel fuel
performance can be obtained by using blends of (LSD) with 500 ppm maximum or ultra low sulfur diesel fuel (ULSD) with
number 2D and number 1D. 15 ppm maximum.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Coolant, anti-freeze agent The cooling system must be

Use only soft tap water (drinking water) to prepare the permanently monitored. Besides
coolant mix. the inspection of the coolant level
this includes also the inspection of
As a protection against frost, corrosion and boiling the concentration of cooling system
point anti-freeze agents must be used under any protection agent.
climatic conditions.
The proportion of cooling system protection agent The concentration of cooling system
must be between min. 35% and max. 45% to the protection agent must be checked with
water. a refractometer (Fleetguard part-no.
C2800). Other measuring equipment
Do not mix different coolants and
is not suitable for highperformance
additives of any other kind.
diesel engines.

Coolant must be changed every two

Environment Cooling system protection years.
agents must be disposed of
environmentally. Environment Cooling system protection
agents must be disposed of
Coolant environmentally.
As a protection against frost, corrosion and boiling
Specification for cooling system protection agent
point anti-freeze agents must be used under any
climatic conditions. ASTM 4958 (GM6038M)
Do not mix different coolants and Anti-freeze concentration
additives of any other kind. Ethylene Glycol
40 % = -23 °C (-10 °F)
If no cooling system protection agent
is available in tropical zones, you may 50 % = -34 °C (-34 °F)
also use a corrosion protection agent 60 % = -54 °C (-65 °F)
(CUMMINS Liquid DCA).
68 % = -71 °C (-90 °F)
Do not mix in more than 50% cooling Propylene Glycol
system protection agent, except when 40 % = -21 °C (-6 °F)
a lower frost protection is required.
However, the proportion of cooling 50 % = -33 °C (-27 °F)
system protection agent should never 60 % = -49 °C (-56 °F)
exceed 68%. A higher concentrations
the frost protection effect drops again.

Use only soft tap water (drinking

water) to prepare the coolant mix.

The water should not contain more

than 100 ppm of sulphates (SO4) or 40
ppm of chlorides (CL).

38 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Hydraulic oil Running-in instructions

The hydraulic system is operated with hydraulic oil The following maintenance work must
HV 46(ISO) with a kinematic viscosity of 46 mm2/s be performed when running in new
at 40°C. For topping up or for oil changes use only machines or overhauled engines:
high-quality hydraulic oil, type HVLP according to DIN
51524, part 3, or hydraulic oils type HV according to Up to approx. 250 operating hours
ISO 6743/3. The viscosity index (VI) should be at least check the engine oil level twice every
150 (observe information of manufacturer). day.
Bio-degradable hydraulic oil
Depending on the load the engine is
On request the hydraulic system can also be filled subjected to, the oil consumption will
with ester based biodegradable hydraulic oil (Panolin drop to the normal level after approx.
HLP Synth. 46). The biologically quickly degradable 100 to 250 operating hours.
hydraulic oil meets all demands of a mineral oil based
hydraulic oil according to DIN 51524. After a running-in time of 30 minutes
In hydraulic systems filled with Panolin HLP Synth. 46 • Retighten the V-belt
always use the same oil to top up. When changing
After 250 operating hours
from mineral oil based hydraulic oil to an ester based
biologically degradable oil, you should consult the • Retighten bolted connections on intake and
lubrication oil service of the oil manufacturer for details. exhaust tubes, oil sump and engine mounts.
Check the filter more frequently after this change. • Retighten the bolted connections on the machine.
Oil change bio-degradable hydraulic oil: • Retighten all wheel fastening screws with the
specified tightening torque.
Perform regular oil analyses for • 1. Oil change vibration bearings
content of water and mineral oil.
• Oil change in drive axle
Replace the hydraulic oil filter • Oil change in wheel hubs
element every 500 operating hours. After 500 operating hours
Oil for drive axle • 2. Oil change vibration bearings
For the drive axle use only multi-purpose transmission • Oil change drum drive gear (only DH and PDH
oil of API-class GL5 with viscosity class SAE 90. machines)
The additives in this oil ensure low wear lubrication After 1000 operating hours
under all operating conditions. • Adjusting the valve clearance
Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention:
Observe the level marks
Engine Engine oil approx. 8.5 litres,
API CH-4/SJ, CI-4/SK (9.0 qt) without oil filter
or
ACEA: E5,E7
SAE 10W/40
-4°F to +104°F
(-20 °C to +40 °C)
SAE 15W/40
+5°F to +104°F
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 150 litres (39.6 gal)
Hydraulic oil approx. 60 litres (15.8 gal)
(ISO), HV 46, kinem.
viscosity 46 mm2/s (cSt) at 40 °C
viscosity index greater than 150
or
Similar to an ISO VG68
60mm2/s (cSt)at 40 °C
viscosity index greater than 140
Vibration bearings Engine oil SAE 15W/40 approx. 3.2 litres (3.4 qt)
Drive axle Gear oil SAE 90, API GL5 approx. 7.3 litres (7.7 qt)
Wheel hubs Gear oil SAE 90, API GL5 approx. .75 litres (0.8 qt)
Gear Box Drum Drive Gear oil SAE 90, API GL5 approx. 2.5 litres (2.6 qt)
(DH/PDH Only)
Air conditioning system Refrigerant R134A approx. 1400 g (3.8 lb)
Engine cooling system Cooling system protection agent approx. 16 litres (16.9 qt)

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Maintenance chart

With all maintenance intervals perform also the work

for shorter preceding service intervals.

Designation Note
Every 10 operating hours
Check the engine oil level Dipstick mark
Checking, cleaning the water separator
Check the fuel level
Check the coolant level
Check the hydraulic oil level Inspection glass
Checking the V-belt
Every 50 operating hours
Check the tire pressure see technical data
Adjust the scrapers
Every 250 operating hours
min. 1x per year
Clean the cooling fins on engine and hydraulic oil cooler
Check the oil level in the drive axle
Check the oil level in the planetary gears
Check the oil level in the vibration bearings
Check the oil level in the drum drive gear
DH and PDH machines
Every 500 operating hours
Changing engine oil and oil filter cartridge min. 1x per year
Servicing the battery distilled water, pole grease
Drain the sludge from the fuel tank
Change the fuel filter cartridge
Changing the fuel pre-filter cartridge
Checking V-belt tension, idler pulley and fan hub

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Designation Note
Every 1000 operating hours
Change the oil in the drive axle min. 1x per year
Change the oil in the planetary gears min. 1x per year
Changing the oil in the drum drive gear DH and PDH machines, at least 1x per
Change the oil in the vibration bearings year min. 1x per year

Check the engine mounts

Check the fastening of the axle on the frame
Tighten the wheel nuts
Check the ROPS
Every 2000 operating hours
Check, adjust the valve clearance Intake = 0,35 mm (0,014IN), exhaust
= 0,5mm (0.020 IN, with hot or cold
engine) at least every 2 years
Changing hydraulic oil and breather filter* at least every 2 years
Changing the hydraulic oil filter* at least every 2 years
Change the coolant at least every 2 years
As required
Cleaning, changing the combustion air filter min. 1x every year, safety cartridge at
leastevery 2 years
Bleed the fuel system
Adjust the parking brake
Change the tires
Chang the fresh air filter in the cabin
Tightening torques
Engine conservation
* Also in case of repairs in the hydraulic system.

42 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Hydraulic pump and drive

component identification

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

1. Control solenoid, high frequency (Y08) 21. Pressure test port, high frequency

2. Servo control, vibration pump 22. Adjustment screw, low frequency

3. Control solenoid, low frequency (Y07) 23. Multi-function valve 345 bar (charge system
and pressure relief ), vibration drive high
4. Pressure test port, pilot pressure low frequency frequency
5. Multi-function valve 400 bar (charge system 24. Multi-function valve 345 bar (charge system
and pressure relief ), travel system reverse and pressure relief ), vibration drive low
6. Port L, leak oil connection to vibration pump frequency

7. Travel control lever 25. Charge pressure relief valve in vibration pump
(blocked)
8. High pressure port 8, high pressure forward
26. Port E, charge oil from travel pump
9. Pressure test ports, pilot pressure
27. Pressure test port Ma, high pressure forward
10. Charge pressure relief valve, 25 bar
28. Port L1, leak oil connection to travel pump
11. Pressure test port Mb, high pressure reverse
29. Charge oil from filter
12. Adjustment screw, high frequency
30. High pressure port A, high pressure forward
13. Port L2, leak oil to tank
31. Port C, connection from solenoid valve for
14. Pressure test port, low frequency
32. Leak oil connection D, leak oil from axle drive
15. High pressure port A, low frequency motor

16. Pressure test port, high frequency 33. Leak oil connection A, leak oil from travel
pump
17. High pressure port 8, high frequency
34. Leak oil connection G, leak oil from drum drive
18. Port L2, to drum drive motor (flushing) motor
19. Multi-function valve 400 bar (charge system 35. Leak oil connection F, leak oil from vibration
pressure relief ), travel system forward motor
20. Port, charge pressure to brake solenoid valve, 36. Leak oil connection B, leak oil to cooler
speed range selector and vibration pump

44 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Instructions for repair

BW177 D/DH/PDH-50

Test and adjustments

Flushing

5/2012 45
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

46 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Special tools

Checking the rotary speed

Checking I adjusting the mechanical neutral position of the travel pump

Pressure tests in the travel circuit

Adjusting the vibrator shaft speed

Pressure tests in the vibration circuit

Checking the leak oil rate of the vibration motor

Pressure tests in the steering circuit

Special tools for flushing

Flushing schematic, travel circuit

Flushing the travel circuit

Flushing schematic, vibration circuit

Flushing the vibration circuit

5/2012 47
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Special Tools
1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
BOMAG part-no.: 050 100 75

Fig. 3
4. Digital rpm-meter for petrol engines
BOMAG part-no.: 079 948 99

Fig. 4

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5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
BOMAG part-no.: 079 948 98

Fig. 6
7. Infrared manual thermometer, -18 to 275°C
BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large
BOMAG part-no.: 007 610 03
Note:
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses

Fig. 8

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9. Hydraulic test case, small

BOMAG part-no.: 079 930 01
Note:
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses

Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03

Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04

Fig. 11
12. Adapter for pressure test hose
BOMAG part-no.: 055 439 02

Fig. 12

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13. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 14

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Checking the rotary speeds

Special Tools:
Vibration reed frequency meter

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50 °C) (122˚F).

1. Drive the machine with the drum on an elastic base

(rubber tires) (Fig. 1).

2. Apply the parking brake and block the wheels

additionally with suitable chocks.
Fig. 1
3. Start the diesel engine and shift the throttle lever
to max. speed position.

Checking the vibrator shaft speed

1. Switch the vibration on.

2. Check the speed, rest the frequency meter

( Fig. 2) on your thumb.

Nominal value:
see technical data

Evaluation of measurement:
Fig. 2 If the nominal value is not reached, check the
engine speed.
If the engine speed is correct, perform trouble
shooting in the vibration circuit.

Checking the diesel engine speed

1. Check the engine speed (Fig. 3).

Nominal value:
low idle speed, see technical data
high idle speed, see technical data

2. Switch the vibration on.

Nominal value:
See technical data

Evaluation of measurement:
Fig. 3 If the nominal value is not reached, perform trouble
shooting on the engine or in the hydraulic vibration
system.

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Checking I adjusting the mechanical neutral

position of the travel pump
Special Tools:
Hydraulic test case

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50°C) (122°F).

1. Block drum and wheels with suitable chocks

(Fig. 1).
Fig. 1
2. Disconnect the plug (Fig. 2) from the brake
solenoid valve.

Fig. 2
3. Detach the travel cable (Fig. 3) from the pump.

Fig. 3
4. Connect 600 bar pressure gauges to the high
pressure test ports MA and MB (Fig. 4).

Fig.4

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5. Join both control chamber ports X3 and X4

(Fig. 5) with a hose.

Fig. 5
6. Start the engine (Fig. 6) to max. speed position.

Fig. 6
Nominal value:
Both pressure gauges (Fig. 7) must show Identical
readings (charge pressure).

NOTE: If necessary repeat the pressure test with

60 bar pressure gauges, for more accurate
readings.

Fig. 7
Evaluation of measurement:
If pressure builds up on one side, adjust the
mechanical neutral position, until, the pressures on
both pressure gauges are identical.
For this purpose slacken the fastening screws on
the cover and slightly change the position of the
cover
(Fig. 8).

Fig.8

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Pressure tests in the travel circuit

Special Tools:
Hydraulic test case

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50°C) (122°F).

1. Block drum and wheels with suitable chocks

(Fig. 1).

Fig. 1
2. IN addition pull the plug (Fig. 2) off the brake
solenoid valve.

Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports MA and MB and a 60 bar
pressure gauge to the charge pressure test port
(Fig. 3). (8702.2 psi) (870.2 psi)

4. Start the diesel engine and move the throttle to the

max. speed position.

5. Read charge pressure and high pressure gauges.

Nominal value:
see technical data of travel pump:
Fig. 3
Charge pressure gauge = charge pressure at high
idle
High pressure gauge = charge pressure at high idle

Evaluation of measurement:
If the nominal value is not reached, check the
steering/charge pump.

Fig.4

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Measurement with quickly operated travel lever

6. Move the travel lever (Fig. 4) quickly to forward and

reverse, read the- pressure gauges.

Nominal value:
See technical data of the travel pump:
Charge pressure gauge = charge pressure at high
idle.
High pressure gauge = pressure override

Evaluation of measurement:
If the charge pressure drops considerably during
Fig. 4 the high pressure test, check the individual
components.
If the high pressure value is not reached, check the
travel pump.

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Checking/Adjusting the vibrator shaft speed

Special Tools:
Vibration reed frequency meter

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50°C) (122°F).

1. Drive the machine on an elastic base (rubber tires)

(Fig. 1)
2. Apply the parking brake and block the wheels
Fig. 1 additionally with suitable chocks.
3. Start the diesel engine and move the throttle
switch to max. speed position.
4. Switch on vibration high frequency / low amplitude
(Fig. 2) or low frequency / high amplitude.
5. Check the speed (Fig. 3), rest the frequency meter
on your thumb.
Nominal value:
high amplitude/
low frequency = see technical data
low amplitude/
Fig. 2
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
If the deviations exceed 10%,
investigate the cause, check engine,
vibration pump and vibration motor!

Fig. 3
6. Adjust the rotary speeds on the corresponding
adjustment screws (Fig. 4).

NOTE: Turn the adjustment screw clockwise to reduce

the speed, turn anti-clockwise to increase the
speed

Fig.4

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Pressure tests in the vibration circuit

Special Tools:
Hydraulic test case

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50 °C) (122°F).

1. Drive the drum of the machine on an elastic

base (rubber buffers), block drums and wheels
additionally with suitable chocks (Fig.1) Apply the
brake.

Fig. 1
2. Connect 600 bar pressure gauges to the high
pressure test ports MA and MB and a 60 bar
pressure gauge to the charge pressure test port
(Fig. 2).
3. Start the diesel engine and move the throttle
switch to max. speed position.

Fig. 2
4. Switch on vibration with high or low frequency
(Fig. 3).
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up
pressure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the components
Fig. 3 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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Checking the leak oil rate of the vibration

motor

Perform measurements at operating

temperature of the hydraulic oil
(approx. 50 °C) (122°F).

1. Drive the drum of the machine on an elastic base

(rubber buffers) and block drums and wheels
additionally with suitable chocks (Fig. 1).

Fig. 1
2. Apply the parking brake (Fig. 2).

Fig. 2
3. Block the flushing valve (Fig. 3) with washers.

Fig. 3
4. Disconnect the leak oil hose (Fig. 4), connect a
measuring hose and hold it into a measuring
beaker.

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

Fig.4

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5. Switch the vibration on (Fig. 5) and measure the

running out leak oil during one timed minute.

This measurement detects only the

external leak oil quantity.

Internal leaks from the high pressure

side to the low pressure side are not
detected.

Nominal value:
max. 0,5 I/min (max. .53 quart/min)
Fig. 5
Evaluation of measurement:
If the permissible leak oil rate is exceeded, replace
the vibration motor.

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Pressure test in the steering circuit

Special tools
Hydraulic test case, gear pump testing equipment
Perform measurements at operating
temperature of the hydraulic oil
(approx. 50 °C) (122°F).

Measurement 1

1. Connect a 600 bar pressure gauge to the steering

pressure test port (Fig. 1) (8702.2 psi).
2. Start the engine and run it with idle speed.
Fig. 1 Do not stand in the articulation area of
the machine.

3. Turn the steering against an end stop or attach the

articulation lock.

4. Read the pressure gauge.

Nominal value:
see technical data, max. steering pressure of
steering/charge pump.
Evaluation of test 1
If the nominal value is reached, check the steering
cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder) on
the steering cylinder and close them with plugs.

6. Run the engine with idle speed.

7. Turn the steering wheel.

8. Read the pressure gauge.

Fig. 2
Nominal value:
see technical data for steering/charge pump.
Evaluation of test 2:
If the nominal value is reached, replace the
steering cylinder.
If the nominal value is not reached, check the
steering/charge pump

9. Reconnect the hydraulic hoses to the steering

cylinder.

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Measurement 3
10. Actuate the emergency stop switch. (Fig . 3)

Fig. 3

11. Close the pump outlet (Fig. 4) with a 200 bar

pressure relief valve.
12. Crank the engine with the starter motor. For this
purpose disconnect the plug from the injection
pump magnet.
Nominal value:
see technical data for steering/charge pump.
Evaluation of test 3
If the nominal value is reached, replace the steering
valve.
If the nominal value is not reached, replace the
steering/charge pump.
Fig. 4

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Special tools for flushing

12. Filling and filtering unit with bag

BOMAG part-no.: 007 610 01

Fig. 1
13. Flushing filter, travel circuit

BOMAG part-no.: 007 000 01

14. Filter element

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

16. Double end union R1’ - 258 (2 pieces)

Fig. 2 BOMAG part-no.: 055400 52

17. Connecting fitting 258

BOMAG part-no.: 055 459 45

Fig. 3

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18. Reducing fitting 258 - 208

BOMAG part-no.: 055 422 98

Fig. 1
19. Connecting fitting 208

BOMAG part-no.: 055 45943

Fig. 2
20. Angular fitting 258

BOMAG part-no.: 055 421 38

Fig. 3
21. Angular fitting 208

BOMAG part-no.: 055 421 37

Fig.4

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Flushing - general Clean the hydraulic tank

Solid particles in the circuit will very
quickly cause damage to machine
components.
Environment Environmental damage
Catch running out hydraulic oil and
dispose of environmentally.
Changing a component
Always flush the complete oil circuit
after you have replaced a component.

Chips (abrasion) in the oil Fig. 2

• Open and clean all components in the oil circuit, Change the oil in case of excessive
replace if necessary. contamination, oil discoloration or if
• Clean all high pressure hoses in the oil circuit, the oil change interval is almost due.
• replace if necessary. • Filter the tank content with the filling and filtering
unit and pump it into the oil bag.
• If abrasion is found in the travel circuit you should
also flush the vibration circuit. • Mark all hoses and disconnect them from the
hydraulic oil tank.
• If abrasion is found in the vibration circuit you
should also flush the travel circuit. • Clean the oil tank thoroughly from inside, if
necessary remove the complete tank cover.
Before flushing
• Reconnect all hoses.
Change the filter element
• Fill the hydraulic oil tank again with the filling and
filtering unit.
Bleeding

Fig. 1
• Change the hydraulic oil filter element (1).

Fig. 3
• Always bleed closed hydraulic circuits if lines had
been removed or connected.

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Servicing the flushing filter kit

Fig. 4
• Replace the filter element of the flushing filter
when the red control pin of the contamination
indicator is pressed out during the filtering
process.
• Clean hoses and connections and store the flushing
kit in a clean and protected environment.

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Hose routing for flushing

BW177DH/PDH

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1. Flushing hose 25S- 20S 7. Angular fitting 20S

2. Angular fitting 25S 8. Connecting fitting 20S
3. Reducing fitting 25S- 20S 9. Double end union R1’ - 25S
4. Travel pump 10. Flushing filter
5. Axle drive motor 11. Connecting fitting 25S
6. Drum drive motor
Installation of flushing filter (Fig. 1)
After changing all component
1. Connect the flushing filter outlet “OUT” with the
1. Always flush the closed circuit. travel pump.

2. Connect the flushing filter inlet “IN” with the hose

Solid particles remaining in the circuit
from the travel motor.
will damage the components again
within a short period of time.
NOTE: The flushing filter must be installed in the low
pressure side in the return flow to the pump, so
In case of excessive oil contamination (abrasion)
that only cleaned oil will enter the travel pump.
With the connection shown in the illustration
1. Open and’ clean remaining components.
the travel pump must therefore be actuated to
travel direction forward.
2. If necessary replace the hydraulic hoses.
Flushing the hoses
3. Flush also the vibration circuit.
1. Take the drum drive motor out of the circuit, for
Before flushing
this purpose join the high pressure lines at the
drum drive motor together.
1. Replace the hydraulic oil filter element.
Flushing the entire system
2. Clean the hydraulic oil tank.
1. Reconnect the drum drive motor and raise the
3. Filter the hydraulic oil.
drum for flushing, so that the drum can rotate
freely without load.
NOTE: For filtering use the filling and filtering unit.
Pump the tank contents through a fine filter
2 To flush the axle drive motor lower the drum to the
into the oil bag or a clean container.
ground and jack the rear of the machine up, so that
the wheels can rotate freely.
Catch the hydraulic oil and dispose of
environmentally! For filling use also Bleeding
the filtering unit with fine filter.
1. Always bleed the hydraulic circuit after removing or
Change the oil: in case of excessive contamination connecting hoses in the closed circuit.
discoloration of the oil if the oil change interval is
almost reached.

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Flushing the travel circuit (travel pump distribution)

Cleaning the hydraulic oil tank

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. Disconnect all hoses (Fig. 1) from the tank cover.
3. Unscrew the fastening screws for the cover and
take the cover off.
Environment Catch the hydraulic oil and dispose
of environmentally!
4. Clean the hydraulic oil tank thoroughly from inside,
Fig. 1
reassemble cover and hoses.
Filter installation to flush the travel circuit
Before the installation of the filters
check hoses and connections for
cleanliness.
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 forward
travel.
With the connection shown in the
illustration the travel pump must
therefore be actuated to forward
direction.
1. Disconnect the high pressure hose (Fig. 2) from the
travel pump. (see chapter “Flushing schematic -
travel circuit”)
Fig. 2

2. Connect the flushing hose 3 (Fig. 3) from the filter

outlet to the travel pump using reducing fitting (2)
and angular fitting (1).

3. Connect the flushing hose (7) from the filter inlet

to the disconnected high pressure hose (4) using
reducing fitting (6) and double end union (5).

Fig. 3

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4. Connect the flushing hose 2 (Fig. 4) towards the

travel pump to the flushing filter outlet “OUT”.

5. Connect the flushing hose (1) joined to the high

pressure hose for the drum drive motor to the
flushing filter inlet “IN”.

Fig. 4
6. Disconnect the high pressure hoses (Fig. 5) from
the drum drive motor and join them with angular
fittings (1) and socket (2).

7. Fill the hydraulic oil tank using the filling and

filtering unit.

8. Keep circulating the tank contents throughout the

complete flushing process.

Fig. 5

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Bleeding the travel circuit

Environment: Catch the hydraulic oil and dispose

of environmentally!
1. Block drum and wheels with suitable chocks. (Fig.6)
2. Connect pressure test hoses to the charge pressure
test port and to the high pressure test ports.

Fig. 6
3. Hold the open ends of the pressure test hoses (Fig.
7) into a container.
4. Crank the engine approx. 30 seconds with the
starter motor. Repeat this procedure after a pause
of one minute. Then repeat this procedure, until oil
starts to run out from the pressure test hoses.
5. Remove the pressure test hoses from the high
pressure test ports.

Fig. 7

6. Connect a 60 bar pressure gauge to the charge

pressure test hose (Fig. 8) and run the engine max.
15 seconds at idle speed.
7. Repeat this procedure after a pause of approx. 30
seconds, until the pressure gauge shows a constant
pressure of 28 bar.
Note: Perform these measures with the travel lever in
neutral position. As soon as charge pressure is
present you may start to bleed the system.

Fig. 8

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Move the travel lever only to travel

direction forward, as otherwise the
flushing filter will be subjected to oil
flow from the wrong direction.

8. For bleeding shift the travel lever (Fig. 9) approx.

1/3 to travel direction forward (I).
9. After running the engine 1 to 2 minutes with idle
speed pause for approx. one minute.
Note: This waiting time is necessary to allow air bubbles
to escape through the leak oil return port on the
pump.
Repeat this measure, until the charge pressure
Fig. 9
reading drops immediately to zero when shutting
the engine down.
In this case the closed travel circuit is properly
bled.
10. Shut down the engine.
11. Disconnect the pressure test hose.
12. Reconnect the hydraulic hoses to the drum drive
motor.

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Flushing the hoses in the travel circuit
Move the travel lever only to travel
direction forward, as otherwise the
flushing filter will be subjected to oil
flow from the wrong direction.
1. Bock drum and wheels with suitable chocks.

Note: Keep circulating the complete tank

content with the filling and filtering unit
throughout the entire flushing process.

2. Run the engine with maximum speed.

Fig. 10
3. Move the travel lever (Fig. 11) to full forward
position.
5. Perform the flushing process at various engine
speeds for approx. 10 minutes.
6. Shut the engine down.

Fig. 11

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Flushing the drum drive motor

1. Reconnect the high pressure hoses to the drum

drive motor.

Danger of squashing!
Do not lay under the jacked up
machine.
Danger of accident!
The drum must rotate freely.

2. Lift or jack the front of the machine up (Fig.12), so

that the drum can rotate freely.
Fig. 12
3. Block the rear wheels with suitable chocks.

4. Repeat the bleeding procedure as described as de-

scribed in the section titled Bleeding the travel cir-
cuit.

5. Pre-select the slow speed range.

Note: Keep circulating the complete tank content
with the filling and filtering unit throughout
the entire flushing process. (Fig. 13)

Move the travel lever only to travel

direction forward, as otherwise the
flushing filter will be subjected to oil
flow from the wrong direction.

Fig. 13
6. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.

7. Perform this flushing procedure for approx. 10 min-

utes. During this process shift the travel lever several
times between full and halve forward travel.

8. Shut down the engine.

9. Remove the flushing filter and reconnect the high

pressure lines.

Fig. 14

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Flushing the travel motor

Danger of squashing!
Do not lay under the jacked up
machine.
Danger of accident!
The drum must rotate freely.

1. Lift or jack the rear of the machine up (Fig.15), so that

the wheels can rotate freely.

2. Block the drum with suitable chocks.

3. Repeat the bleeding procedure as described as de-

Fig. 15
scribed in the section titled Bleeding the travel cir-
cuit.
4. Pre-select the slow speed range.

Note: Keep circulating the complete tank

content with the filling and filtering unit
throughout the entire flushing process.
(Fig. 16)

4. Start the engine, run it with maximum speed and

shift the travel lever to travel direction forward.

Move the travel lever only to travel

direction forward, as otherwise the
flushing filter will be subjected to oil
flow from the wrong direction.
Fig. 16
5. Perform this flushing procedure for approx. 10
minutes. During this process keep changing the
pump flow by shift the travel lever several times
between full and halve forward travel.

6. Shut the engine down.

7. Remove the flushing filter and reconnect the high

pressure hoses.
Bleeding the travel circuit
8. Repeat the bleeding procedure as described as
described in the section titled Bleeding the travel
circuit.

Keep circulating the tank content.

9. After completing the bleeding process circulate the

tank contents with the filtering unit for another 15
minutes.

10. Remove the filtering unit and fasten the tank cover.

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Function test

1. Check the hydraulic oil level (Fig. 17) in the tank, top
up if necessary.

2. Check all connections for leaks with the engine

running (visual inspection).

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 the hydraulic connections once again for

leaks (visual inspection).

Fig. 17 Maintenance of the flushing filter kit

1. Change the flushing filter element, if the red control
pin of the contamination indicator is pressed out.

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.

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Flushing schematic, vibration drive

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1. Flushing hose 20S - 25S 5. Angular fitting 20S

2. Vibration pump 6. Double end union R1’ - 25S

3. Vibration motor 7. Flushing. filter

4. Connecting fitting 20S

Flushing the vibration circuit Installation of flushing filter (Fig. 1)

Note: Observe the chapter “Flushing - General” Before the installation of the filters
After changing a component check hoses and connections for
cleanliness.
1. Always flush the closed circuit.
The flushing filter must be installed in
Solid particles remaining in the circuit the low pressure side in the return flow
will damage the components again to the pump, so that only cleaned oil
within a short period of time. will enter the vibration pump in high
frequency.
In case of excessive oil contamination (abrasion)
For the connection schematic shown
1. Open and clean remaining components. here the vibration must always be
filtered with “high frequency / low
2. If necessary replace the hydraulic hoses. amplitude”.
3. Flush also the travel circuit. 1. Connect the flushing hose (flushing filter outlet
“OUT”) to the (high pressure port A) on the vibration
Before flushing
pump.
1. Replace the hydraulic oil filter element.
2. Disconnect the high pressure hose from the vibration
2. Clean the hydraulic oil tank. pump and connect it with the flushing hose (flushing
filter inlet “IN”).
3. Filter the hydraulic oil.
Flushing the hoses
Note: For filtering use the filling and filtering unit. Pump
the tank contents through a fine filter into the oil 1. Take the vibration motor out of the circuit, for this
bag or a clean container. purpose join the high pressure lines together.

Catch the hydraulic oil and dispose of Flushing the entire system
environmentally! For filling use also 1. Reconnect the vibration motor and pull it out of the
the filtering unit with fine filter. coupling for flushing.

Change the oil: Bleeding

in case of excessive contamination discoloration of the 1. Always bleed the hydraulic circuit after removing or
oil if the oil change interval is almost reached. connecting hoses in the closed circuit.

Function test

1. Perform a test drive.

2. Check all connections for leaks.

3. Check the vibrator shaft speeds.

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Flushing the vibration circuit

Cleaning the hydraulic oil tank
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. Disconnect all hoses (Fig. 1) from the tank cover.
3. Unscrew the fastening screws for the cover and
take the cover off.
Environment: Catch the hydraulic oil and dispose
of environmentally!
4. Clean the hydraulic oil tank thoroughly from inside,
reassemble cover and hoses.
Fig. 1

Filter installation to flush the vibration circuit

1. Disconnect the high pressure hose (Fig. 2) from the

vibration pump.

Fig. 2
2. Connect the flushing hose 1 (Fig. 3) from the
flushing filter outlet to the vibration pump.

3. Connect the flushing hose (4) from the flushing

filter inlet with the disconnected high pressure
hose (2) using the double end union (3).

Fig. 3

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4. Connect the flushing hose 1 (Fig. 4) from the

vibration motor high pressure hose to the flushing
filter intlet ”IN”•
5. Connect the flushing hose (2) towards the vibration
pump to the flushing filter outlet “OUT”.

Fig. 4
6. Disconnect the high pressure hoses from the
vibration motor and join them with angular fittings
(1) (Fig. 5) and socket (2).
7. Fill the hydraulic oil tank using the filling and
filtering unit.
8. Keep circulating the tank contents throughout the
complete flushing process.

Fig. 5

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Bleeding the vibration circuit

Environment: Catch the hydraulic oil and dispose
of environmentally
1. Connect pressure test hoses (Fig. 6) to the charge
pressure test port and the high pressure test ports.
2. Hold the open ends of the pressure test hoses into
a container.
3. Crank the engine for approx. 10 seconds only with
the starter motor. Repeat this procedure after a
pause of one minute. Then repeat this procedure,
until oil starts to run out from the pressure test
hoses.
Fig. 6 4. Remove the pressure test hoses from the high
pressure test ports.
5. Connect a 60 bar pressure gauge to the charge
pressure test hose (Fig. 7) and run the engine max.
15 seconds at idle speed.

6. Repeat this procedure after a pause of approx.

30 seconds, until the pressure gauge shows a
constant pressure of 28 bar.

Note: Perform all these measures with the vibration

switched off. As soon as charge pressure is
present you may start to bleed the system.

Use only low frequency, as otherwise

the flushing filter will be subjected to
Fig. 7
oil flow from the wrong direction.

7. For bleeding run the vibration with low frequency

(Fig. 8).

8. After running the engine 1 to 2 minutes with idle

speed pause for approx. one minute.

Note: This waiting time is necessary to allow air bubbles

to escape through the leak oil return port on the
pump.
Repeat this measure, until the charge pressure
reading drops immediately to zero when shutting
the engine down.
In this case the closed travel circuit is properly
bled.
Fig. 8
9. Disconnect the pressure test hose.

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Flushing the hydraulic hoses

1. Run the engine with maximum speed.

Use only low frequency, as otherwise

the flushing filter will be subjected to
oil flow from the wrong direction.

2. Switch vibration on with low frequency (Fig. 9).

3. Perform this flushing procedure for approx. 10
minutes. Switch the vibration on and off at intervals
of approx. 30 seconds.
4. Shut the engine down.
Fig. 9 Flushing the vibration system

1. Unscrew the fastening screws for the vibration

motor and pull the motor out of the coupling (Fig.
10).
2. Reconnect the high pressure hoses to the vibration
motor.
3. Repeat the bleeding procedure as described above.
4. Run the engine with maximum speed.
Use only low frequency, as otherwise
the flushing filter will be subjected to
oil flow from the wrong direction.

5. Perform this flushing procedure for approx. 10

Fig. 10 minutes. Switch the vibration on and off at intervals
of approx. 30 seconds.
6. Shut the engine down.
7. Remove the flushing filter and reassemble the
vibration motor.
8. Repeat the bleeding process.

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9. After completing the bleeding process circulate the

tank contents with the filtering unit for another 15
minutes.
10. Remove the filtering unit and fasten the tank cover.

Function test

1. Check the hydraulic oil level (Fig. 11) in the tank,

top up if necessary.
2. Perform a test drive.
3. Check all connections for leaks.

Maintenance of the flushing kit

1. Change the flushing filter element, if the red

control pin of the contamination indicator is
pressed out.
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.
Fig. 11 3. Change the flushing filter element of the filling
and filtering unit when the red control pin of the
contamination indicator is pressed out.

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Instructions for repair

BW177 D/DH/PDH-50

Trouble shooting

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General

Trouble shooting charts

The following work must only be carried out by qualified and trained
personnel or by the after sales service of BOMAG.

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General hoses are in good condition. Hydraulic oil emerging

General notes for trouble shooting in hydraulic from a small opening can hardly be seen; when
systems checking for leaks you should therefore use a piece of
cardboard or wood.
The following checks are used for fault diagnosis
and are intended for precisely locating a fault in the Consult a doctor if you are injured by pressurized oil,
hydraulic system. as this may cause serious infections.

In some cases these tests may finally lead to the Check the hydraulic oil level before and after work.
detection of faults on hydraulic components in the Use only clean oil according to the specifications.
power transmission system. Check the hydraulic system for leakages, detect the
On the basis of these preliminary tests, the individual cause and seal the leak.
test points have the function to initially pinpoint the Ensure strict cleanliness, clean connections and fittings
fault to a general area and then to determine exactly before unscrewing them.
the faulty oil circuit or hydraulic component.
Cover all openings and connections or close them with
These tests must be performed if hydraulic components suitable plugs.
are working to slowly or not at all, if the hydraulic oil is
overheating or if major repairs have been carried out Fill new components with hydraulic oil before starting
in the hydraulic system and on power transmission to operate.
elements. Always bleed and flush the hydraulic system thoroughly
In all cases the tests must be performed in the following after changing a component.
order and all instructions must be strictly complied If possible perform all measurements and tests at
with. operating temperature of the hydraulic oil (approx.
Important points on trouble shooting and fault 50°C/122°F).
remedy After changing a component check charge and high
Danger of injury! pressure and, if necessary, the rotary speeds.

Keep away from rotating parts of the Hydraulic hoses must be checked visually in regular
engine. intervals.
Hydraulic hoses must be immediately replaced in case
When working on the travel pump
of:
block the drum with suitable chocks.
The outer layer is worn down to the metal lining (e.g.
Hydraulic oil escaping under pressure
chafing, cuts, cracks)
can penetrate the skin and cause
serious injuries. Embrittlement of the outer layer (development of
cracks in the hose material)
It is not recommended to open or
repair hydraulic components without Deformation in pressureless and pressurized condition,
which are not in accordance with the natural shape of
specific knowledge.
the hose
Risk of damage to pressure gauges!
Deformation in bends, e.g. squeezing, sharp bends,
Use only specified pressure gauges. layer separation, development of blisters
Ensure strict cleanliness, clean all Leakages
connections and fittings before Non-conformity with installation requirements
unscrewing them.
Separation of the hydraulic hose from the fitting
Cover all openings and connections or
close them with suitable plugs. Corrosion of the fitting, which impairs the function and
the strength
Hydraulic oil escaping under pressure can penetrate the
skin and cause serious injuries. You should therefore Damage or deformation of the fitting, which impairs the
depressurize the system before disconnecting any function and strength of the hose/hose connection
hoses. Before repressurizing the system you should Expiration of the storage and utilization period
make sure that all line connections are tight and all

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In the trouble shooting chart it has been assumed that

the machine is correctly equipped, that all installations
are according to specifications and that hoses and
connections are free of faults.
The chart lists progressive tests for localizing the cause
of a fault and, consequently, its elimination.

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Trouble shooting charts

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The machine drives with the travel lever in “NEUTRAL”

Check the neutral position

- Set the travel lever to “Neutral”

- Detach the travel cable from the pump
- check, whether bores of ball socket and
control lever are in line.

Adjust the travel

control cable

Bores are no
in line?

yes

Check the mechanical O-position

- Connect the control chambers with a hose

no*
Neutral position
OK?
*Stop - inform the service department of BOMAG!
yes*

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Adjust the mechanical 0-position

- Adjust the mechanical O-position so that both sides
- Install 600 bar pressure gauges to the
have identical pressure (charge pressure)
high pressure test ports
- Repeat the test with 60 bar pressure gauges
- Pull the plug off the brake solenoid
valve and block the drum
- Run the diesel engine with max. speed
- Read the pressure gauges.

Check the servo control

- Remove the servo control

- Check moveability and wear of pistons and
linkages

no Replace the
Servo control
OK? servo control

yes

Replace the
travel pump

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The machine does not drive

(to both travel directions)

Check high and charge pressure

- Install 600 bar pressure gauges to the high pressure test ports
- Install 600 bar pressure gauges to the charge pressure test ports
- Pull the plug off the brake solenoid valve
- Start the engine and run it with max. speed
- Drive the machine against the closed brake, actuate the travel
lever for a moment and read the pressures gauges
Nominal value:
High pressure approx.425 bar
Charge pressure approx. 25 bar

yes
High pressure
OK?

no

Check the magnetic coil of the brake valve

- Start the engine and release the brake

(disengage the travel lever)
- Check voltage and current consumption of the
coil with a measuring instrument
Nominal value:
14V / 1.8A
Perform trouble
no*
Magnetic coil shooting in the
OK? electric system

Check the travel control cable yes*

- Check whether the pump control
lever is actuated when operating
the travel lever.
no Replace the travel
Control cable
OK? control cable

*Stop - inform the service department

yes
of BOMAG!

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Check the brake releasing pressure

- Install a 60 bar pressure gauge to the
rake releasing hose and check whether
the brake value opens.
Nominal value: approx. charge pressure

no
Brake valve
OK?

yes

Mechanical fault on
axle drum

no
Charge pressure
OK?

yes*
*Stop - inform the service department of BOMAG!

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Check the steering/charge pump

- Install a 600 bar pressure gauge to the
steering pressure test port
-Pull the plug off the staring solenoid and
crank the engine with the starter
-Turn the steering against the end stop
and read the pressure gauge
Nominal value: approx. 200 bar (battery
fully charged)

no* Perform trouble shooting

Steering pressure
in the steering system
OK?

yes*

- Loosen the brake releasing

Iines to the drum motor
and the axle motor one
after the other, close them
no with plugs and repeat the
Charge pressure
charge pressure test.
OK?
- Repair the unit after the
yes separation of which the
charge pressure is OK.

*Stop - inform the service department of BOMAG!

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Check the charge pressure relief valve

no Replace the charge pressure

Valve OK?
relief valve

yes

Check the flushing valve for the axle

drive motor

no Replace the
Flushing valve
flushing valve
OK?

yes

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Check the individual

components
Check the drum drive motor
- Close the high pressure ports on the
drum drive motor with plugs and repeat
the pressure test

yes
Pressures Replace, repair the drum drive motor
OK?

no

Check axle drive motor / travel pump

- Close the high pressure ports on the
travel pump with plugs and repeat the
pressure test

yes Replace repair the axle

Pressures
drive motor
OK?

no

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Check the servo control

- Remove the servo control
- Check the nozzles, clean if necessary
- Check the linkage, repair if necessary

no Replace the
Servo control
servo control
OK?

yes

Replace, repair the

travel pump

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Insufficient travel power, max. speed not reached

Check the engine speed

Nominal value:
2200 rpm (nominal speed)

no Perform trouble
Speed
shooting on
OK?
the engine

yes

Check trouble travel cable

- Detach the travel cable
-Check bores and pin for
excessive play and wear

no Replace the travel

Control cable
control cable
OK?

yes

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- Actuate the travel lever to

forward and reverse
- Check, whether the control
lever reaches the max. positions

max.
no Adjust/replace travel
positions
lever or control cable
OK?

yes

Check the charge pressure

- Install a charge pressure gauge (60 bar)
- Start the engine and run it with idle
speed
- Read the pressure gauge
Normal value:
min. 24 bar

no
Charge pressure
OK?

yes

*Stop - inform the service department of BOMAG!

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Check the steering/charge pump

- Install a 600 bar pressure gauge to the
steering pressure test port
-Pull the plug off the staring solenoid and
crank the engine with the starter
-Turn the steering against the end stop
and read the pressure gauge
Nominal value: approx. 200 bar (battery
fully charged)

no* Perform trouble shooting

Steering pressure
in the steering system
OK?

yes

Check the leakage of the brake

- Release the brake, to do so disengage
the travel lever from the brake position
and repeat the charge pressure test.

- Loosen the brake releasing Iines to

the drum motor and the axle motor
one after the other, close them with
plugs and repeat the charge pressure
no test.
Charge pressure
OK? - Repair the unit after the separation of
which the charge pressure is OK.
yes

*Stop - inform the service department of BOMAG!

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Check the charge pressure relief valve

no Replace the charge pressure

Valve OK?
relief valve

yes

Check the flushing valve for

the axle drive motor

Flushing no Replace the

valve OK? flushing valve

yes

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Check the individual

components
Check the drum drive motor
- Close the high pressure ports on the
drum drive motor with plugs and repeat
the pressure test

yes
Pressures Replace, repair the drum drive motor
OK?

no

Check axle drive motor / travel pump

- Close the high pressure ports on the
travel pump with plugs and repeat the
pressure test

yes Replace repair the axle

Pressures
drive motor
OK?

no

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Check the servo control

- Remove the servo control
- Check the nozzles, clean if necessary
- Check the linkage, repair if necessary

no Replace the
Servo control
servo control
OK?

yes

Replace, repair the

travel pump

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Hydraulic oil overheating, >90 ˚C (194 ˚F)

Check the thermostat valve

- Check, whether to hose to the cooler warms up
at a hydraulic oil temperature of >60 ˚C (>140 ˚F)

Thermostat no Replace the

opens thermostat valve

yes

Check the multi-function valves

- Pull the plug off the brake solenoid valve
- Actuate the travel control lever to both
travel directions and check the multi-
function valves for overheating

- Check the hoses for kinks

Valves no
Overheating? - Check the components for
excessive heat

yes*

Clean” replace the respective

multi-function valve *Stop - inform the service department of BOMAG!

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No vibration
(travel system OK)

Check the magnetic coil of the vibration valve

- Switch the ignition on
- Switch the vibration on at high or low frequency
- Check voltage and current consumption with a
measuring instrument
Nominal value:
12V/2.5A

no Perform trouble
Voltage / current shooting in the
OK? electrical system

yes*

Check the pilot pressure

- Stand the drum on rubber tires
- Unscrew the plugs from the control
chambers and install pressure test ports
- Install 60 bar pressure gauges
- Run the diesel engine with max. speed
- Switch the vibration on and read the
pressure gauge
Nominal value:
approx. 20 bar

no Check the solenoid valve,

Pilot pressure replace if necessary
OK?

yes

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Check the vibration pump

- Close the high pressure ports on the vibration
pump with plugs
- Install 600 bar pressure gauges to the high
pressure test ports
- Run the diesel engine with max. speed
- Switch the vibration on and read the pressure
gauge
Nominal value:
approx. 370 bar

yes Replace / repair the

High pressure
OK? vibration pump

no

Check the vibrator shaft bearings

- Remove the vibration motor
- Check the axial play and the moveability
of the shaft
- Check the condition of the coupling

Bearings and no Replace bearing or

coupling OK? coupling

yes

Replace / repair the vibration

motor

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Vibrator shaft speed too low

Check the engine speed
Nominal value:
2200 rpm (nominal speed)

Engine speed no Perform trouble

OK? shooting on the engine - Adjust the speeds for
high or low frequency
yes

Drop in
vibrator shaft no
speed > 10%

yes

Check the vibration pump

- Install 600 bar pressure gauges to the high pressure
test ports
- Install 60 bar pressure gauges to the charge pressure
test ports
- Stand the drum on rubber tires
- Run the diesel engine with max. speed
- Switch the vibration on and read the pressure gauge
Nominal value:
Starting pressure 350 bar
no* operating pressure approx. 100 ... 150 bar
Charge pressure Charge pressure min. 24 bar
OK?

yes
*Stop - inform the service department of BOMAG!

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Check flushing valve

and flushing spool

no Replace the
Flushing valve
flushing valve
OK?

yes

Check the steering / charge pump

- Install a 600 bar pressure gauge to the

steering pressure test port
- Pull the plug off the starting solenoid
and crank the engine with the starter
- Turn the steering against the end stop
and read the pressure gauge
Nominal value:
approx. 140 bar (battery fully charged)

no Perform trouble shooting

Steering pressure
in the steering system
OK?

yes

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Check the charge

pressure relief valve

no Replace the charge

yes Valve OK?
pressure relief valve
Operating pressure
OK?
yes
no*
yes
Starting pressure
OK?

Check the leak oil rate of the

vibration motor
- Block the flushing valves with
washers
- Unscrew the leak oil hose and fit
a testing hose
- Switch the vibration on and
measure the leakage rate
Nominal value:
max. 0,5 I/min at approx. 100 bar

no Replace / repair the

Leak oil OK?
vibration motor

yes

*Stop - inform the service department of BOMAG!

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Check the individual

components
- Close the high pressure
ports on the vibration pump
with plugs and repeat the
pressure test

yes Replace / repair the

High pressure
vibration motor
OK?

no

Check the vibration shaft bearings

- Remove the vibration motor
- Check the axial play and the moveability of
the shaft

Check the multi-function valve

Valves no
OK?

yes
Replace the multi
function valves

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Check the way-valve

- Disassemble the way-valve
- Check the nozzle (1 ), clean if necessary

yes Replace, repair the

Way-valve
way-valve
OK?

no

Replace, repair the

way-valve

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No steering function / steering sticky / end stops not reached

Note: The steering pump serves also as charge
Check the steering pressure
- Install a 600 bar pressure gauge to the
steering pressure test port
- Pull the plug off the starting solenoid
and crank the engine with the starter
- Turn the steering against the end stop
and read the pressure gauge
Nominal value:
- approx. 200 bar (battery fully charged)

yes* Check moveability of articulated

Steering pressure
joint and steering cylinders
OK?

no*

Check the steering cylinders

- Close the hydraulic hoses at the steering
cylinder ports ,.R” and “LlI with plugs
- Repeat the pressure test

yes Replace the

Steering pressure
steering cylinders
OK?

no

*Stop - inform the service department of BOMAG!

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Check the steering/charge pump

- Close the pump outlet port with a 200
bar pressure relief valve
- Install a 600 bar pressure gauge
- Crank the engine with the starter
- Read the pressure gauge
Nominal value:
approx. 200 bar

yes Replace, repair the

Steering pressure
steering valve
OK?

no

Replace, repair the

steering/charge pump

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Instructions for repair

BW177 D/DH/PDH-50

Drum

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Special tools

Removing and installing the drum

Drum repair overview

Repairing the drum

Disassembling and assembling the change-over weight

Changing the rubber buffers

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Special tools

1. Disassembly device for side plate

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2

3. Pressing plate for cylindrical roller bearings

Fig. 3

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4. Pressing plate for grooved ball bearing

Fig. 4
5. Pressing sleeve for radial seal

Fig. 5
6. Lifting gear for vibrator unit

BOMAG part-no. 007 215 08

Fig. 6

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Removing and installing the drum

Removing the drum
Environmental damage
Catch running out hydraulic oil and dispose of
environmentally.
1. Unscrew the fastening screws (Fig. 1) from the hose
brackets on both sides of the drum.

Fig. 1
2. Mark the hydraulic hoses (Fig. 2) on the vibration
motor and disconnect them from the ports.
3. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 2
4. Mark the· hydraulic hoses (Fig. 3) on the travel
motor and disconnect them from the ports.
5. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 3
Danger of accident!

6. Jack the front frame up, until the rubber buffers are
unloaded.
7. Properly support the front frame on both sides of
the rear cross-member.
8. Unscrew the fastening screws (Fig. 4) from the
spacer pieces on the vibration motor.

Fig.4

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9. Unscrew the fastening screws (Fig. 5) from the

spacer piece on the drum drive motor.

Fig. 1
Danger of squashing!
Do not stand or step under loads being
loaded.
Note: If necessary it is possible to remove the side plate
and lift the drum out sideways.
10. Attach the lifting tackle to the drum (Fig. 6) and lift
the drum carefully out of the front frame.

Fig. 2
11. Check all rubber buffers on the vibration ·motor
side (Fig. 7), replace if necessary (see corresponding
chapter).

Fig. 3
12. Check all rubber buffers on the drum drive motor
side (Fig. 8), replace if necessary.

Fig.4

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Installing the drum

Danger of squashing!
Do not stand or step under loads being
loaded.

1. Lift the drum into the frame (Fig. 9) and align it

parallel to the frame.

Fig. 9
2. Fasten the spacer piece on the travel motor with
screws (Fig. 10) and nuts to the side plate.

Fig. 10
3. Measure the distance “X” between spacer piece and
side plate (Fig. 11) on the vibration motor side.
4. Calculate the thickness of the compensation plates.
Nominal value:
Distance “XI” + 1.5 mm
5. Turn one screw into each welded nut at front
and rear and open a sufficient gap to insert the
compensation plates.

Fig. 11
6. Insert the compensation plates (Fig. 12).
7. Unscrew the screws from the welded nuts.
8. Fasten the spacer piece on the vibration motor with
screws and nuts to the side plate.

Fig.12

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1. Unscrew the fastening screws (Fig. 1) from the hose

9. Fasten the brackets for the hydraulic hoses (Fig.
13) on both sides.
10. Connect the hydraulic hoses according to the
marking to the ports on travel and vibration
motors.
After connecting the hydraulic hoses
and before starting operation bleed
the hydraulic system, check the
function and inspect the system for
leaks.
Fig. 13

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Repair overview, drum

Fig. 1

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1. Vibration bearing 4. Vibration bearing

2. Change-over weight 5. Rubber buffer

3. Vibrator shaft 6. Travel bearing

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Repairing the drum

1. Remove the drum.

2. Unscrew the fastening nuts (Fig. 1) and take the
spacer piece off.

Fig. 1
3. Unscrew the fastening screws from the flanged
cover (Fig. 2) and take the cover with the vibration
motor off.

Fig. 2
4. Attach the lifting tackle to the drum drive motor.
5. Unscrew the fastening nuts (Fig. 3) and take the
drive disc with the drum drive motor off.
6. Check all rubber buffers for wear, replace if
necessary (see corresponding chapter).

Fig. 3
7. Pull the coupling sleeve off the hub (Fig. 4) and
check it for wear.

Fig.4

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Disassembling the bearing cover.

1. Remove the circlip 1 (Fig. 5) from the bearing
housing.

Fig. 5
2. Pull the bearing cover off the bearing housing
(Fig. 6).

Fig. 6
3. Knock the grooved ball bearing 1 (Fig. 7) out of the
bearing cover.

Fig. 7
4. Take the V-ring 1 (Fig. 8) off the bearing housing.

Fig.8

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Removing the vibrator shaft

1. Pull the coupling hub off the vibrator shaft (Fig. 9)..

Fig. 9
2. Unscrew the filler plug 1 (Fig. 10).
Environment
Catch running out oil and dispose of environmentally.
3. Unscrew the drain plug (2) and drain the oil from
the bearing housing.

Fig. 10
4. Unscrew the fastening screws 1 (Fig. 11) from the
bearing housing (2).

Fig. 11
5. Attach the lifting gear to a crane and slide it over
the vibrator shaft.

6. Force the bearing housing with screws 1 (Fig. 12)

out of the drum.

Fig. 12

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7. Pull the vibrator shaft out of the drum (Fig. 13).

Fig. 13
Dismantling the vibrator shaft
1. Remove the bearing housing from the vibrator
shaft (Fig. 14).

Fig. 14
2. Take the O-ring 1 (Fig. 15) off the bearing housing.

Fig. 15
3. Remove the circlip 1 (Fig. 16) and knock the
cylinder roller bearing (2) out.

4. Knock the radial seal (3) out of the bearing

housing.

Fig. 16

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5. Take the fitting key 2 (Fig. 17) out of the groove.

Note: If inner bearing race and inner ring are very tight
on the shaft, heat them up with a torch.
6. Knock inner bearing race (1) and inner ring (3) of
the shaft.

Fig. 17
7. Remove the circlip from the groove in front of the
change-over weight (Fig. 18).

Fig. 18
8. Knock the change-over weight 1 (Fig. 19) off the
vibrator shaft.
Note: If necessary disassemble, assemble the change-
over weight (see corresponding table).
9. Take the circlip (2) out of the groove in the vibrator
shaft.

Fig. 19
10. Pull the Inner bearing race 1 (Fig. 20) off the other
side of the vibrator shaft.
Use protective gloves.

Note: If the inner bearing race is very tight on the shaft,

heat it up with a torch.

Fig. 20

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11. Remove the circlip from the groove in front of the

change-over weight (Fig. 21).

Fig. 21
12. Knock the change-over weight 1 (Fig. 22) off the
vibrator shaft.
Note: If necessary disassemble, assemble the
change-over weight (see corresponding table).
13. Take the circlip (2) out of the groove in the vibrator
shaft.

Fig. 22
Removing the cover
1. Unscrew the fastening screws 1 (Fig. 23) for the
cover (2).

Fig. 23
2. Force the cover with screws 1 (Fig. 24) off the drum

Fig. 24

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3. Take the O-ring 2 (Fig. 25) off the cover.

4. Remove the circlip (1) and knock the cylinder roller
bearing (3) out.

Fig. 25
Installing the cover
1. Press the new bearing 3 (Fig. 26) into the cover
until it bottoms and apply some oil.
2. Install the circlip (1).
3. Assemble the new O-ring (2) with grease.

Fig. 26
4. Assemble the cover 2· (Fig. 27) and fasten it with
the screws (1).

Fig. 27
Assembling the vibrator shaft

During assembly observe the

installation direction of the change-
over weights (Fig.28).

Fig. 28

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1. Snap the circlip 2 (Fig. 29) into the groove in the

vibrator shaft.
Danger of burning!
Use protective gloves.

2. Heat the change-over weight (1) up to approx.

80°C and slide it on the vibrator shaft.

Fig. 29
3. Install the circlip (Fig. 30).

Fig. 30
Danger of burning!
Use protective gloves.

4. Heat the inner bearing race 1 (Fig. 31) up to

approx. 80°C and slide it on the shaft against
the shoulder with the bigger outer diameter
facing forward.

5. Heat the inner ring (3) up to approx.80 °C and

slide it on against the stop.

6. Press the circlip (2) into the groove in the

Fig. 31 vibrator shaft.

7. Snap the circlip 2 (Fig. 32) into the groove in the

vibrator shaft.

Observe the installation direction.

8. Heat the change-over weight (1) up to approx.

80°C and slide it on the vibrator shaft.

Fig. 32

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9. Install the circlip (Fig. 33).

Fig. 33
Danger of burning!
Use protective gloves.

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

and slide it on the vibrator shaft against the
shoulder with the bigger outer diameter facing
forward (Fig. 34).

Fig. 34
11. Press the new bearing 2 (Fig. 35) into the
bearing housing until it bottoms and apply some
oil.
12. Install the circlip (1).

Fig. 35
13. Insert the new O-ring 1 (Fig. 36) with grease into
the bearing housing.

Fig. 36

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14. Slide the bearing housing over the vibrator shaft

(Fig. 37).

Fig. 37
Assembling the vibrator shaft

1. Slide the lifting device over the vibrator shaft and

insert the vibrator shaft carefully into the bearing
on the opposite side (Fig. 38).

Fig. 38
2. Fasten the bearing housing 2 (Fig. 39)’with the
screws (1).

Fig. 39
3. Turn an eye bolt M16 (Fig. 40) into the bore in
the vibrator shaft to measure the end float.
4. Push the vibrator shaft into the bearing housing
against the end stop.

Fig. 40

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5. Measure the distance from the face of the vibrator

shaft to the bearing housing (Fig. 41).

Fig. 41
6. Pull the vibrator shaft out of the bearing housing
against the end stop (Fig. 42).

Fig. 42
7. Measure the distance from the face of the vibrator
shaft to the bearing housing (Fig. 43) again.

Note: Subtract the second measurement from the first

measurement to calculate the end float.

Nominal value:
min. +0,3 mm
max. + 1,8mm

8. If a new bearing housing has been installed heat

the spacer ring 1 (Fig. 44) up to approx. 80°C and
slide it on the bearing housing against the stop
Fig. 43 with the bigger outer diameter facing forward.

The outer rim of the seal ring must be

absolutely dry and free of grease, oil,
lacquer and conserving agent.

Fig. 44

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9. Apply some Hylomar to the outer rim of seal ring 1

(Fig. 45) and press the seal ring with the sealing lip
forward into the bearing housing, until it bottoms.

Fig. 45
10. Knock the coupling hub 1 (Fig. 46) on the vibrator
shaft.

Fig. 46
11. Push the new V-ring 1 (Fig. 47) on the bearing
housing with the sealing lip pointing to the outside.

Fig. 47
12. Unscrew the plugs 1 and 2 (Fig. 48) and fill in engine
oil as specified in the maintenance instructions.
13. Screw the plugs back in (1 and 2).

Fig. 48

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9. Apply some Hylomar to the outer rim of seal ring 1

(Fig. 45) and press the seal ring with the sealing lip
forward into the bearing housing, until it bottoms.

Fig. 45
10. Knock the coupling hub 1 (Fig. 46) on the vibrator
shaft.

Fig. 46
11. Push the new V-ring 1 (Fig. 47) on the bearing
housing with the sealing lip pointing to the outside.

Fig. 47
12. Unscrew the plugs 1 and 2 (Fig. 48) and fill in engine
oil as specified in the maintenance instructions.
13. Screw the plugs back in (1 and 2).

Fig. 48

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Assembling the bearing cover

1. Knock the grooved ball bearing 1 (Fig. 49) into the

bearing cover until it bottoms and fill it with grease.

Fig. 49
2. Pull the bearing cover on against the end stop
(Fig. 50).

Fig. 50
3. Install the circlip 1 (Fig. 51).

Fig. 51
4. Check the splines in the coupling sleeve (Fig. 52) for
wear, if necessary use a new one.

Fig. 52

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5. Push the new V-ring (Fig. 53) on the flange cover of

the vibration motor with the sealing lip pointing to
the outside.

Fig. 53
6. Assemble the flange with vibration motor (Fig. 54) .

Fig. 54
7. Fasten the spacer piece (Fig. 55) to the rubber
buffers.

Fig. 55
8. Assemble the drum drive motor with the drive disc
(Fig. 56).
9. Install the drum (see corresponding chapter).

Fig. 56

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Dismantling, assembling the change-over weight

Dismantling the change-over weight.
1. Unscrew all screws 1 (Fig. 1).

Fig. 1
2. Turn the screws 1 (Fig. 2) into the tapped bores in
the cover and force the cover off.
Environmental damage
Catch running out oil and dispose of environmentally.

Fig. 2
3. Take the O-rings 1 and 2 (Fig. 3) out of the grooves.

Fig. 3
4. Take the weight 1 (Fig. 4) out of the housing.

Fig.4

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Assembling the change-over weight

1. Insert the change-over weight into the housing

with the bevelled inner edge 1 (Fig. 5) pointing up..

Fig. 5
2. Insert the new O-rings 1 and 2 (Fig. 6) with some
grease.

Fig. 6
3. Fill in approx. 1 liter of silicone oiJ;47V1000cst. to
the edge of the housing (Fig. 7).

Fig. 7
4. Install the cover.
5. Cover the screws with Loctite green No. 601 (Fig. 8).
6. Tighten the screws with 34 Nm.

Fig. 8

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Changing the rubber buffers

1. Jack the frame up at the side to relieve the rubber

buffers.
2. Unscrew the nut 1 (Fig. 1) and take the washer off.
3. Unscrew the screws (2).
4. Take the rubber buffers (3) off.
5. Insert the new rubber buffer into the slot in the
582615 drive disc and align the bores to the tapped
holes in the drum.

Fig. 1 6. Screw the screws in and tighten them.

7. Attach the washer, screw the nut on and tighten it.
8. Lower the jacked up side of the frame..

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Instructions for repair

BW177 D/DH/PDH-50

Oscillating articulated joint

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Special tools

Removing and installing the oscillating articulated joint

Oscillating articulated joint repair overview

Dismantling the oscillating articulated joint

Assembling the oscillating articulated joint

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Special tools
1. Pressing mandrel for rocker bearings

Fig. 1
2. Pressing sleeve for outer and inner race of rocker
bearing

Fig. 2
3. Guide journal

Fig. 3
4. Clamping device

Fig. 4

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Removing and installing the oscillating articulated

joint
1. Support the rear of the frame safely with trestles or
wooden blocks (Fig. 1).

Fig. 1
2. Support the rear frame near the articulated joint
safely with trestles or wooden blocks (Fig. 2).

Fig. 2
3. Attach the lifting gear to the front frame near the
articulated joint (Fig. 3).

Fig. 3
4. Unscrew the screws 1 (Fig. 4) and take the bracket
(2) off.
5. Knock the bearing pin (3) out.
6. Retract the steering cylinder (4).

Fig. 4

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Danger of accident!

7. Support the oscillating articulated joint safely in the

middle with a jack or something similar.
8. Unscrew the screws 1 (Fig. 5) and take them off with
the washers (2)

Fig. 5
9. Unscrew the nuts 3 (Fig. 6) and take the lock
washers (2) off.
10. Pull the screws (1) out.
11. Lift the front frame slightly up and lower the
oscillating articulated joint to the ground.
12. Pull the oscillating articulated joint out.

Fig. 6
Note for Installation:
Install the oscillating articulated joint with the
bore 1 (Fig. 7) for the articulation lock on the left
hand side.
Insert the steering cylinder pins so that the
groove (2) is parallel with the tapped bores (3).

Fig. 7

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Overview Articulated Joint

1. Housing 12. Cover

2. Seal ring 13. Cover
3. Cover 14. Intermediate ring
4. Rocker bearing 15. Rocker bearing
5. Pin 16. Intermediate ring
6. Shim/backing disc 17. Rocker bearing
7. Belleville spring 18. Cross beam
8. Rocker bearing 19. Friction bearing
9. Console 20. V-ring
10. Belleville spring 21. Seal ring
11. Shim/backing disc

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Dismantling the oscillating articulated joint

1. Unscrew the nuts from the hexagon screw 1 (Fig. 1)
and pull the hexagon screw out.

Fig. 1
2. Unscrew the screws from the cover.
3. Take the cover with Belleville springs, shims and
backing disc off (Fig. 2).
4. Remove also the cover from the other side.
Note: There are no Belleville springs, shims and backing
disc under this cover.

Fig. 2
5. Knock the console with a plastic hammer to one
side to the end stop (Fig. 3).
Note: The outer race of the rocker bearing is thereby
forced off.

Fig. 3
6. Lever the inner race 1 (Fig. 4) of the rocker bearing
off the pin.
7. Take the backing disc (2) off.
8. Knock the console to the opposite side and take
the rocker bearing off in a similar way.

Fig. 4

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9. Unscrew the screws 1 (Fig. 5).

10. Force the pin (3) out of the console with forcing
screws (2).
Note: Extract the piston on the other side in the same
way.

Fig. 5
11. Lift the console 1 (Fig. 6) off the housing (2).

Fig. 6
12. Take the sealing rings out of the console (Fig. 7).

Fig. 7
13. Remove the cover from the housing.
14. Remove shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).

Fig. 8

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15. Unscrew the screws 1 (Fig. 9), take the cover (2) off.

Fig. 9
16. Take the intermediate ring out of the housing (Fig.
10).

Fig. 10
17. Lift the housing· slightly up and knock the cross
beam out downwards (Fig. 11).

Fig. 11
18. Pull the housing off the cross beam (Fig. 12).

Fig. 12

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19. Knock the outer races of the friction bearings out of

the housing (Fig. 13).

Fig. 13
20. Knock the friction bearings out of the housing
(Fig. 14).

Fig. 14
21. Take the sealing ring 1 (Fig. 15)’snd’thEifV-ring (2)
off the cross beam.

Fig. 15
22. Check the rocker bearings, if necessary press them
out of the housing (Fig. 16).

Fig. 16

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Assembling the oscillating articulated joint

1. If disassembled, press the rocker bearings with a
pressing mandrel completely into the housing
(Fig. 1).

Fig. 1
2. Push the new V-ring on the cross beam against the
end stop with the lip pointing upwards
(Fig. 2).

Fig. 2
3. Attach the sealing ring to the cross beam (Fig. 3).
4. Fill the space between V-ring and sealing ring with
multi-purpose grease.

Fig. 3
5. Press the friction bearing completely into the
housing with the slanted surface facing to the
outside (Fig. 4).

Fig. 4

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6. Slide the housing over the cross beam (Fig. 5).

Note: The journal on the housing must be in the middle
above the recess on the cross beam.

Fig. 5
7. Press the sealing ring carefully in until it is located
in the recess in the housing (Fig. 6).

Fig. 6
8. Spray the running face on the outer race of the
rocker bearing with sliding lacquer OKS 571.
Do not use grease.

9. Press the outer race of the rocker bearing 1 (Fig 7)

with a pressing sleeve (2) completely in with the
wider outer rim forward.

Fig. 7
10. Press the inner race of the rocker bearing 1 (Fig 8)
completely in with the pressing sleeve (2)

Fig. 8

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11. Insert the intermediate ring (Fig. 9).

Fig. 9
12. Press the inner race of the rocker bearing 1 (Fig. 10)
completely in with the pressing sleeve (2).

Fig. 10
8. Spray the running face on the outer race of the
rocker bearing with sliding lacquer OKS 571.
Do not use grease.

14. Press the outer race of the rocker bearing 1 (Fig. 11)
with a pressing sleeve (2) completely in with the
wider outer rim facing upwards.

Fig. 11
15. Press the intermediate ring 1 (Fig. 12) in until it
bottoms.
16. Attach the cover (2) with the machined rim
forward.
17. Screw the screws (3) in and tighten them crosswise.

Fig. 12

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18. Determine the thickness of the shims, therefore-

stand the carrier on a wooden plate with a “ 18 mm
bore.
19. Push the rod of the clamping device in from un-
derneath, attach the plate, screw the nut on and
tighten it with 120 Nm.
20. Measure the distance from the housing edge to the
intermediate ring (Fig. 13) and write it down, e.g. 4,6
mm.
Note: Subtract the fixed value of 3.9 mm from the
measured value 4.6 mm to determine the
Fig. 13 required thickness of the shim.
Example of a calculation:
measured value: 4,6 mm
fixed value: 3,9 mm
Thickness of shims: 0,7 mm
21. Remove the clamping device.

22. Insert the shim 2 (Fig. 14) of appropriate’ thickness

and the backing disc (1) into the cover.

Fig. 14
23. Insert the Belleville springs with the convex side
forward into the cover (Fig. 15)..

Fig. 15

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24. Attach the cover 2 (Fig. 16) with Belleville springs,

shims and backing disc.
25. Screw the screws (1) in and tighten them crosswise.

Fig. 16
26. Insert new sealing rings into the respective groove
in the console (Fig. 17).

Fig. 17
27. Lift the console 1 (Fig. 18) over the housing (2).

Fig. 18
28. Screw four guide pins into the bores in the housing
(Fig. 19).

Fig. 19

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Note: Perform the following eight steps on both sides.

29. Push the pins over the guide pins (Fig. 20) and
knock them in until they bottom.

Fig. 20
When knocking the pin in make sure
that the sealing ring on the back (Fig.
21) is not pressed out of the console.

Fig. 21
30. Unscrew the guide pins.
31. Screw the screws in and tighten them with 75 Nm
(Fig. 22).

Fig. 22
32. Slide the backing disc over the pin (Fig. 23).

Fig. 23

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33. Attach the inner bearing race of the rocker bearing

with the wider outer rim pointing forward (Fig. 24)
and knock it on until it bottoms.

Fig. 24
34. Spray the running face of the outer rocker bearing
race with sliding agent OKS 571.

Do not use grease.

35. Attach the outer race of the rocker bearing with

It the wider outer rim pointing outwards (Fig. 25)
and knock it in until it bottoms.

Fig. 25
36. Attach the cover 1 (Fig. 26) to the bottom side of
the console.
37. Screw the screws (2) in and tighten them crosswise.

Fig. 26
38. Determine the thickness of the shims, therefore
insert the rod 1 (Fig. 27) of the clamping device
from underneath. Attach the plate (2), screw the
nut (3) on and tighten it with 120 Nm.

Fig. 27

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39. Measure the distance from the outer race of the

rocker bearing to the surface of the console (Fig. 28)
and write it down, e.g. 3,4 mm.
Note: Subtract the fixed value of 3.2 mm from the
measured value 3.4 mm to determine the
required thickness of the shim.
Example of a calculation:
measured value: 3,4 mm
fixed value: 3,2 mm
Thickness of shims: 0,2 mm
40. Remove the clamping device.
Fig. 28

41. Insert the shim 2 (Fig. 29) of appropriate’ thickness

and the backing disc (1) into the cover.

Fig. 29
42. Insert the Belleville springs with the convex side
forward into the cover (Fig. 30)..

Fig. 30

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43. Attach the cover 1 (Fig. 31) with Belleville springs,

shims and backing disc.
44. Screw the screws (2) in and tighten them crosswise.

Fig. 31
45. Insert the hexagon screw 1 (Fig. 32) so that the
screw head rests on the upper side of the console.

Fig. 32
46. Attach the plate, screw the nut on and tighten it
with 120 Nm (Fig. 33).

Fig. 33

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Instructions for repair

BW177 D/DH/PDH-50

Service Training

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Diesel engine monitoring:

Warning and control lights are integrated in the instrument cluster

Display and shut-down functions

Control Lights Warning Buzzer Shut Down Time Shut Down Time
10s 2min
Water separator X X X
fuel filter
Engine oil pressure X X X
Coolant X X X
temperture

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The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
• travel pump with control and safety elements,
• Drum drive motor without brake,
• axle drive motor,
• rear axle with brake,
• charge pump (also for vibration circuit),
• hydraulic oil filter (in charge circuit),
• hydraulic oil cooler with thermostat
• hydraulic lines.

Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (Δp = 400 bar between low and high pressure
sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 080) flushes a certain
oil quantity out of the closed circuit when the machine is driving (Δp between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is fitted
with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven by
the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.

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Travel pump

The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.

Fig. 2: Hydraulic diagram of travel pump

1. Pump drive 3. Charge pressure relief valve

2. Servo control 4. Multi-function valves

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The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.

Fig. 3: Travel pump

1. Control lever 5. Cylinder block

2. Drive shaft 6. Valve plate

3. Swash plate bearing 7. Control piston

4. Pistons with slipper pads

With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are integrated
in the pump.
Note:
These machines are equipped with two charge pumps.

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Cross-sectional view of travel pump

Fig. 4: Cross-sectional view of travel pump

1. Retainer for swash plate 7. Swash plate bearing

2. Sliding block 8. Swash plate guide

3. Control piston 9. Swash plate

4. Servo arm 10. Swashing lever

5. Servo valve 11. Charge pump (only in vibration pump)

6. Feedback device

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View of the rotating group

Fig. 5: Travel pump, view of the rotating group

1. Working pistons

2. Slipper pad

3. Pre-tensioning spring

4. Cylinder block

5. Drive shaft

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Description of function

Fig. 6: Function of travel pump

1. Drive shaft 5. Cylinder block

2. Drive shaft bearing 6. Multi-function valves

3. Swash plate 7. Charge pump (only in vibration pump)

4. Pistons with slipper pads 8. Valve plate

The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).

With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).

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When moving the swash plate out of neutral position, the working pistons will perform a stroke movement
with every rotation of the cylinder block.

The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.

During a full rotation of the cylinder block each working piston will move through the bottom and top
dead centre back to the initial position. During this movement each piston performs a complete stroke.

During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.

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Tandem pump

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Tandem pump, connections an adjustment points

Fig. 7: Connections and adjustment points

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1 Control solenoid, high frequency (vibration pump)

2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 End plate with integrated charge pump (only in vibration pump)
19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Adjustment screw for mechanical neutral position, vibration

Thermostat housing: 33, 34, 35, 36 Leak oil port

37 cooler inlet

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Servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the swashing
direction (flow direction of the pressure fluid).

The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).

Servo cylinder

Control piston

Sliding block

Servo arm

Fig. 8: Control piston

A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any damage
to the servo control.

The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.

Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:

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• when shutting the engine down,

• if the external control cable comes loose,
• if the pressure in the charge circuit drops below a certain value.

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Multi-function valves

High pressure limitation

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.

Fig. 9: Multi-function valves

1. to the control 6. Drive shaft

2. Multi-function valve 7. to the control piston

3. Charge pump 8. to the control piston

4. Charge pressure relief valve A Port A

5. Pilot pressure relief valve B Port B

If the adjusted pressure is reached, the pressure override will move the swash plate quickly back towards
neutral position, thereby limiting the system pressure. The average response time is less than 90 ms.

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In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override works
as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the high
pressure relief valve is higher than the pressure level of the pressure override. The high pressure relief
valves will only respond if the pressure override is not able to swash the pump back quick enough in case
of sudden pressure peaks.

2 3
4
5
1

6
9 7
8
10
11
Fig. 10: Multi-function valve, details

1. Reducing fitting 7. Check valve

2. Hydraulic by-pass piston 8. Pressure limitation

3. Spring plate 9. Spring

4. Spring 10. By-pass housing

5. High pressure relief valve 11. By-pass sleeve

6. Valve seat

Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.

With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.

Note:
The multi function valves must be tightened with a torque of 89 Nm!

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Multi-function valves

The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.

The pressures of both pumps are limited by a charge pressure relief valve.

The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).

The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the
multidisc brakes in the travel drives.

Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.

When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).

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Flushing valve

Fig. 11Cross-section of flushing valve

1 Flushing spool
2 Flushing pressure relief valve

The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.

The valve is operated by the pressure difference between the two sides of the closed circuit (A and B). If the
pressure in one side is higher than in the other, this pressure will move the valve out of neutral position
against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows through
a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is immediately
replaced by oil entering from the charge circuit through the corresponding boost check valve (part of the
multi-function valve).

In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.

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Axle drive motor

The axle drive motor is a swash plate controlled axial piston motor of series 51 C 080 with variable
displacement.

Fig. 12: Axle drive motor,

1. Control piston 7. Cylinder block

2. Flushing valve 8. Universal joint

3. Control 9. Output shaft

4. Spindle with ball 10. Output shaft bearing

5. Qmin-screw 11. Working piston

6. Valve plate

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The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.

With a large angle position the motor works with maximum displacement, slow speed and high torque.

When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.

The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side with
pressure oil from the charge circuit via a 4/2-way solenoid valve.

Function

The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil
flows under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.

Once the respective piston has passed its dead centre (max. extended position), it will change to the low
pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is thereby
displaced out of the cylinder chamber through the low pressure side back to the pump.

The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.

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Rear axle

Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 13: Manual releasing of rear axle brakes

• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• Turn the brake releasing screw (2) in against the stop.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
• Repeat this procedure on the opposite side of the axle.

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Front drum drive motor: Radial piston motor MSE 18 2 CX

On single drum rollers of series D-50 the drum is driven by a hydraulic radial piston motor.

These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.

Fig. 14: Drum drive motor

1. Drive shaft with output flange

2. Piston with roller

3. Oil distributor

4. Cylinder block

5. Cam ring

6. Bearing plate

The housing consists of:

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• bearing section (drive shaft bearings),

• torque section (cam race) and
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.

This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.

The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.

The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.

The movement of a piston along the cam race must be examined in several phases during a full rotation:

Fig. 15: Function of the radial piston motor

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Piston position 1:

The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the roller
along the cam and causes a rotation of the cylinder block.

Piston position 2:

At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.

Piston position 3:

Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.

Piston position 4:

Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to the
pump.

Piston position 5:

The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.

Reversing the oil flow reverses also the rotation of the motor.

The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.

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Travel circuit: Drum drive with radial piston motor

Fig. 16: Single drum rollers D-50, travel circuit, hose installation

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Brake control: Travel motor in axle

Fig. 17: Brake circuit

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Travel drive, components and test points

Travel pump:

1
Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values
diagram diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure 10, A
port, forward
3 Charge pressure 7, MA 26 bar
port

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Travel pump: right hand side

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure 10, B
port, reverse
3 Travel control
(travel control
cable)

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Front travel motor, without brake (radial piston motor)

2 1

4
3

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 High pressure 12, L
port, forward
2 High pressure 12, R
port, reverse
3 Cross-flushing of 12
travel pump T1
4 Leak oil port 12, 1

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Rear travel motor: Axle motor

4
1
3
2

5
7

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Solenoid for speed Y31 14 Motor Qmax---
range selector depressurized,
valve Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure 14, A
port, drum drive
motor forward
4 High pressure 14, B
port, drum drive
motor reverse
5 High pressure 14, A
from travel pump
forward
6 High pressure 14, B
from travel pump
reverse
7 Qmin- setscrew 14

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Rear travel motor: Axle motor

BW177D-50

BW177DH/PDH-50

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized

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Travel lever console

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Travel lever *

1
2

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Initiator for B14 08, 0 / 12V, normally
backup alarm closed
2 Initiator for brake B13 Normally closed,
opened in braking
position 0/12V

* BW177D-50 only

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Trouble shooting

The following trouble shooting chart contains a small selection of possible faults, which may occur during
operation of the machine. The fault list is by no means complete, however, the fault table is based on the
experience of the central service department, i.e. the list covers almost all faults that have occurred in the
past.

Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

Machine travels with travel lever in 'Neutral'

Machine does not drive (forw. and reverse)
Machine drives to one direction only
TROUBLE SHOOTING TRAVEL

Max. travel speed not reached

SYSTEM

Hydraulic oil overheating

SYMPTOMS

POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle-drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Clutch- Dieselmotor-Pumpe 2
Dieselmotor 1

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Vibration system

The vibration system of the single drum rollers of generation D-50 works with two frequencies and
two amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of:
• the vibration pump,
• the vibration motor and
• the pressure resistant connecting hoses

Fig. 1: Vibration circuit

1. Vibration pump

2. Vibration motor

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Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.

When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding side
and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator
shaft inside the drum.

When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.

Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.

• Large angle = high displacement = high vibrator shaft speed (frequency)

• Small angle = low displacement = slow vibrator shaft speed (frequency)

The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on
the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.

This results in the following constellations:

• Basic weight + change-over weight = high amplitude

• Basic weight - change-over weight = low amplitude
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

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Vibration system
Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.

The displacement of the pump is proportional to the engine speed and the chosen displacement.

When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from ”0” to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are integrated
in the pump.

Fig. 3: Hydraulic diagram vibration pump

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Function

Fig. 4 Cross-section of vibration pump

1. Servo piston

2. Working pistons

3. Charge pump

4. Valve plate

5. Roller bearing

6. Swash plate

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Vibration pump

Fig. 5 Cross-section of vibration pump

1. Control

2. Servo piston

3. Friction free swash plate bearing

4. Attachment plate

5. Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.

The slipper pads rest against the sliding surface of the swash plate and are at the same time held on the
sliding surface by a retaining device.

During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.

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During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into the piston
chamber. On the opposite side the piston presses the oil out into the high pressure side of he closed circuit.

Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt solenoid
valve, the pump is always actuated to one of the two end stop positions.

Charge pumps
These machines are equipped with two charge pumps.

One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine and
serves also as steering pump.

The second pump is an internal gear pump and is located in the end cover of the vibration pump.

The oil flow generated by the charge pumps is joined together with the return flow from the steering valve before
the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration pump.

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High pressure relief valves

As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.

Fig. 6 Pressure relief valve

1. From the charge pump

2. Closed circuit

3. High pressure relief valve with integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the vibration,
very high pressure peaks will occur in the high pressure side of the closed circuit during this phase. The
high pressure relief valve reduces these pressure peaks to a value of max. 371 bar (pressure difference
between high and low pressure side = 345 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter “travel
system”.

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High pressure relief valves

The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is most
suitable for the use in closed hydraulic circuits.

The output speed of the motor depends on the oil quantity supplied by the vibration pump.

Fig. 7 Cross-section of vibration motor

1. Flushing valve block

2. Flushing valve

3. Working pistons with slipper pads

4. Roller bearing for output shaft

5. Radial seal

6. Output shaft

7. Swash plate

8. Retaining plate

9. Pre-tensioning spring

10. Flushing pressure relief valve

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The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.

Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.

When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a value
between 100 and 150 bar (operating pressure). The value of the operating pressure mainly depends on
the condition of the ground (degree of compaction, material etc.).

• Hard ground = High operating pressure

• Loose ground = Low operating pressure

A MA

3 1

B MB

Fig. 8 Circuit diagram of vibration motor

1. Vibration motor

2. Flushing valve

3. Flushing pressure relief valve

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The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.

Fig. 9 Flushing valve

1. Flushing spool

2. Flushing pressure limitation valve

The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only a
certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately replaced
with fresh and filtered oil through the corresponding boost check valve.

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High pressure relief valves

Fig. 10Cross-section of drum

1. Drum shell 8. Change-over weight

2. Vibration bearing 9. Coupling vibr.-motor – vibrator shaft

3. Basic weight 10. Travel bearing

4. Vibrator housing 11. Travel bearing housing

5. Cooling fan 12. Rubber buffer

6. Vibrator shaft 13. Vibration motor

7. Elastic coupling between shafts 14. Flanged bearing housing

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Vibration system: Components and test ports

Vibration pump

1
2

5
6 3
4

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Pressure test port, MA 26 bar
charge pressure
2 Hydraulic oil 07
filter (charge
circuit) with
visual pressure
differential
indicator
3 High pressure MF
port, low
amplitude
4 High pressure ME
port, high
amplitude
5 Solenoid valve, Y08 12V / 3,33A
low amplitude
6 Solenoid valve, Y07 12V / 3,33A
high amplitude

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Vibration pump

1
2

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Pressure test port, MF max. 371 bar
vibration pressure
low amplitude
2 Pressure test port, ME max. 371 bar
vibration pressure
high amplitude

low amplitude high amplitude

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Vibration motor

3 2

5 4
5

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 High pressure 16
port, high
amplitude
2 High pressure 16
port, low
amplitude
3 Leak oil and 16 approx. 7 l/min,
flushing oil port incl. flushing
quantity
4 Flushing spool 16

5 Flushing valve 16 13 bar

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Trouble shooting

The following trouble shooting chart contains a small selection of possible faults, which may occur during
operation of the machine. The fault list is by no means complete, however, the fault table is based on the
experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
TROUBLE SHOOTING
VIBRATION
SYMPTOMS

POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1

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Trouble shooting
Single drum rollers of series BW 177 D/DH/PDH -50 are equipped with a hydrostatically operated
articulated steering system.

The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.

Fig. 1 Steering hydraulics

1. Rating pump

2. Distributor valve

3. Steering pressure relief valve (Δp =175 bar)

4. Check valve (pre-loaded to 0.5 bar)

5. Anti-cavitation valve

6. Shock valves (240 bar)

7. Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering
valve and the connected steering unit under the operator’s platform of the machine. If the steering is
not operated, the complete oil supply will flow through the fine filter to the charge system for the closed
travel circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod
side of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

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Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.

Fig. 2 Steering pump

1. Housing

2. Flange

3. Shaft

4. Bearing plate

5. Bearing plate

6. Cover

7. Gear (driving)

8. Gear (driven)

9. Seals

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Working principle of the gear pumps

The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.

The displacement chambers are created between the tooth flanks, the inside wall of the housing and the
faces of the bearing plates.

When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.

For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.

This pressure field is always under the actual system pressure.

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Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.

Fig. 3 Cross-sectional view of steering valve

1. Neutral setting springs

2. Housing

3. Inner spool

4. Outer spool

5. Universal shaft

6. Ring gear

7. Gear

8. Check valve

9. Pressure relief valve

When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating pump.
The rating pump guides the oil flow through the distributor valve to the corresponding sides of the steering
cylinders. The rating pump measures the exact oil quantity in accordance with the rotation angle of the steering
wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.

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Fig. 4 Steering valve, hydraulic diagram

The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar. The
charge pressure value must be added to this pressure, because the oil leaving the steering system is fed
into the charge circuit for the closed travel circuits.

The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.

Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.

A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case of
pressure peaks caused by sudden steering movements. In such a case the steering cylinders would act as
pumps and press the oil back to the pump.

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Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.

Fig. 5 Articulated joint

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The rear console is tightly bolted to the rear frame.

The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.

The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.

The steering cylinder anchor point is welded to the front console.

When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.

All bearings on the articulated joint are maintenance free and do not require any lubrication.

Notes on assembly:

When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.

Please follow the instructions in the repair manual for the articulated joint.

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Steering: Components and test ports

Steering pump

2
1

Pos. Designation Pos. in wiring Pos. in hydraulic Measuring values

diagram diagram
1 Steering pump 09
(and charge pump)
2 Steering pressure MB max. 175+26 bar
test port

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Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump.

It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.

The damper is mounted to the front plate of the rear frame, between both steering cylinders.

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Steering valve

The steering valve is located under the operator’s stand

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Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur during
operation of the machine. The fault list is by no means complete, however, the fault table is based on the
experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

TROUBLE SHOOTING STEERING

SYSTEM

End stops are not reached

Steering hard to move
No steering function
SYMPTOMS

POSSIBLE CAUSES
Steering orbitrol valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2

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Electrics: Single drum rollers D-50

This chapter describes the peculiarities in the electric system and the necessary adjustments. This
instruction solely describes the electrical testing of D-50 machines belonging to single drum roller series.

Function test:
Turn the ignition key to “Ignition ON”.

• The round gauge runs a 3 second self test.

• All control lights are active during this time.

• Brake control light (travel lever in braking position), charge control light (engine stopped) and oil
pressure warning light (engine off) are active.

Warning and control lights are integrated in the instrument cluster!

Table 1: Inspection of display and shut-down functions

Control Lights Warning Buzzer Shut Down Time Shut Down Time
10s 2min
Water separator X X X
fuel filter
Engine oil X X X
pressure
Coolant X X X
temperture

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Instrument cluster

Electric control cabinet with vibration module

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Plug assignment with operating hour meter

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Technical description

Vibration Module

- 057 670 52 -

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Description
This module is an electronic toggle relay for 12 and 24 Volt. A ground switching pulse on Pin (S) sets the output
(56b) (operating voltage applied to the output). The next pulse resets the output (56b) (no operating voltage
applied to the outlet). If the operating voltage (15/54) is switched off, the output will remain dead when
switching on again.
Description
Here this modul it concerns an electronic toggle relay for 12 volt and 24 volt. By an impuls (ground potential) at
pin (S) the output (56b) is set (supply voltage is on the output) and reset (no supply voltage is on the output) by
the next impulse. If the supply voltage is switch off, then there is no output signal after the resetting.
E:\Bauteile_Datenblaetter_mit_TNr\STW\05766734\05766734_Technische

Beschreibung.doc Alexander Hehner / TE

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Replacing the cab window panes

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Assembly of window panes

Fig. 1

1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap

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Special tools

13.2 Special tools

1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2

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Auxiliary materials

13.3 Auxiliary materials

Safety gloves
3. Cutter

Commercial

Fig. 1
4. Window glass bonding agent

BOMAG part-no.: 009 780 34

Fig. 2
5. Activator

BOMAG part-no.: 009 780 33

Fig. 3

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Auxiliary materials

6. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

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Removing and installing the window pane

13.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.

! Danger

Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).

Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.

Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).

Fig. 3

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Removing and installing the window pane

6. Turn the fixing and spacer washer hand-tight onto

the thread of the fastening element (Fig. 4).

i Note
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

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Removing and installing the window pane

14. Remove the suction lifter (Fig. 8).

Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).

i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.

Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).

Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).

Fig. 11

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Removing and installing the window pane

19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

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Fundamental electrics

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Understanding circuit diagrams

Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure
l
Table of contents (Fig. 6)
l Function groups (Fig. 7)
l List of components (Fig. 9)

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Understanding circuit diagrams

Table of contents (Fig. 6)

The table of contents lists all function groups.

Fig. 6 Table of contents

Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.

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Understanding circuit diagrams

Function groups (Fig. 7)

On the individual pages the electric circuits are combined to function groups.

Arrangement of current paths

The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential).
l
From left to right.
l From function group to function group.
l
Via cross references for potentials and relays.

Fig. 7 Function groups

Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.

Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.

Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.

Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".

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Understanding circuit diagrams

Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 8) (0 ..... 20).

Fig. 8 Current paths

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Understanding circuit diagrams

List of components (Fig. 9)

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 9 List of components

Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.

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Terminal designations in wiring diagram

Terminal designations in wiring diagram

For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a ter-
minal designation. In Germany the designation of the individual connection terminals is determined by the stand-
ard DIN 72552. The following table represents a section with the most important terminals from this standard.

Terminal designation Meaning

1 Ignition coil, ignition distributor low voltage
1a Ignition distributor with 2 separate electric circuits, to ignition timer 1
1b Ignition distributor with 2 separate electric circuits, to ignition timer 2

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

4a Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4
4b Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4

15 Switch plus (after battery) : Output of ignition-travel switch

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus

31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus

32 Electric motors, return line

33 Electric motors, main connection

33a Electric motors, limit shut down
33b Electric motors, shunt field
33f Electric motors, for 2nd lower speed range
33g Electric motors, for 3rd lower speed range
33h Electric motors, for 4th lower speed range
33L Electric motors, counter-clockwise rotation
33R Electric motors, clockwise rotation

45 Starter, separate starter relay output; starter: Input (main current)

45a 2-starter parallel operation, start relay for engagement current, output starter 1
45b 2-starter parallel operation, start relay for engagement current, output starter 2

48 Terminal on starter and on start repeat relay, monitoring of starting process

49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit

50 Starter, starter control

50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control

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Terminal designations in wiring diagram

Terminal designation Meaning

50c Start relay for sequence control of engagement current in parallel operation of 2 start-
ers, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2 start-
ers, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output

51 A.C.-generator, direct voltage on rectifier

51a A.C.-generator, direct voltage on rectifier with reactance coil for day travel

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
53c Electric windscreen washer pump
53e Wiper, braking effect
53i Wiper motor with permanent magnet and 3rd brush for higher speed

54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromagnetical-
ly operated

55 Fog light

56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light

57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right

58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right

59 A.C.-generator (magneto generator), alternating voltage output or rectifier input

59a A.C.-generator, charging armature output
59b A.C.-generator, tail light armature output
59c A.C.-generator, brake light armature output

61 Generator control

71 Intermittent tone control unit, input

71a Intermittent tone control unit, output to horn 1 + 2 (low)
71b Intermittent tone control unit, output to horn 3 + 4 (high)

72 Alarm switch (flashing beacon)

75 Radio, cigarette lighter

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Terminal designations in wiring diagram

Terminal designation Meaning

76 Loudspeaker

77 Door valve control

81 Switch (breaker and two-way contact), input

81a Switch (breaker and two-way contact), output 1
81b Switch (breaker and two-way contact), output 2

82 Switch (maker), input

82a Switch (maker), output 1
82b Switch (maker), output 2
82z Switch (maker), input 1
82y Switch (maker), input 2

83 Switch (multi-position switch), input

83a Switch (multi-position switch), output position 1
83b Switch (multi-position switch), output position 2
83L Switch (multi-position switch), output position left
83R Switch (multi-position switch), output position right

84 Current relay, input drive and relay contact

84a Current relay, output drive
84b Current relay, output relay contact

85 Switching relay, output drive winding end (minus or ground)

86 Switching relay, input drive winding start

86a Switching relay, input drive winding start 1st winding
86b Switching relay, input drive winding start 2nd winding

87 Relay contact on breaker and two-way contact, input

87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3

88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3

B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)

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Terminal designations in wiring diagram

Terminal designation Meaning

DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

V Three-phase generator, three-phase terminal
W Three-phase generator, three-phase terminal

C Travel direction indicator (flasher relay) control light 1

C0 Main connection for control light separated from flasher relay
C2 Travel direction indicator (flasher relay) control light 2
C3 Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation)
L Indicator left
R Indicator right

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Circuit symbols in the circuit diagram

Circuit symbols in the circuit diagram

Circuit symbol
l
Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.

Fig. 1 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)

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Battery ground and analog ground

Battery ground and analog Current and voltage

ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.

Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.

Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons

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Current and voltage

The following statements concerning electric volt- Current

age can be made
Electric current generally describes the directed
l
electric voltage is the pressure or force applied to movement of charge carriers.
free electrons. l
The charge carriers may either be electrons or ions.
l
the electric voltage is the cause of electric current l
Electric current can only flow if there is a sufficient
l
electric voltage is a result of the equalization at- amount of free moving charge carriers.
tempt of electric charges. l The higher the number of electrons flowing through
Voltage is measured with a Voltmeter. a conductor per second, the higher the amperage.
Unit, Volt Current is measured with an ammeter.

The electric voltage (U) is measured in Volt (V). Unit, Ampere

The electric amperage (I) is measured in Ampere

(A).

The technical flow direction is specified from

PLUS to MINUS.

i Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.

Circuit

Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).

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Current and voltage

Types of current Pulse width modulation (PWM)

Direct current (D.C.)

Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole. Fig. 4 PWM
Pure D.C.-voltages are only delivered by accumula- The PWM signal is in most cases generated by a con-
tors or batteries. trol and can be used to trigger proportional valves.
The voltage in the vehicle wiring system is no pure The signal (square wave signal) is changed in its
D.C.-voltage. Even without the generator running, but pulse control factor, the period, however, remains un-
the consumers switched on, the voltage is not con- changed.
stant, but drops gradually according to the battery The following applies:
charge condition. l The signal voltage cannot be measured.
The internal resistance of the battery also causes per- l The current can be measured.
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
! Caution
Alternating current (A.C.)
Solenoid valves must not be interference sup-
pressed with suppressor diodes.

Fig. 2 Alternating current (A.C.)

Alternating current not only changes its direction, but
also its amperage.

Pulsating direct current

Fig. 3 Pulsating direct current

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.

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Resistance

Resistance l The cleaner the contacts, the better the current.

l
The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.

Fig. 2 Spring clamps

Connecting clamps for flexible conductors
BOMAG No. 057 565 72
Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
Fig. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.

Symbol, R

Unit, Ohm Ω

The electric resistance (R) is measured in Ohm Ω.

Rule of thumb:
l The thicker the cable cross-section, the lower the
voltage loss.
l The shorter the cable, the better the current.

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Resistance

Sometimes the flanks of flat plugs bend open. If these

are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.

Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.

Fig. 4 Balistol oil

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Series / parallel connection

Series / parallel connection l

In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined l
The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- l The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).

Fig. 1 Series connection

Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3

Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3

Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3

Series connection of batteries

Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.

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Series / parallel connection

Parallel connection l In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
l
All resistances (consumers) are supplied with the
same voltage.
l
Plus and minus poles have the voltage of the single
battery applied.
l
Each of the resistances (consumers) draws as
much current as required.
l
The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3

Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3

Resistance
The total resistance is less than the lowest individual
resistance.

Parallel connection of batteries

Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.

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Ohm's law

Ohm's law Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.

Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω

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Formula diagram

Formula diagram
Description:
l Select the desired value from the inner circle.
l
Determine the formula variables in the quarter circle
l Calculate

Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

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Metrology

Metrology Multimeter
This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.

Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
!Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.

Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.

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Metrology

Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 l
Measurement at the voltage source measures the
measuring points. currently available Voltage.
l
The meter is always connected parallel to consum-
er, component or power source.

Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.

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Metrology

Current measurement with the multimeter Clip-on measuring instrument

The clip-on measuring instrument can be used to
measure current, voltage and resistance.

Fig. 6 Measuring current

l
The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.

Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement

Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.

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Metrology

Magnet tester Power measurement

The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l
The magnetic coil can also be tested under a pro-
tective cap.

Fig. 2

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Diodes, relays, fuses

Diodes, relays, fuses Diode logics and free-wheeling diode

Diodes

Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

Diodes are used:
l For rectifying A.C. voltage.
l For absorbing voltage peaks (free-wheeling diode).
l For construction of logical circuits.

Fig. 3 Diode circuitry

l The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
l Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
l Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.

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Diodes, relays, fuses

Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.

Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil

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Diodes, relays, fuses

85 = Ground supply for coil Fuses

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact

Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.

! Caution
Fuses must not be repaired or bridged.
The melting time at 23 °C is:
l
approx. 1 hour with 1.5 times the rated current
l
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A

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Batteries

Batteries Battery maintenance

Battery – accumulator
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- l Remove the battery and store it in a cool, dry and
ments, i.e they can be recharged after discharging frost protected room.
electric current. l Check the open circuit voltage on the battery at reg-
The basic element of a lead accumulator is the cell. It ular intervals (at least once every month).
contains the plate blocks consisting of positive and l Recharge immediately if the open circuit voltage
negative plates. These plates are separated from has dropped to 12.25 Volt (no rapid charging).
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of i Note
the cells. The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.

Battery test in general

l Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
l Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.

Testing batteries with screw plugs

Checking the acid density:
l The cells are filled with diluted sulphuric acid as
electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
Fig. 2 which has a density of 1.285 kg/dm3 at a tempera-
All cells are filled with a conductive fluid, the electro- ture of +27° Celsius. This means that one litre of
lyte. For a 12 Volt battery 6 cells are connected in se- electrolyte has a weight of 1.285 kg. As the cell is
ries. being discharged lead sulphate (PbSO4) will form
on both electrodes and the electrolyte will increas-
Capacity ingly change to water. Since water has a lower spe-
is a synonym for the amount of current taken up and cific weight than diluted sulphuric acid the density of
discharged by a battery over a specified period of the electrolyte will also drop during the discharge
time. and with a fully discharged cell and a temperature
of 27°C it will only be 1.18 kg/dm3.
l
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead

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Batteries

battery. The so-called acid tester (hydrometer) is

used for this purpose. In a battery of good condition
the acid density should be the same in all cells.

Acid density at 27 °C in kg/dm3

l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
l 1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
l 1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.

Fig. 4 Battery and generator tester

i Note
The battery and generator tester comes with an 8-line
If the current consumption during charging is not 1/20 LC display with background illumination and is able to
of the nominal capacity (example 100 Ah battery: print out test results via an (optional) integrated ther-
100Ah x 1/20 = 5 A) or full charging of the battery re- mal printer.
sults in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge. i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.

Fig. 3 Reading the acid level

l
Maximum permissible tolerance between highest
and lowest measuring value of the 6 cells: 0.03 kg/
dm3.

Testing batteries without screw plugs

On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:

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Batteries

Charge condition with hydrometer

Fig. 5 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low

Danger
!

Danger of explosion!!! If the electrolyte level is too

low, the battery must no longer be charged.

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Generator

Generator (1) AC generator / dynamo

General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

Terminal designations
l
B61, L = charge control
l
B+, B = battery plus, also with the designation "30"
l
B- = battery minus, also with the designation "31"
l
D+ = dynamo plus corresponds with terminal "61"
and "L"
l D- = dynamo minus (this designation is only found Fig. 6 Dynamo, Kubota engine
on D.C. generators or A.C. generators with regula- This dynamo is a generator with revolving 8-pole per-
tor removed) manent magnet. It is of extremely simple design and
l
DF = dynamo field (this designation is only found on consists only of stator and rotor. The rotor consists of
D.C. generators or A.C. generators with regulator eight permanently magnetic pole shoes, which are ar-
removed). Note: The designation DF is also found ranged on a common shaft. This shaft is also the axle
on older alternators with externally arranged regula- of the stator with eight generator coils arranged
tor on the connection of the exciting coil to the reg- around it. Such a dynamo generates higher voltages
ulator or on the regulator itself at lower speeds and supplies charge current for the
battery, even when the engine is idling.
l
DF1 = dynamo field 1
l
DF2 = dynamo field 2
l
IG = "15" ignition switch

Fig. 7 Regulator to dynamo, Kubota engine

1 Regulator
2 Dynamo
3 Consumer
4 Charge control light
5 Battery
6 Blue strand, GEN terminal
7 Yellow strand, BATT voltage test terminal
8 Red strand, BATT plus pole
9 Green strand, LAMP terminal
10Black strand, BATT minus pole
The regulator is responsible for rectification and volt-
age regulation. Here the alternating voltage is con-
verted to direct voltage, which is fed to the consumers
and charges the battery. However, if the battery volt-

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Generator

age exceeds a certain value, the charged direct volt- (2) AC-generator
age is interrupted to protect the battery against being
The AC-generator first of all produces AC-voltage /
overcharged.
AC-current.

Why does AC-current need to be rectified?

There are a few components for which can either be
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
l
Incandescent lamps
l
Fluorescent lamps
l
Glow lamps
l Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
This includes :
l
Electric motors
l
Relays.
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 8 AC-generator, Kubota engine

1 V-belt pulley
2 Holding plate
3 Bearing cover
4 Stator
5 Terminal
6 Plug connectors
7 Regulator

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Generator

8 Spring
9 Brush
10Rectifier
11Cover
12Rotor
13Bearing

Fig. 11 3-phase current

Fig. 9 Rotor with claw poles The wiring diagram (Fig. 11) shows the 3 windings in
Y-connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 10), whereas the excit-
er winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 9). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 10 Stator with 3 windings

The three stator windings (Fig. 10) are electrically off-
set to each other by 120°. The excitation of the mag-
netic field requires direct current, which is fed to the
rotor via two carbon brushes and slip rings.

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Generator

Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 12 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 12) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.

Fig. 13 plus controlled charging regulator

(Fig. 13) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

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Generator

Charge controller Electronic charge regulator

The charge controller has the following functions
l
To regulate the voltage generated by the generator
l
To protect against overloads caused by too high
output current
l
Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
Fig. 15
Electro-magnetic charge regulator
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
Fig. 14 tion dependent internal resistance of the stator coils or
1 Voltage regulator thermal monitoring.
2 Voltage relay (relay for charge control light)
3 Voltage winding
4 Current winding
The two-part and twin-pole regulator used here con-
sists of a voltage switch (1) and a voltage relay (2) with
two contact sets.
Similar to a switching controller the field coil uses its
inductivity to smoothen the field current. If the D.C.
generator, due to its low speed, generates a voltage
that is lower than the voltage of the vehicle battery, the
reverse current switch uses its switching contact to
disconnect the connection between generator output
and battery. The regulator keeps the voltage constant
over a wide range of the generator speed and has a
very long contact lifetime.

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Generator

(3) Checking the generator

! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
Fig. 16 plus controlled regulator underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
Fig. 17 minus controlled regulator ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
First one must check whether the generator is actually
defective.
l This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
Fig. 18 Regulator, Kubota engine
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l
When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l
Cable connections on the generator OK?
l
V-belt OK?
l
Generator ground (engine ground) OK?
l
Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be

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Generator

replaced or the following trouble shooting procedure Checking the pre-exciter circuit, D+ generator
must be performed. The most common reason for a 3-phase alternator not
charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
the connected consumer (resistance), e.g. charge
control light or relay of a MD+ engine control.
The pre-excitation current should be approx. 250 mA
at 12 Volt. This corresponds with a 3 Watt light bulb or
an equivalent combination of light bulb + resistance or
an LED + resistance.
The total resistance of the disconnected dead supply
line D+ max. should not exceed 48 Ohm.
In case of faults like
l
charge control light stays on
l no voltage increase, e.g. from 12 V to 14 V
one should check that the correct resistance is as-
sured.

Fig. 19 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 19). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.

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Generator

Measuring the charge current Checking the rotor

l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
l The generator ground connection must be OK. The rotor coils can only be measured in disassembled
l During the measurement switch on as many con- state.
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all consumers.

Fig. 20 Rotor
l Remove the regulator with carbon brush.
l Contact the rotor slip ring with the tester points.
l
The resistance should be between 3 and 6 OHM Ω.
l
The rotor coils should not have continuity to ground.

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Generator

Checking the stator Checking the regulator voltage with the generator
tester
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.

Fig. 22
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.
l
All plug-and-socket connectors must be free of cor-
Fig. 21 Stator
rosion and intermittent contact.
l
The generator ground connection must be OK.
i Note l
The battery should be in good condition – the idle
The stator coils can only be measured in disassem- speed voltage of the battery should be at least 12.6
bled state. Volt.
l
Measure the resistance of all three coils. l
If possible switch off all consumers.
l
The coils should not have contact among each oth- l
Perform the measurement at raised engine speed.
er.

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Generator

Checking the regulator voltage with the multime- Checking the regulator in disassembled state
ter On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator.

i Note
When testing the regulator one should be aware that
Fig. 23 there are 2 different types of regulators:
l All plug-and-socket connectors must be free of cor- l If the carbon brush is not connected to ground the
rosion and intermittent contact. regulator is a so-called minus controlled regulator.
l The generator ground connection must be OK. The exciter winding is positioned between D+ and
l The battery should be in good condition – the idle DF, the regulator therefore regulates the exciter
speed voltage of the battery should be at least 12.6 winding on the ground side. The other carbon brush
Volt. is connected with the cathodes of the exciter di-
odes, terminal D+. This leaves one further terminal,
l If possible switch off all consumers.
this is DF.
l Perform the measurement at raised engine speed.
D+ (vehicle wiring system)
l The voltage (B+) should adjust itself at 13 to 14 Volt.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 24
l
If the carbon brush is connected to ground the reg-
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

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Generator

Replacing carbon brushes

l On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
l For replacing the carbon brushes in the Delco-
Fig. 25
Remy generator the generator needs to be disas-
E.g minus controlled regulator sembled and partly dismantled. The carbon brush
One connects the regulator (Fig. 17) with D+ and D- to holder is located inside the collector ring bearing.
the power source, as shown in the illustration, and the
lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
will first become brighter, because the regulator al-
lows all lamp current (= exciter current) to flow at volt-
age values up to 14.4V. Once the regulator voltage is
reached, the regulator switches the lamp current off.
When returning the voltage back below the control
voltage, the regulator will switch the lamp back on.
With this test the major difficulty is the problem to re-
move the regulator an identify terminals D+, DF and
D-.

Fig. 26

Fig. 27
The illustrations (Fig. 26) and (Fig. 27) show two dif-
ferent regulator types.

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Electric starter

Electric starter (1) Direct acting electric starter

This shows the design of this starter. It consists of a
General
starter motor and a magnetic switch.
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l
establish the gear connection between starter and
combustion engine.
l
to maintain this connection.
Fig. 1
l
to switch on the starter current.
1 Magnetic switch
After starting the engine:
2 Armature
l
to return the starter pinion to initial position.
3 Actuating lever
l
to switch off the starter current.
4 Freewheeling clutch
5 Resetting spring
6 Brush
7 Exciter winding
8 Armature
9 Collector

Ignition switch in position "START"

Fig. 2 Magnetic switch open

With the ignition switch (5) in "START" position cur-
rent flows from the battery (10) through the holding
winding (2) and the pick-up winding (3).
The armature (1) is magnetically picked up and forces
the pinion (8) with the actuating lever (6) to engage
with the ring gear (7).
1 Armature
2 Holding winding
3 Pick-up winding
4 Magnetic switch

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Electric starter

5 Ignition switch Engine running

6 Actuating lever
7 Ring gear
8 Pinion
9 Freewheeling clutch
10 (Battery

Pinion meshes with the ring gear

Fig. 4
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
Fig. 3 Magnetic switch closed 3 Freewheeling clutch
When the pinion (3) meshes with the flywheel mount- 4 Armature
ed ring gear (4) and the magnetic switch (2) is closed,
a strong current flows from the battery (7) directly into Ignition switch released
the exciting winding (6) and the armature winding, but
not into the pick-up winding.
This causes the armature (5) to rotate with high speed
and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery
Fig. 5
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding

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Electric starter

4 Resetting spring (2) Starter with geared motor

5 Magnetic switch
(1) with planetary gear
6 Ignition switch
The reduction gear is a planetary gear which reduces
7 Pinion the speed of the armature shaft (9) at the drive shaft
8 Ring gear in the ratio of approx. 1:5.
9 Battery The actuator lever (2) forces the pinion (4) with the
freewheeling clutch (5) against the ring gear.

Fig. 1 with planetary gear

The working principle of this starter is the same as

with the "direct acting electric starter".
1 Holding plate
2 Actuating lever
3 Magnetic switch
4 Pinion
5 Freewheeling clutch
6 Output shaft
7 Transmission
8 (8) Pinion
9 (9) Armature shaft

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Electric starter

(2) with spurgear reducer 3 Pinion

The starter is a heat and vibration proof geared motor 4 Freewheeling clutch
with a small, fast running electric motor, the armature 5 Holding winding
of which drives the pinion with a reduction ration of ap-
6 Pick-up winding
prox. 1:3 to increase the torque.
7 Ignition switch
8 Battery
9 Armature

Pinion meshes with the ring gear

Fig. 2 with spurgear reducer

1 Drive gear
2 Armature
3 Exciting winding
4 Brush Fig. 4

5 Intermediate gear When the pinion (1) meshes with the flywheel mount-
6 Pinion ed ring gear (4) and the magnetic switch is closed, a
strong current flows from the battery (7) directly into
7 Freewheeling clutch
the exciting winding (6) and the armature winding, but
8 Magnetic switch not into the pick-up winding (6). This causes the arma-
9 Armature ture (3) to rotate with high speed and drives the pinion
(1), which in turn drives the ring gear (4) with a speed
Working principle of the starter of 200 to 300 rpm.
Ignition switch in position "START" 1 Pinion
2 Exciting winding
3 Armature
4 Ring gear
5 Holding winding
6 Pick-up winding
7 Battery

Fig. 3
With the ignition switch (7) in "START" position cur-
rent flows from the battery (8) through the holding
winding (5) and the pick-up winding (6). The armature
(9) is magnetically picked up and presses the pinion
(3) outwards.
1 Armature
2 Ring gear

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Electric starter

Engine running 4 Holding winding

5 Pick-up winding
6 Ignition switch
7 Battery
8 Armature

Fig. 5
Once the engine is running and drives the pinion (1)
via the ring gear (3, the freewheeling clutch (4) will
open and prevent the armature (2) from being driven
by the engine.
1 Pinion
2 Armature
3 Ring gear
4 Freewheeling clutch

Ignition switch released

Fig. 6
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (7) through the contact plate in the pick-up
winding (5) and the holding winding (4).
Since both coils generate opposed magnetic fields,
the magnetic field will collapse and the resetting
spring (3) takes the armature (8) back to its initial po-
sition. This opens the current circuit on the contact
plate and the pinion (1) is pulled back from the ring
gear (2) and stops.
1 Pinion
2 Ring gear
3 Resetting spring

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Electric starter

Magnetic switch Freewheeling clutch

Fig. 1 Direct acting electric motor Fig. 1 Freewheeling clutch

The freewheeling clutch is designed in such a way,
that the flow of force is automatically interrupted if the
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine.
1 Freewheeling ring
2 Roller
3 Roller spring
4 Splined shaft
5 Pinion
6 Pinion

Fig. 2 Geared motor

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide

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Electric starter

Trouble shooting "Starter" l

Ignition switch OK?
l
Travel lever in correct position?
!Caution
l Emergency stop not actuated?
So-called jump starting (using an additional exter- l Battery sufficiently charged?
nal battery) without the battery connected is dan- l Battery poles OK?
gerous. When disconnecting the cables from the l
Main battery fuse OK?
poles high inductivities (arcs, voltage peaks) may l Main battery switch closed?
occur and destroy the electrical installation.
l Main starter cable (terminal 30) OK?
For purposes like e.g. purging the fuel systems, l Starter control cable (terminal 50) OK, voltage
starters may be operated for maximum 1 minute
drop?
without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again. l
Ground cable OK?
During the 1 minute starting period this process l
Switching of magnetic switches OK?
should not be interrupted. The sequence of these tests is generally of no signifi-
Starter motors must not be cleaned with high cance. It mainly depends on:
pressure steam cleaning equipment. l
the experience of the specialist
The contacts on starter terminals 30, 45, 50 must l the failure probability of the component to be tested
be protected against unintended shorting (jump and the testing effort for the respective part.
protection).
Only if all criteria mentioned above are OK, the fault
When replacing the starter the ring gear on the en- must be in the starter itself. In this case it can be re-
gine flywheel must be checked for damage and its paired or replaced.
number of teeth - if necessary replace the ring
gear.
Always disconnect the battery before starting as-
sembly work in the starter area of the engine or on
the starter itself.

i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
Frequently a jammed return mechanism is the reason
for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
l
Immobilizer deactivated?

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Electric starter

Testing and measuring the starter

i Note
The highest current flows when the starter is blocked!
(Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to
accelerate the flywheel to starting speed.

Function test with starter installed

l Initiate the starting process and measure the volt-
age on the pickup solenoid switch (50a). At least
10.8 Volt should be applied.
l
When operating the starter switch the magnetic
switch must engage in the flywheel ring gear (no-
ticeable clicking sound) and release the starting
current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
this does not happen even though voltage is ap-
plied, replace the magnetic switch.

Function tests with disassembled starter

l
Check the wear on the carbon brushes and their
contact pressure.
l Check the collector, it must not have electrical con-
tact with the rotor shaft.
l Check the drive pinion for excessive wear.
l
The return mechanism should not be tight, if neces-
sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
l Measure the resistance of the magnetic switch main
contact in disengaged condition. Maximum value
0.2 OHM Ω.

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Telemecanique switch

Telemecanique switch
Example of terminal designations

Fig. 1 Terminal designations

l Normally open contact 23 located on block 2
l Normally open contact 24 located on block 2
l Normally closed contact 12 located on block 1
l Normally closed contact 11 located on block 1
l
Normally open contact 34 located on block 3
l Normally open contact 33 located on block 3
l Normally open contact 63 located on block 6
l Normally open contact 64 located on block 6
l Normally open contact 43 located on block 4
l Normally open contact 44 located on block 4

i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.

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Telemecanique switch

Disassembly

Fig. 2 Disassembly
l Lift up the interlock (5).

Fig. 4 Pulling out the front element

l
Lift up the interlock (2) and pull out the front element
(3).
Fig. 3 Folding down the switch block
l Fold down the switch block (4).
l Loosen screw (1).

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Telemecanique switch

Assembly

Fig. 5 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.

Fig. 7 Assemble the switch block

l
Clip on the switch block (4).

Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
l Clip the fastening adapter (6) onto the front element
(3).

i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
l Tighten the screw (1) with a tightening torque of 0.6
Nm.

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Inductive proximity switches

Inductive proximity switches NPN circuitry

General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.

Working principle

LED

Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11

This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry

Fig. 9 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.

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Angle sensors

Angle sensors

Sensor with current output

Fig. 1 Angle sensor

The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall.
The advantage of the Hall sensor lies in the fact that,
in contrast to the potentiometer, there is no dragging
Fig. 12 Circuit diagram, making contact contact and thus no wear by abrasion.
The circuit diagram (Fig. 12) shows a proximity switch The Hall sensor generates an electric voltage, the Hall
with normally open contact. voltage. The necessary electric and magnetic proc-
esses take place in a very confined space inside the
Brown = voltage supply
Hall-IC. Since a vast variety of electronic elements
Blue = ground supply work together in highly complicated circuitries inside
Black = switching output the Hall-IC, the Hall sensor needs an external power
supply, which is not possible through the vehicle
The initiator switches the relay (K05)
mains supply or the associated control unit.
The Hall effect is based on the phenomenon that elec-
trons are deflected to one side when they pass
through a magnetic field that acts from the outside. In
this case an excess of electrons is created on the side
used by the electrons, because the negative electrical
potential of the flowing electrons predominates. On
the opposite side the electrically positive potential of
the stationary atomic cores is predominant, after the
associated electrons were forced to the opposite side.
A semi-conductor is used as current conductor.

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Angle sensors

Situation without external magnetic field

Fig. 2
I = Current in semi-conductor of Hall-IC
W = Semi-conductor as current conductor in Hall-IC
Current passes through the semi-conductor W in the Fig. 4 Connection diagram
Hall-IC. Since there is no other magnetic force, the The angle sensor has 3 electric connections (Fig. 4).
electrons pass evenly through the semi-conductor.
Ub, supply voltage (+ 8.5 Volt)
There is no measureable Hall voltage (UHall = 0 V).
Gnd, ground
Situation with external magnetic field
Out, output current 4-20 mA.
l
at -35° = 4 mA output current
l
at 0° = 12 mA output current
l at +35° = 20 mA output current.

Fig. 3
Current passes through the semi-conductor W in the
Hall-IC. Since there is the effect of an external mag-
netic field, the electrons are deflected to the left. There
is an excess of electrons on the left, and a lack of elec-
trons on the right. Hall voltage (UHall > 0 V) can be
measured on the side surfaces.

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Plug connectors

Sensor with voltage output 7.19 Plug connectors

The design is almost identical with the angle sensor
Duties and requirements
on the new single drum rollers of generation -4 with
electronic steering wheel, where a sensor with a volt- Electric plug connectors must provide a reliable con-
age output of 0-8.5 V is mounted on the articulated nection between different system components and
joint. The potentiometer inside the sensor transmits a thus ensure the safe function of the systems under
variable voltage potential to the control. Due to the any operating condition. There design ensures that
short distance between articulated joint and central they will withstand the applied loads throughout the
electrics it is in this case possible to use a voltage sig- lifetime of the machine.
nal. Examples for these loads are:
l
Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l
Dampness
l
Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials.
l Excellent leak tightness against water and mois-
ture.

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Magnetic coil plug

Magnetic coil plug with LED and suppres-

7.20 Magnetic coil plug

sor diode
The plug is equipped with a polarized function display
and a suppressor diode as protection against over-
voltages.

Fig. 5 Magnetic coil plug without LED and with-

The plug is polarized, it does not matter whether Pin1 out supressor diode
or Pin 2 is supplied with current, Pin 3 is not used. The
The plug has no LED and no suppressor diode as pro-
LED lights if voltage is applied to the solenoid valve.
tection against overvoltages.

Fig. 6

Fig. 7 Switching symbol in circuit diagram

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Magnetic coil plug

Assembly of magnetic coil plugs

These instructions are intended to explain the correct
installation of the magnetic coil plug. The objective of
the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
ture and any related corrosion damage.

Fig. 10
l Fasten the screw with a suitable screwdriver.

Fig. 8 Solenoid valve plug with pointed cable

Fig. 11
l
Press the plug firmly on again.

Fig. 9
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.

Fig. 12
l
Retighten the screw.

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Deutsch plug, series DT and DTM

Deutsch plug, series DT and

DTM

General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.

Fig. 13

! Caution
There should be no gap between plug and sole-
noid coil!

Fig. 15 Crimp connections

Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 14 Correctly installed plug without gap When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).

Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.

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Deutsch plug, series DT and DTM

DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

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Deutsch plug, series DT and DTM

Installing DT contacts

Fig. 4
l Insert the contacts through the rubber grommet until
they click into place.
l Insert the orange wedge in direction of arrow.

! Caution
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

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Deutsch plug, series DT and DTM

Disassembling DT contacts

Fig. 5
l
Pull the orange wedge out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
l
Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.

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Deutsch plug, series DT and DTM

DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

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Deutsch plug, series DT and DTM

Installing DTM contacts

Fig. 4
l
Insert the contacts through the rubber grommet until
they click into place.
l
Insert the orange wedge, until it clicks into place.

Caution
!

Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

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Deutsch plug, series DT and DTM

Disassembling DTM contacts

Fig. 5
l Pull the orange wedge (interlock) out with long nose
pliers.
l Slightly pull the lead and unlock the interlocking
hook with a screw driver.
l
Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.

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Plugs and terminals in spring clamping technology

Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!

Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 mm² to 4 mm², single or multi-
ple strand up to 2.5 mm². And this even without tools
(Fig. 3).

That's how it works

l Strip 9-10 mm of the lead. Fig. 3 Connecting clamp

l Open the actuating lever and insert the strand.

l Return the actuating lever to initial position.

! Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

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Plugs and terminals in spring clamping technology

Series clamp

Fig. 4 That's how it works

That's how it works

l Insert a screw driver into the actuating opening until
it bottoms.
l Strip 9-10 mm of the lead and insert it into the
clamp.
l Pull out the screw driver.

! Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.

Fig. 5 Test adapter

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Plugs and terminals in spring clamping technology

X-COM System for universal system wiring, ever since it was intro-
The X-COM-SYSTEM, a synthesis of plug connector duced in 1997. All the familiar series clamping func-
and series clamp, has grown up to a construction kit tions have thus become pluggable.

X-COM plug clamp

Fig. 6 That's how it works Measuring signals

That's how it works
l Insert a screw driver into the actuating opening until
it bottoms.
l Strip 9-10 mm of the lead and insert it into the plug.
l Pull out the screw driver.

! Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

Fig. 8 X-COM plug plugged onto the series clamp

Fig. 7 X-COM plug with measuring cable

l
The most reliable measurements on the plug can be
made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).

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Electronic control units

Electronic control units Modules

In the latest generation of machines BOMAG uses
Control units machine programmable modules. A module mainly
consists of a programmable microprocessor with ad-
Control units (ECU = electronic control unit or ECM =
ditional circuitry for inputs and outputs.
electronic control module) are electronic modules
which are mainly installed in places where something
needs to be controlled or regulated. Control units are
used in almost any electronic sector in the automotive
industry, but also to control machines, plants and oth-
er technical processes.
Control units generally work according to the IPO-
principle. IPO stands for Input-Processing-Output.
Sensors are available for input. Sensors determine a
physical characteristic like e.g. rotary speed, pres-
sure, temperature, etc. This value is compared with a
setpoint entered into or calculated in the control unit.
If the measured value does not match the stored val-
ue, the control unit regulates the physical process by
means of actors, so that the measured actual values
match the setpoint again. This means that the actors
correctively interfere with the ongoing process.

Fig. 1 Module
The modules have control lights on inputs and outputs
to monitor the applied signals.

Fig. 1 Electronic control (ESX)

In current vehicles control units are linked via various
system buses (CAN, LIN, MOST, Flexray). The units
exchange information about operating states and oth-
er relevant data in vehicle across the system. Further-
more, the on-board diagnostic or the diagnostic
system of the vehicle is connected via such busses
(and possible K-lines). Furthermore, external diag-
nostic devices (alternatively Personal Computers or
Notebooks plus matching Interface) can communicate
with the control units. In this case the system will be
interrogated to find out whether the permanent self
tests of the control unit has revealed and registered
any faults in itself or on the connected sensors.

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Electronic control units

Binary signals CAN-bus, Controller Area Network

Process states are bivalent (binary) if they have only created by Bosch at the end of the eighties for auto-
2 possible states of truth, such as e.g. button pressed/ mobile applications.
not pressed, object present/not present. The two
states of truth are mapped by means of defined states Development objectives:
of an information carrier, e.g. 'not pressed' equals 0 V, Real-time critical, robust and low price communication
'pressed' equals 24 V. These states are described of control units, such as transmission and engine con-
with {0,1} or {false, true} trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.
Analog signals
Process states are continuous when they can be
mapped by means of a real number, e.g. temperature
= 65.5 °C. The sensor converts a continuous process
status into an analog signal. If the control unit needs
the numerical value of the analog signal, an analog-
digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.

Fig. 1

Why CAN?
l Networking of control units for the realization of
complex functions.
l Reduction of the extend of wiring and plug connec-
tions.
l Better diagnostic possibilities (central diagnostics
socket).

Characteristics of CAN
It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per me-
tre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow

Measuring on the CAN

Signals transmitted through the bus line can generally
not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user.
Correct connection of lines can only be checked by
means of a continuity test. BOMAG display modules
are connected to the BUS to give engineers and user
the possibility to detect faults or to receive information
from the BUS.

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Special tools, electrics

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Special tools, electrics

Special tools, electrics

Measuring equipment
14. Electric test case

BOMAG part-no.: 057 505 70

Fig. 2
15. Multimeter

BOMAG part-no.: 057 509 91

Fig. 3
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 53

17. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 54

Fig. 4
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 51

19. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 52

Fig. 5

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Special tools, electrics

20. Measuring and connecting lines with 4mm plug,

high flexible design, black, length 0.5 m.

BOMAG part-no.: 079 900 58

21. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 1 m.

BOMAG part-no.: 079 900 59

22. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 2 m.

BOMAG part-no.: 079 900 60

23. Measuring and connecting lines with 4mm plug,
Fig. 6 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

24. Measuring and connecting lines with 4mm plug,
high flexible design, red, length 1 m.

BOMAG part-no.: 079 900 56

25. Measuring and connecting lines with 4mm plug,
high flexible design, red, length 2 m.

BOMAG part-no.: 079 900 57

26. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 300 mm.

BOMAG part-no.: 079 900 63

27. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 600 mm.

BOMAG part-no.: 079 900 64

28. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 7
BOMAG part-no.: 079 900 61
29. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 600 mm.

BOMAG part-no.: 079 900 62

30. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign

BOMAG part-no.: 079 900 65

Fig. 8

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Special tools, electrics

31. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 9
32. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 10
33. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 11
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 12) to open spring
clamps (Fig. 13).

BOMAG part-no.: 972 024 68

Fig. 12

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Special tools, electrics

35. Testing adapter to measure the signals from the

series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 13
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

Fig. 14
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
AWG 12 = 4,0 mm2 cable cross-section
BOMAG part-no.: 079 900 79

Fig. 15
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section

BOMAG part-no.: 079 900 69

Fig. 16

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Special tools, electrics

39. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
AWG 16, BOMAG part-no.: 079 900 71
AWG 12, BOMAG part-no.: 079 900 72
AWG 8, BOMAG part-no.: 079 900 73

Fig. 17
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 18
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 19
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 20

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Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 21
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.

BOMAG part-no.: 057 509 94

Fig. 22
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 23
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).

BOMAG part-no.: 079 900 35

Fig. 24

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Special tools, electrics

47. Crimping pliers for AMP-contacts of series SU-

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.

BOMAG part-no.: 079 900 48

Fig. 25
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).

BOMAG part-no.: 079 900 23

Fig. 26
49. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.

BOMAG part-no.: 079 900 88

Fig. 27
50. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.

BOMAG part-no.: 079 900 89

Fig. 28

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Special tools, electrics

51. Crimping tool for Powertimer contacts with indi-

vidual strand sealing (example: ESX control)

BOMAG part-no.: 079 900 25

Fig. 29
52. Crimping jaws for Crimping tool 079 900 25

BOMAG part-no.: 079 900 27

Fig. 30
53. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77

Fig. 31
Universal tools
54. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.

BOMAG part-no.: 972 038 47

Fig. 32

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Special tools, electrics

55. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.

BOMAG part-no.: 079 900 70

Fig. 33
Measuring adapter
56. Current measurement adapter for Hirschmann
plugs.

BOMAG part-no.: 057 503 83

Fig. 34
57. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

Fig. 35
58. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.

BOMAG part-no.: 079 900 83

Fig. 36

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Instructions for repair

BW177 D/DH/PDH-50

Air Conditioning

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Heating/air conditioning control

Heat Temperature Control* Control panel for cabin fan and AC*

g = Rotary switch for cabin heater e = Rotary switch for cabin ventilator*
(temperature selector switch)* Position ’’0“ = Cabin ventilator switched off.
Position 1, 2 = Ventilator stages of different
Position ’’0“ = Cabin heater switched off.
and 3 strengths
Position red = Temperature selection for
f = Rotary switch for Air Conditioning
range cabin heater.
Temperature*
Position ’’0“ = Cabin AC switched off.
Postion blue = Temperature selection for air
range conditioning.

* Optional equipment

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Heating/air conditioning control

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Air conditioning system

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Physical basics

Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

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Physical basics

Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l
Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.

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Physical basics

Excerpt from the wet steam table 1 R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

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Refrigerant R134a

Refrigerant R134a Characteristics of the refrigerant R134a:

Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a

Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.

Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
-101.6 °C compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).

Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

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Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, Compressor oil / refrigeration oil
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of re-
Inflammability: frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger- Compressor oil (the oil quantity should be 10 % of the
ant is decomposed by flames or glowing surfaces. Ul- refrigerant weight) mixes with the refrigerant and cir-
traviolet light also cracks refrigerant (caused by culates permanently through the system.
electric welding). This results in toxic fission products, In connection with R134a- air conditioning systems
these must not be inhaled. However, irritation of the special synthetic compressor oils, e.g. polyalkylene
mucous membranes is an early and in-time warning. glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
from this, the materials in the R134a air conditioning
Filling factor: system may be attacked when the mixture is flowing
In a container there must be a steam space above the through the refrigerant circuit under high pressure and
liquid space. The liquid expands with increasing tem- at high temperatures or if the lubrication film in the
perature. The steam filled space becomes smaller. compressor tears off. The use of non-permitted oils
From a certain time on the container will be filled with can cause damage to the air conditioning system, you
just liquid. After this only a minor temperature in- should therefore only used the approved oils.
crease is enough to generate very high pressures in
the container, because the liquid would like to expand,
but there is no more room. The related forces are high Properties of compressor oil / refrigeration oil:
enough to cause the container to burst. In order to The most important properties are high solvency in
avoid overfilling of a container the pressure gas direc- connection with refrigerants, good lubrication charac-
tive clearly specifies how many kilograms of refriger- teristics, that they are free of acids and their low water
ant may be filled into the container per litre volume. content. For this purpose only certain oils can be
Multiplied with the internal volume this "filling factor" used. PAG-oils suitable for use with refrigerant R134a
determines the permissible filling capacity For refrig- are highly hygroscopic and will not mix with other oil.
erants used in motor vehicles it is 1.15 kg/l. As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
gressive against metals.
The contribution of R134a to the greenhouse effect is
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.

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Working principle of the air conditioning system

Working principle of the air Monitoring devices

conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.

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Description of components

Monitoring chain Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l
1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l 6 Relay
the function of the system. Coupling and decoupling is
l 7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)

! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.

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Description of components

Reason of oil loss Amount of oil lost Condenser

Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

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Description of components

Dryer / filter / fluid container / inspection Safety valve

glass

Fig. 2

Fig. 1 The fluid container is equipped with a safety valve.

Response pressure 32 +/- 4 bar
Dryer / filter
Tightening torque 10 - 15 Nm
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Inspection glass
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
i Note During operation the refrigerant must flow through the
Since the absorbing capacity of this filter/dryer is lim- inspection glass without air bubbles. In most cases
ited, it must be changed within certain service inter- the presence of air bubbles is a sign for a too low re-
vals. We recommend to replace it 1 x per years, frigerant level in the system. Apart from this, the refrig-
before the start of the season. erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
Caution
!
down to a level, at which gaseous refrigerant could
The filter/dryer must generally be replaced when- flow through the rising tube to the inspection glass.
ever opening the refrigerant circuit, because This results in abnormally high temperatures in and on
moisture will enter in such a case. the fluid lines (between refrigerant container and ex-
This requires emptying the air conditioning sys- pansion valve), as well as very high pressures in the
tem! pressure side.

Installation position: However, incorrect evacuation or filling may also be

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.

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Description of components

i Note Expansion valve

Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger

In case of mechanical damage or corrosion on

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.

i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+

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Description of components

Evaporator Defroster thermostat

Fig. 1 Fig. 1

The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (± 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5,5°C (± 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.

! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

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Description of components

Pressure switch Pipes and hoses

Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

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Checking the compressor oil level

Checking the compressor oil level

Checking the compressor oil level / refrig-
eration oil level

! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
l
Run the compressor for 10 minutes at engine idle
speed.
l
In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi-
tioning system.
Fig. 2
l Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.

i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
l Insert the oil dipstick.
l
Pull out the dipstick and count the notches covered
by oil.
l
Drain off oil or fill up as specified in the table.

Environment
Used compressor oil / refrigeration oil must be
Fig. 1 disposed of as hazardous waste.
l
Measure the fastening angle (Fig. 1) of the com-
pressor (oil plug at top) Fastening angle (de- Oil dipstick in incre-
gree) ments
l Remove the oil filler plug.
0 5-7
10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.

! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

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Checking the magnetic clutch

Checking the magnetic clutch i Note

l
Measure the voltage. The gap should be 0.4 to 0.8 mm.
l
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
l
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
l
Check the current consumption. magnetic clutch needs to be replaced.

Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.

Fig. 1

i Note
at 12 Volt vehicle voltage approx. 3.5 Amp.
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Fig. 3 Cross-section of magnetic clutch

Fig. 2 Measuring the air gap

l
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

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Inspection and maintenance work

Inspection and maintenance work Checking, replacing the refrig-

l Visual inspection of the complete system for dam-
erant compressor V-belt 1
age.
l Check the compressor mounting bracket on the ve- Danger
!

hicle engine for tight fit and damage. Danger of injury!

l Check the condition, alignment and tightness of the Work on the V-belt must only be performed with
V-belt. the engine shut down.
l Check the routing of refrigerant hoses and cables in Wear safety goggles.
the area of the vehicle engine and transmission, as
well as on the chassis for chafing and rectify any de- Check the V-belt
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
l Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
l Check all hose and screw fittings for leaks.
l Check the fastening of the condenser unit.
l Clean the condenser fins, replace the condenser
block if damaged fins are found.
l Check the fastening of the evaporator unit.
l Check the function of evaporator and condenser
fans.
Fig. 4
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
l Inspect the entire circumference of the V-belt (Fig.
and possibly also the corresponding relays. 4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Switch on the cooling system and check the refrig-
erant level.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
l Filter/dryer and filter/dryer/fluid container combina- inches) between the V-belt pulleys, retighten if nec-
tions must always be replaced after opening the re- essary.
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer Tighten the V-belt.
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference 1
should be at least 8-10 K.
2
4
l Measuring the pressure in the refrigerant circuit

Fig. 5
l Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
1 Optional equipment

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Service the air conditioning

Insert a ½ inch Breaker into box (4)

Service the air conditioning 1
l

rotating the compressor in direction of

arrow, until the correct V -belt tension is
reached. Cleaning the condenser
l Retighten all fastening screws.
! Caution
Changing the V-belt A soiled condenser results in a considerable re-
duction of air conditioning power.
l
Slightly slacken the fastening screws 1, 2 and 3.
Under extremely dusty conditions it may be nec-
l
Press the compressor against the direction of arrow
essary to clean the condenser several times per
completely against the engine.
day.
l
Take the old V-belt off. If, during operation of the air conditioning system,
l
Fit the new V-belt to the V-belt pulleys. the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
l
Tension the V-belt as previously described.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
! Caution ment.
Check the V-belt tension after a running time of 30
minutes.
! Danger

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.

Fig. 6
l
Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

1 Optional equipment

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Service the air conditioning

Fig. 7 Fig. 9
l Switch the air conditioning (Fig. 7) on. l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.

i Note
The refrigerant level is correct.

Fig. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l Check, whether the outflowing air is noticeably cool-
er. Fig. 10
l If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
l Open the hood. The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

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Service the air conditioning

Checking the moisture level of the drying

agent

Fig. 12
l
Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
l
Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
l
Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

! Caution
Have the drier/collector unit replaced by the serv-
ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

! Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

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Drying and evacuation

Drying and evacuation Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.

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Leak test

Leak test

! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.

Leak test with electronic leak tester

Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.

Leak test with soap bubbles

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.

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Filling instructions

Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

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Filling instructions

Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge

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Filling instructions

19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.

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Trouble shooting in refrigerant circuit, basic principles

Trouble shooting in refriger-

ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l
technical equipment

Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l
Scales
l
Suction station
l
Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.

Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)

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Trouble shooting in refrigerant circuit, basic principles

Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.

Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
∆ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. ∆ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.

Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause

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Trouble shooting in refrigerant circuit, basic principles

a formation of bubbles in front of the expansion ele-

ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

∆ tc2u = tc - tc2u
∆ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

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Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion

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Trouble shooting, refrigerant circuit diagram

Trouble shooting, refrigerant

circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air

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Trouble shooting procedure

Trouble shooting procedure l

Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l
Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l
The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

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Trouble shooting procedure

Measuring points and measurements

Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l
C, condenser measuring points tainer the inspection glass is most suitable to check
l
E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l
a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- l b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator l
c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l
e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „∆to2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used

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Trouble shooting procedure

Solution: be a defect in the expansion valve or problems in the

l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) ∆to2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required ?
l b) Where to measure with which size ?
l c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "∆tc2u" ?
l f) Evaluation of the measured supercooling.

Solution:
l a) Pressure gauge, thermometer, steam table
l b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l
d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) ∆tc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also

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Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X

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Suction pressure too low (1), high pressure too

low to normal (2)

Fig. 3

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently

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Suction pressure normal (1), high pressure too

high (2)

Fig. 4

Cause Possible effect Remedy

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power

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Suction pressure too high (1), high pressure too

low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

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Suction pressure too high (1), high pressure too

high (2)

Fig. 6

Cause Possible effect Remedy

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor

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Other faults

Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary

Noise in system

Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float

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Inspection glass

Faults Possible cause Remedy

Steam bubbles in inspection glass No supercooling before expansion Fill up the system, replace the filter
valve, lack of refrigerant in system, dryer, perform a leak test
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Discolouration of inspection glass Lubricant destroyed by excessive Replace the refrigeration oil, exam-
(black from inside) operating temperatures ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too Replace the filter dryer
high
Ball floats at bottom lack of refrigerant Fill the system

Monitoring devices

Faults Possible cause Remedy

The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan

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Steam table for R134a

Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam

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Series 42
Axial Piston Closed
Circuit Pumps

Service Manual

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Series 42 Axial Piston Closed Circuit Pumps

Service Manual
Using this manual

ORGANIZATION AND To help you quickly find information in this manual, the material is divided into sections,
HEADINGS topics, subtopics, and details, with descriptive headings set in red type. Section titles
appear at the top of every page in large red type. Topic headings appear in the left
hand column in BOLD RED CAPITAL LETTERS. Subtopic headings appear in the body
text in bold red type and detail headings in italic red type.

References (example: See Topic xyz, page XX) to sections, headings, or other publications are
also formatted in red italic type. In Portable Document Format (PDF) files, these references
represent clickable hyperlinks that jump to the corresponding document pages.

TABLES, ILLUSTRATIONS, Tables, illustrations, and graphics in this manual are identified by titles set in blue italic
AND COMPLEMENTARY type above each item. Complementary information such as notes, captions, and drawing
INFORMATION annotations are also set in blue type.

References (example: See Illustration abc, page YY) to tables, illustrations, and graphics
are also formatted in blue italic type. In PDF files, these references represent clickable
hyperlinks that jump to the corresponding document pages.

SPECIAL TEXT Defined terms and acronyms are set in bold black type in the text that defines or
FORMATTING introduces them. Thereafter, the terms and acronyms receive no special formatting.

Black italic type is used in the text to emphasize important information, or to set-off
words and terms used in an unconventional manner or alternative context. Red and blue
italics represent hyperlinked text in the PDF version of this document (see above).

TABLE OF CONTENTS An indented Table of Contents (TOC) appears on the next page. Tables and illustrations
in the TOC set in blue type. In the PDF version of this document, the TOC entries are
hyperlinked to the pages where they appear.

© 2007 Sauer-Danfoss. All rights reserved. Printed in U.S.A.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Front cover illustrations: F101 373, F101 374, P106 153E

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Service Manual
Table of Contents

INTRODUCTION Overview .............................................................................................................................................................................. 6

Warranty ............................................................................................................................................................................... 6
General instructions ......................................................................................................................................................... 6
Safety precautions ............................................................................................................................................................ 7
Unintended machine movement .......................................................................................................................... 7
Flammable cleaning solvents ................................................................................................................................. 7
Fluid under pressure .................................................................................................................................................. 7
Personal safety ............................................................................................................................................................. 7
Symbols used in Sauer-Danfoss literature................................................................................................................ 8
Ordering replacement parts and service .................................................................................................................. 8

1998 MODEL RELEASE Overview .............................................................................................................................................................................. 9

Description of change ..................................................................................................................................................... 9
Housing........................................................................................................................................................................... 9
Charge pump ................................................................................................................................................................ 9
Auxiliary flange shipping cover ............................................................................................................................. 9
Charge relief valve ...................................................................................................................................................... 9
Spool - loop flushing .................................................................................................................................................. 9

FUNCTIONAL General description and cross-sectional view ......................................................................................................10

DESCRIPTION The system circuit............................................................................................................................................................11
Pump features ..................................................................................................................................................................11
The basic closed circuit ...........................................................................................................................................11
Case drain and heat exchanger............................................................................................................................11
Charge pump ..............................................................................................................................................................11
Charge relief valve ....................................................................................................................................................12
Loop flushing valve ..................................................................................................................................................12
Filtration options .............................................................................................................................................................13
Displacement limiters ....................................................................................................................................................14
Charge check / high pressure relief valves .............................................................................................................14
Bypass valves ....................................................................................................................................................................14
Auxiliary mounting pads ..............................................................................................................................................15

PUMP CONTROL Manual displacement control (MDC) .......................................................................................................................16

OPTIONS Electrical displacement control (EDC)......................................................................................................................16
Non-feedback proportional hydraulic (NFPH) control.......................................................................................17
Non-feedback proportional electric (NFPE) control ...........................................................................................17
Forward-Neutral-Reverse (FNR) three-position electric control.....................................................................17

TECHNICAL Specifications ....................................................................................................................................................................18

SPECIFICATIONS General specifications .............................................................................................................................................18
Hardware specifications .........................................................................................................................................18
Case pressure ..............................................................................................................................................................18
Speed limits .................................................................................................................................................................18
System pressure .........................................................................................................................................................18
Theoretical flow .........................................................................................................................................................18
Inlet pressure ..............................................................................................................................................................18

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Table of Contents

PRESSURE Required tools ..................................................................................................................................................................19

MEASUREMENT Port locations and pressure gauge installation ....................................................................................................19
Ports and pressure gauges...........................................................................................................................................19

INITIAL START-UP General ................................................................................................................................................................................21

PROCEDURE Start-up procedure .........................................................................................................................................................21

FLUID AND FILTER Recommendations..........................................................................................................................................................22

MAINTENANCE

TROUBLESHOOTING System operating hot ....................................................................................................................................................23

System response is sluggish ........................................................................................................................................24
System will not operate in either direction............................................................................................................25
System will not operate in one direction................................................................................................................26
Neutral difficult or impossible to find ......................................................................................................................26

ADJUSTMENTS Displacement limiter adjustment..............................................................................................................................27

Conversions .................................................................................................................................................................28
Pump neutral adjustment ............................................................................................................................................29
Control neutral adjustment for MDC and EDC .....................................................................................................30

MINOR REPAIR Standard procedures .....................................................................................................................................................31

Remove the pump ....................................................................................................................................................31
Keep it clean ................................................................................................................................................................31
Inspect for system contamination ......................................................................................................................31
Replace the O-rings and gaskets .........................................................................................................................31
Lubricate all moving parts .....................................................................................................................................31
Size and torque for plugs and fittings......................................................................................................................32
Charge relief valve...........................................................................................................................................................33
Shim adjustable style (pre-blockpoint change) .............................................................................................33
Externally adjustable style .....................................................................................................................................33
Conversions .................................................................................................................................................................34
Optional speed sensor...................................................................................................................................................35
Removal ........................................................................................................................................................................35
Reassembly..................................................................................................................................................................35
MDC Module .....................................................................................................................................................................36
Removal ........................................................................................................................................................................36
Installation ...................................................................................................................................................................36
EDC Module.......................................................................................................................................................................38
Removal ........................................................................................................................................................................38
Replacement ...............................................................................................................................................................38
MDC / EDC Spool, linkage, and neutral adjustment screw ...............................................................................40
Removal ........................................................................................................................................................................40
Installation ...................................................................................................................................................................41
MDC Neutral start / backup alarm switch ..............................................................................................................42
MDC Solenoid override valve......................................................................................................................................44
Removal ........................................................................................................................................................................44
Installation ...................................................................................................................................................................44
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MINOR REPAIR FNR, NFPE, and NFPH Controls....................................................................................................................................45

(continued) Removal of FNR and NFPE modules ...................................................................................................................45
Installation of FNR and NFPE modules ..............................................................................................................45
Conversions .................................................................................................................................................................46
System Check Relief (SCR) valves (high pressure relief, charge check, and bypass valves)...................47
Conversions .................................................................................................................................................................48
Filtration adapters ...........................................................................................................................................................49
Filter-related pump hardware ..............................................................................................................................49
Removal ........................................................................................................................................................................49
Replacement ...............................................................................................................................................................50
Auxiliary pad/charge pump cover ............................................................................................................................51
Removal of charge pump cover/auxiliary pad ...............................................................................................51
Conversions .................................................................................................................................................................52
Installation ...................................................................................................................................................................52
Charge pump ....................................................................................................................................................................53
Disassembly ................................................................................................................................................................53
Assembly ......................................................................................................................................................................54
Units without integral charge pump..................................................................................................................55
Conversions .................................................................................................................................................................55
Servo piston covers and NFPH control orifice ......................................................................................................57
Disassembly ................................................................................................................................................................57
Assembly ......................................................................................................................................................................58
Loop flushing and loop flushing relief valve .........................................................................................................59
Loop flushing valve ..................................................................................................................................................59
Loop flushing relief valve .......................................................................................................................................59
Conversions .................................................................................................................................................................60
Defeating loop flushing ..........................................................................................................................................60
Shaft seal, roller bearing, and shaft replacement .................................................................................................61
Seal removal ................................................................................................................................................................61
Shaft removal..............................................................................................................................................................62
Shaft bearing replacement ....................................................................................................................................62
Reassembly..................................................................................................................................................................63
Conversions .................................................................................................................................................................63

APPENDIX A - TORQUES Torque table ......................................................................................................................................................................64

APPENDIX B - Pre-block point change .................................................................................................................................................65

SPECIFICATION TAGS Post-block point change...............................................................................................................................................65

APPENDIX C - Pre-block point change nomenclature ...................................................................................................................66

NOMENCLATURE Post-block point change nomenclature .................................................................................................................67

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Introduction

OVERVIEW This manual includes information for the installation, maintenance, and minor repair of
Series 42 axial piston closed circuit pumps. It includes a description of the unit and its
individual components, troubleshooting information, and minor repair procedures.

Performing minor repairs requires you remove the unit from the vehicle/machine.
Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirt
and contamination are the greatest enemies of any type of hydraulic equipment, follow
cleanliness requirements strictly. This is especially important when changing the system
filter and when removing hoses or plumbing.

A worldwide network of Sauer-Danfoss Global Service Partners (GSPs) is available for

major repairs. Sauer-Danfoss trains and certifies ASCs on a regular basis. You can locate
your nearest ASC using the distributor locator at www.sauer-danfoss.com. Click on the
Sales and Service link.

WARRANTY Performing installation, maintenance, and minor repairs according to the procedures in
this manual does not affect your warranty. Major repairs requiring the removal of a unit’s
rear cover or front flange voids the warranty unless done by a Sauer-Danfoss global
service partner.

GENERAL INSTRUCTIONS Follow these general procedures when repairing Series 42 variable displacement closed
circuit pumps.

w Remove the unit

Prior to performing minor repairs, remove the unit from the vehicle/machine. Chock
the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that
hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the pump
and fittings for damage. Cap hoses after removal to prevent contamination.

e Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life, on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts with a clean solvent wash
and air drying is usually adequate.

As with any precision equipment, you must keep all parts free of foreign material and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the pump with a protective layer of plastic.

d Replace all O-rings and gaskets

Sauer-Danfoss recommends replacing all O-rings, gaskets, and seals when servicing.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

t Secure the unit

For repair, place the unit in a stable position with the shaft pointing downward. It is necessary
to secure the pump while removing and torquing end covers, controls, and valves.

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Introduction

SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing a
hydraulic system.

Unintended machine movement

W Warning
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable/
disconnect the mechanism while servicing.

Flammable cleaning solvents

W Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.

Fluid under pressure

W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.

Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

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Introduction

SYMBOLS USED IN  WARNING may result in injury  Tip, helpful suggestion

SAUER-DANFOSS
LITERATURE  CAUTION may result in damage to  Lubricate with hydraulic fluid
product or property
 Apply grease/petroleum jelly
 Reusable part
 Apply locking compound
 Non-reusable part, use a new part
 Inspect for wear or damage
 Non-removable item
 Clean area or part
 Option – either part may exist
 Be careful not to scratch or damage
 Superseded – parts are not
interchangeable  Note correct orientation

 Measurement required  Mark orientation for reinstallation

 Flatness specification  Torque specification

 Parallelism specification  Press in – press fit

 External hex head  Pull out with tool – press fit

 Internal hex head  Cover splines with installation

sleeve
 Torx head
 Pressure measurement/gauge
 O-ring boss port location or specification

The symbols above appear in the illustrations and text of this manual. They are intended
to communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend
above defines each symbol and explains its purpose.

ORDERING Sauer-Danfoss provides a complete repair service for its products. Contact any Sauer-
REPLACEMENT PARTS Danfoss Global Service Partner for details.
AND SERVICE
To ensure the best performance, use genuine Sauer-Danfoss replacement parts. To order
parts, contact Sauer-Danfoss Extended Customer Service (ECS) at (515) 239-6078, fax
(515) 239-6230, or your nearest Global Service Partner.

Some service parts may be available only in kits, while other parts may be available on
an individual basis. See publication 520L0589 Series 42 PV 41cc Service Parts Manual or
520L0590 Series 42 PV 28cc Service Parts Manual for listings of available service parts and
service kits for Series 42 units.

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1998 Model Release

OVERVIEW Parts may or may not be interchangeable between pre-1998 and post-1998 model
year pumps. Many parts, including the housing assembly, are unique to the model year
change.

DESCRIPTION OF Housing
CHANGE The port cover for the control spool (FOB option - 28 cm3 only) changed from a flat plate
with two screws to an SAE O-ring boss plug. The screw holes for the servo covers and
four of the six screw holes for the side cover are deeper to accept a 10 mm longer screw.
The two holes next to the charge pump cover stayed the same length.

Charge pump
The gerotor drive pin changed to a parallel key. A retaining ring was added to the charge
pump shaft to locate the gerotor. The outer step on the gerotor cover was eliminated
and the locating pin slot depth increased.

Auxiliary flange shipping cover

The cover changed to a flat cover plate with a special seal ring (not to be used to seal an
auxiliary pump) under the cover (A pad only).

Charge relief valve

The relief valve changed from a non-adjustable to an adjustable relief valve. This change
requires a 1998 upgrade housing.

Spool - loop flushing

The spool changed to become common between the 28 and 41/51 cm3 pumps. This
change requires a 1998 upgrade housing.

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Functional Description

OVERVIEW This section describes the operation of pumps and their serviceable features. It is a useful
reference for readers unfamiliar with the function of this specific pump.

GENERAL DESCRIPTION The Series 42 pumps are servo controlled, axial piston pumps designed for closed
AND CROSS-SECTIONAL circuit applications. The input shaft turns the pump cylinder block containing nine
VIEW reciprocating pistons that are held to the swashplate with a block spring. Each piston has
a brass slipper connected to one end by a ball joint. The reciprocating movement occurs
as the slippers slide along the inclined swashplate during rotation. As each piston cycles
in and out of its bore, fluid is drawn from the inlet and displaced to the outlet thereby
imparting hydraulic power to the system. Via the valve plate, one half of the cylinder
block is connected to low pressure and the other to high pressure. Clearances allow a
small amount of fluid to flow from the cylinder block/valve plate and slipper/swashplate
interfaces for lubrication and cooling. Case drain ports return this fluid to the reservoir.

The angle of the swashplate controls the volume of fluid displaced into the system.
The servo piston forces the swashplate into an inclined position (into stroke). Internal
moments and centering springs within the servo piston return the swashplate to the
neutral position (out of stroke).

Cross section
Slipper
Swashplate
Piston

Cylinder block

Roller bearing Charge pump

Valve plate
P100382E

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Functional Description

THE SYSTEM CIRCUIT System circuit diagram

Servo control cylinder
Displacement control valve

Heat exchanger Reservoir

bypass
Filter

Fixed
Control Heat displacement
handle exchanger motor
Cylinder Cylinder
block block
assembly Charge relief assembly
valve

Output
Charge shaft
pump
Input
shaft Variable Suction flow
displacement Check valves Charge pressure
pump with high pressure Servo pressure
relief valves High pressure
Case flow
P100384E

The basic closed circuit

Hydraulic lines connect the main ports Charge pump
of the pump to the main ports of the O-ring
motor. Fluid flows in either direction
from the pump to the motor and back. Gerotor cover
Either of the hydraulic lines can be under
high pressure. The position of pump
swashplate determines which line is high
pressure as well as the direction of flow.
Square key Coupling
Case drain and heat exchanger
Both the pump and motor must drain
Gerotor set
fluid. A case drain line achieves this. The
line connects to the pump or motor
at the top-most drain port in order to
maintain an adequate fluid level in the
Retainer
components. Fluid cooling demands may ring
require a heat exchanger with a bypass Orientation
valve to cool the case drain fluid before it pin
returns to the reservoir.

PUMP FEATURES Charge pump

The charge pump is necessary to supply
fluid to maintain positive pressure in the
system loop, to provide pressure to operate
the control system, and to make up for
internal leakage and loop flushing flow. To
prevent damage to the transmission, the
pump must maintain the specified charge
pressure under all conditions of operation. P101118E

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Functional Description

PUMP FEATURES The charge pump is a fixed-displacement, gerotor type pump. The main pump drives
(continued) the charge pump off the main shaft. A spring and poppet style relief valve limits charge
pressure.

The standard charge pump is satisfactory for most applications; however, other
displacements are available. A gear pump, mounted to the auxiliary pad, may augment
charge flow if additional volume is required. For repairs to the charge pump, see pages
51 to 56.

Charge relief valve

The charge relief valve maintains charge pressure at a designated level. The charge relief
valve is a direct acting poppet valve which opens and discharges fluid to the pump case
when pressure reaches that level. It is nominally set with the pump running at 1800 rpm.
In forward or reverse, charge pressure is slightly lower than when in neutral position. The
model code of the pump specifies the charge relief valve setting. For adjustments to the
charge relief valve, see pages 33 and 34.

Loop flushing valve

A loop flushing valve dumps flow from the low side of the main loop, removing heat
and contaminants faster than otherwise possible. Pumps equipped with an integral loop
flushing valve also include a loop flushing relief valve. The loop flushing relief valve poppet
includes an orifice that controls flushing flow under most conditions. A combination of
orifice size and charge pressure relief setting produces a specific flushing flow.

Charge relief, loop flushing relief, and loop flushing valve

Charge relief
valve

Loop flushing
relief valve

Loop flushing
spool
Loop flushing
defeat spool
P101119E

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Functional Description

FILTRATION OPTIONS Series 42 pumps may be equipped with provisions for either suction or charge pressure
filtration to filter the fluid entering the circuit.

Suction filtration
The suction filter is in the circuit between the reservoir and the inlet to the charge pump.

Charge pressure filtration Suction filtration

The pressure filter is remotely mounted Filter
in the circuit after the charge pump.
Reservoir

You may use partial or full flow pressure

filtration circuits with Series 42 pumps. Strainer
Without a filter adapter, suction filtration To low pressure
side of loop and Charge
is the only option. servo control pump

Charge
relief
valve
Filtration adapters
To pump case P001603

Partial flow pressure filtration

Reservoir
Partial flow Strainer
pressure
filtration Filter

Charge pump
To low pressure
side of loop and
Full flow servo control
Full flow suction
pressure filtration Charge
filtration relief valve

To pump case P001604E

Full flow pressure filtration

Reservoir

Strainer

Filter
with bypass
To low pressure
side of loop and Charge
servo control pump

Charge
P101120E relief
pump

To pump case P001605E

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Functional Description

DISPLACEMENT LIMITERS Series 42 pumps are available with Displacement limiters

mechanical displacement limiters in the Displacement limiter
servo covers. The displacement limiters (factory set for maximum displacement)
can limit displacement of the pump
to any value from maximum to zero in
either direction. See page 27 and 28 for
adjustments to the displacement limiters.
Servo control
cylinder
Displacement limiter
CHARGE CHECK / HIGH All series 42 pumps have a combination (set for reduced maximum displacement)
PRESSURE RELIEF VALVES charge check/high pressure relief valve. P100395E

The charge check function allows

pressurized flow from the charge pump High pressure relief valve
to enter the low pressure side of the loop.
This flow is necessary to replenish fluid High pressure
discharged to the pump/motor case for side of working loop
lubrication and cooling requirements.
Since the pump can operate in either
direction, it uses two charge check valves
to direct the charge supply into the low
pressure side. Charge check and
high pressure
relief valve
High pressure relief valves are available in P100393E

a range of settings as shown in the model

code. The model code may specify individual pressure settings. The high pressure relief valve
settings are referenced to charge pressure and are set at 3.8 l/min (1 US gal/min) of flow.

BYPASS VALVES Optional bypass plungers are available Charge check and high pressure relief
for use when it is necessary to move the valves with bypass
vehicle or mechanical function and the To/from other
bypass valve
prime mover is not running.
To/from
working loop
CCAUTION Together, these valves connect both
Bypass valves are for sides of the main hydraulic circuit,
moving a machine or allowing fluid to circulate without
vehicle for very short rotating the pump and prime mover.
distances at very slow
speeds. They are not tow The bypass function is integral to the Charge check and
Bypass high pressure
valves. If pressure builds charge check/high pressure relief valve relief valve
plunger
within the system, the assembly. Depressing the plunger in P100394E
valves may close causing the plug of the valve assembly opens
damage to the pump and the valve. The valve remains open until the prime mover restarts or pressure builds in
motor or prime mover. the system and causes the valve the close. You must depress the plungers in both of the
Move the vehicle/machine check/relief valve assemblies for proper bypass operation. C
at no more than 20% of
top speed for no more
than three minutes.

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Functional Description

AUXILIARY MOUNTING SAE A and SAE B auxiliary mounting flanges are available on all Series 42 pumps and are
PADS integral to the charge pump cover. This flange allows mounting of auxiliary hydraulic
pumps and mounting of additional Series 42 pumps to make tandem pumps. The pads
allow full through-torque capability.

Auxiliary mounting pads

Charge pump cover

O-ring

x6

x7

Cover plate
Charge pump cover
x7 Pad seal

P101124

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Pump Control Options

MANUAL DISPLACEMENT The Manual Displacement Control (MDC) uses a mechanical input to operate the control spool
CONTROL (MDC) in the pump. A cam connects the input handle to the control spool allowing manipulation of
the operating curve using different cam profiles. The control spool modulates the pressure
balance across the pump’s servo piston. The angle of the swashplate is proportional to the
angular position of the control input. A mechanical feedback linkage moves the control spool
toward neutral as the swashplate angle reaches the commanded position. Mechanical feedback
allows the pump to hold very accurately at
the commanded displacement. Centering MDC on series 42 pump
springs and internal moments return
the swashplate to neutral position in the
absence of control input.

Solenoid override valve

A solenoid override valve is available for the
manual displacement control. This safety
feature shunts the servo piston allowing the
pump to return to neutral when activated.
Normally open or normally closed options
are available.
P101258

Neutral start switch (NSS)

The Neutral Start Switch (NSS) is an optional cam-operated ball-type microswitch. When
connected properly to the vehicle’s electrical system, the NSS ensures that the prime
mover will start only when the control input shaft is in the neutral position.

Back-up alarm switch (BAS)

The Back-up Alarm Switch (BAS) is available for the MDC and works in association with
the NSS. When connected properly to the vehicle’s electrical system, the BAS can sound
an alarm when the control commands the vehicle into reverse. One cam and switch
assembly controls both functions. Repositioning the cam accommodates both clockwise
and counterclockwise control handle rotation to reverse direction.

ELECTRICAL The Electrical Displacement Control (EDC) is a three-stage control using a DC input current to
DISPLACEMENT control pump displacement. Stage one, the Pressure Control Pilot (PCP) valve, uses the DC input
CONTROL (EDC) to operate a torque motor which drives a flapper valve. The flap in the PCP blocks a portion of
flow from one or the other of two nozzles. The two nozzles modulate pressure balance across
a piston in the control: this is stage two. The control piston is connected to the control spool in
the pump: stage three. The control spool
modulates the pressure balance across EDC on series 42 pump
the pump’s servo piston. The angle of the
swashplate is proportional to the input
current. A mechanical feedback linkage
moves the control spool toward neutral
as the swashplate angle reaches the
commanded position. Mechanical feedback
allows the pump to hold very accurately at
the commanded displacement. Centering
springs and internal moments return
the swashplate to neutral position in the
absence of control input.
P101257

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Pump Control Options

NON-FEEDBACK The Non-Feedback Proportional NFPH control on series 42 pump

PROPORTIONAL Hydraulic (NFPH) control is a hydraulic
HYDRAULIC (NFPH) displacement control. External valving
CONTROL supplies an input pressure directly to the
pump servo piston via control ports X1
and X2 to control pump displacement.

Pump displacement is proportional to the

pressure difference across the servo piston.
However, because this control does not use
mechanical feedback, displacement also
depends upon input speed and system
pressure. This characteristic provides
a power limiting function by reducing
displacement as system pressure increases. P100440

NON-FEEDBACK The Non-Feedback Proportional Electric NFPE control on series 42 pump

PROPORTIONAL (NFPE) control is an electric control. A
ELECTRIC (NFPE) PWM input signal to one of two solenoids
CONTROL on the control valve ports charge pressure
to one side of the servo piston.

Pump displacement is proportional to

the signal current. However, because
this control does not use mechanical
feedback, displacement also depends on
input speed and system pressure. This
characteristic provides a power limiting
function by reducing displacement as
system pressure increases. P100415

FORWARD-NEUTRAL- The Forward-Neutral-Reverse (FNR) is FNR control on series 42 pump

REVERSE (FNR) THREE- a three-position control. It uses a 12
POSITION ELECTRIC or 24 Vdc electrically operated spool
CONTROL valve to port pressure to either side of
the servo piston. Energizing one of the
two solenoids will cause the pump to
go to its maximum displacement in the
corresponding direction. The FNR control
does not use mechanical feedback.

All functions of the three position (FNR)

electric control are preset at the factory.

P100418

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Technical Specifications

SPECIFICATIONS General specifications

Product line Series 42 pumps
Pump type In-line, axial piston, positive displacement variable pumps including cradle
swashplate and servo control
Direction of input rotation Clockwise or counterclockwise available
Installation position Pump installation recommended with the control at the top or side. Consult
Sauer-Danfoss for non-conformance guidelines. Housing must always be filled
with hydraulic fluid.
Filtration configuration Suction or charge pressure filtration
Other system Independent braking system, suitable reservoir and heat exchanger.

Hardware specifications
Model 28 41 51
Pump configuration Single variable pump Single variable pump Single variable pump
Displacement 28 [1.71] 41 [2.50] 51 [3.11]
cm3/rev [in3/rev]
Mass kg [lbm] 34.5 [76] 42 [92] 42 [92]

Case pressure
Rated pressure bar [psi] 3.4 [50]
Maximum pressure (cold start) bar [psi] 10.5 [150]

Speed limits
Frame size cm3 28 41 51
Minimum speed min¯¹ (rpm) 500 500 500
Rated speed at maximum displacement min¯¹ (rpm) 3400 3200 2900
Maximum speed at maximum displacement min¯¹ (rpm) 3750 3600 3400

System pressure
Frame size cm3 28 41 51
Rated pressure bar [psi] 385 [5584] 385 [5584] 350 [5076]
Maximum pressure bar [psi] 415 [6019] 415 [6019] 385 [5584]

Theoretical flow
Frame size cm3 28 41 51
Theoretical flow at rated speed l/min [US gal/min] 95.2 [25.1] 131 [34.6] 148 [39.1]

Inlet pressure
Rated pressure (absolute) bar [in Hg vacuum] 0.8 [6]
Minimum pressure (absolute) (cold start) 0.2 [24]
bar [in Hg vacuum]

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Pressure Measurement

REQUIRED TOOLS You can perform the service procedures in this manual using common mechanic’s hand-
tools. Calibrate gauges frequently to ensure accuracy. Use snubbers to protect pressure
gauges.

PORT LOCATIONS AND A pump with a manual displacement control (MDC) and no filtration adapter is shown.
PRESSURE GAUGE With non-feedback controls, the positions of the case drains may vary (shown in gray). With
INSTALLATION a filtration adapter, the porting in the filtration options area varies as outlined on page 13.

PORTS AND PRESSURE Proper service and diagnosis may require pressure measurement at various points in
GAUGES the hydraulic circuit. The Series 42 pump has several locations at which to take these
measurements. The following illustration shows the locations of the various gauge ports.
The table shows the recommended gauge size and the fitting size for each port. Refer to
this information when installing pressure gauges.

Gauge ports
Gauge Pressure measured Recommended gauge O-ring boss
port size 28 cc 41 / 51 cc
M1 & M2 System pressure for ports A and B 600 bar [8700 psi] 9/16/-18 9/16/-18
M3 Charge pressure 60 bar [870 psi] 3/4-16 * 3/4-16 *
M4 & M5 Servo pressure 60 bar [870 psi] 9/16-18 9/16-18
L1 & L2 Case pressure 35 bar [510 psi] 1-1/16-12 1-5/16-12
S Charge pump inlet pressure 1 bar [30 in Hg vacuum] 1-1/16-12 1-5/16-12

* Some older models may use a 9/16-18 O-ring fitting.

28 cm3 base unit with MDC and no filtration adapter

Servo pressure
System pressure gauge port M5
gauge port M2
Servo pressure Charge pressure
gauge port M4 gauge port M3
System (charge pressure
pressure Case drain supply for no
port B port L2 charge pump
Case drain option)
System
pressure port L1
port A
Case drain Charge pump
port L1 inlet port S
Case Drain
System pressure
Port L2
gauge port M1
LEFT SIDE VIEW RIGHT SIDE VIEW P101103E

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Pressure Measurement

PORTS AND PRESSURE 41/51 cm3 base unit with MDC and no filtration adapter
GAUGES (continued) System pressure Servo pressure
gauge port M2 gauge port M5
Charge pressure
gauge port M3
Servo pressure
System
gauge port M4
pressure

M3
port B Case drain
port L2
System
pressure
port A Case drain Charge pump
port L1 inlet port S

System pressure
gauge port M1
LEFT SIDE VIEW RIGHT SIDE VIEW
P100104

Filtration adapters (28 cm3, and 41/51 cm3 models)

Outlet to
filter, port D

Charge pressure
gauge, port M3 Charge pressure
gauge, port M3

Inlet from
filter, port E
P101578E

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Initial Start-Up Procedure

GENERAL Follow this procedure when starting-up a new Series 42 installation or when restarting
an installation in which the pump has been removed.

WARNING
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable/
disconnect the mechanism while servicing.

Prior to installing the pump, inspect for damage incurred during shipping. Make certain
all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean
prior to filling with fluid.

START-UP PROCEDURE 1. Connect the pump to the prime mover. Ensure that pump shaft is properly aligned
with the shaft of the prime mover. 
 CAUTION
Incorrect shaft alignment 2. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10
may result in damage micron absolute filter pouring into the reservoir. Never reuse hydraulic fluid.
to drive shaft, bearings,
or seal which can cause 3. Fill the main pump housing with clean hydraulic fluid. Pour filtered oil directly into
external oil leakage. the upper most case drain port.

4. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for
properly tightened fittings and be certain it is free of restrictions and air leaks.

5. To ensure the pump stays filled with oil, install the case drain line in the upper most
case drain port.

6. Install a gauge at port M2 to monitor system pressure during start up.

Follow recommendations in the vehicle/machine operator’s manual for prime mover

start up procedures.

7. While watching the pressure gauge at M2, jog the prime mover or run at the lowest
possible speed until system pressure builds to normal levels (minimum 11 bar [160
psi]). Once system pressure is established, increase to full operating speed. If the
pump does not maintain system pressure, shut down the prime mover, determine
cause, and take corrective action. Refer to Troubleshooting, page 23.

8. Operate the hydraulic system for at least fifteen minutes under light load conditions.

9. Check and adjust control settings as necessary after installation. Refer to Adjustments,
page 27.

10. Shut down the prime mover and remove the pressure gauge. Replace plug at port M2.

11. Check the fluid level in the reservoir; add clean filtered fluid if necessary.

The pump is now ready for operation.

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Fluid and Filter Maintenance

RECOMMENDATIONS To ensure optimum life of Series 42 products, perform regular maintenance of the fluid
and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid
cleanliness when servicing.

Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid
odor. Water in the fluid may be noted by a cloudy or milky appearance or free water
in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to
excessive heat. Change the fluid immediately if these conditions occur. Correct the
problem immediately.

Change the fluid and filter per the Fluid and filter change intervals
vehicle/machine manufacturer’s Sealed reservoir 2000 hours
recommendations or at these intervals: Breather reservoir 500 hours

Change the fluid more frequently if it becomes contaminated with foreign matter (dirt,
water, grease, etc.) or if the fluid is subjected to temperature levels greater that the
recommended maximum.

Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.

Change filters whenever the fluid is changed or when the filter indicator shows that it is
necessary to change the filter. Replace all fluid lost during filter change.

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Troubleshooting

OVERVIEW This section provides general steps to follow if you observe certain undesirable system
conditions. Some of the items are system specific. Always observe the safety precautions
listed in the introduction of this manual. If standard troubleshooting procedures do not
remedy the problem, contact a Sauer-Danfoss Global Service Partner.

SYSTEM OPERATING HOT Item Description Action

Oil level in reservoir Insufficient hydraulic fluid will Fill the reservoir to the proper level
not meet the cooling demands of with clean hydraulic oil.
system.
Heat exchanger (if equipped) The heat exchanger is not Check the air flow and input air
sufficiently cooling the system. temperature for the heat exchanger.
Clean, repair, or replace the heat
exchanger as necessary.
Bypass valve A partially activated bypass valve Verify that the bypass valve is fully
may result in heat generation within closed and that the valve is seating
the system. properly. Repair or replace it as
necessary.
SCR (System Check / Relief ) A partially activated SCR valve or Verify that the SCR valve is seating
Valves SCR valves with relief settings too properly and is at the correct relief
low may result in heat generation setting. Repair or replace it as
within the system. necessary.
Oil filters Clogged oil filters may result in an Inspect the oil filters and verify that
insufficient supply of cool oil to the they are still operable. Replace them
system. if necessary.
Machine load Excessive loads or extreme duty Verify that the machine is operating
cycles could result in the pump and/ within the parameters for which it
or motor operating at speeds and was designed. If necessary, reduce
pressures beyond system design the load on the machine.
limitations.

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Troubleshooting

SYSTEM RESPONSE IS Item Description Action

SLUGGISH Reservoir oil level There is an insufficient amount Fill the reservoir to the proper level
of hydraulic fluid, resulting in an with clean hydraulic fluid.
inadequate supply for the system
loop.
Input control signal The pump is receiving a faulty Verify that the input signal is correct
(linkage, current, or pressure) control signal: (MDC - binding or and identical in both directions.
broken linkage; EDC - faulty or
inadequate electrical signal; HDC
- blocked or incorrectly orificed
control lines).
Pump control A damaged pump control or control Verify that the pump’s control is
spool will not correctly transmit the operating properly and that the
control input signal to the pump. control spool is not damaged or
worn and moves freely within its
bore. Clean, repair, or replace it as
necessary.
Bypass valve A partially activated bypass valve Verify that the bypass valve is
will cause cross port leakage. closed and that the valve is seating
properly. Clean, repair, or replace it
as necessary.
SCR (system check / relief ) One or both of the SCR valves may Verify that the SCR valves operate
valves be binding within their bores. freely. Repair or replace them as
necessary.
Charge pressure (in neutral) The is low charge pressure resulting Inspect the charge pump for
from a damaged charge pump or damage and verify the charge
low charge pressure relief valve pressure relief valve setting. Repair
setting. or replace it as necessary.
Charge pressure (in stroke) There is low charge pressure Repair or replace the component
resulting from internal leakage or components within the system
within the system. causing the internal leakage.
Servo pressure There is insufficient pressure Check servo pressures at port M4
differential across the servo piston. and M5 to verify sufficient pressure
delta. Verify that the servo supply
and drain paths are unobstructed
and that any orifices are of the
correct size and free of debris. Clean,
repair, or replace as necessary.
Charge pump The charge pump has been Verify that the charge pump is in
damaged or installed with the good working order and that it is
incorrect rotational orientation. correctly installed. Repair or replace
it as necessary.

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Service Manual
Troubleshooting

SYSTEM WILL NOT Item Description Action

OPERATE IN EITHER Oil level in reservoir There is insufficient hydraulic fluid Fill the reservoir to the proper level
DIRECTION to supply the system loop. with clean hydraulic oil.
Input control signal The pump is receiving a faulty Verify that the input signal is correct
(linkage, current, or pressure) control signal: (MDC - binding or and identical in both directions.
broken linkage; EDC - faulty or Adjust, clean, repair, or replace the
inadequate electrical signal; HDC input device as necessary.
- blocked or incorrectly orificed
control lines).
Oil filters Clogged oil filters may result in Inspect the oil filters and verify that
an insufficient supply of oil to the they are still serviceable. Replace
system. them as necessary.
Bypass valve A partially activated bypass valve Verify that the bypass valves are
may result in a cross port leakage. closed and that the valves are
seating properly. Clean, repair, or
replace them as necessary.
Charge pressure Charge pressure may be insufficient Inspect the charge pump for
(in neutral) to recharge the system loop. damage and verify that the charge
pressure relief valve is at the proper
setting. Repair or replace it as
necessary.
Charge pressure There is low charge pressure Repair or replace the component
(in stroke) resulting from internal leakage or components within the system
within the system. causing the internal leakage.
Servo pressure There is an insufficient pressure Check servo pressures to verify
differential across the servo piston. sufficient pressure delta. Verify that
the servo supply and drain paths are
unobstructed and that any orifices
are of the correct size and free of
debris. Clean, repair, or replace them
as necessary.
Charge pump The charge pump is damaged or Verify that the charge pump is in
has been installed with the incorrect good working order and that it is
rotational orientation. correctly installed. Repair or replace
it as necessary.
SCR (system check / relief ) The SCR valves are malfunctioning Verify that the SCR valves are
valves or improperly set. operating and properly set. Repair or
replace them as necessary.
Displacement limiters Displacement limiters may be Verify that the displacement limiters
improperly adjusted such that the are adjusted to the proper setting.
servo piston is locked in place.

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Service Manual
Troubleshooting

SYSTEM WILL NOT Item Description Action

OPERATE IN ONE Input control signal (linkage, The pump is receiving a faulty Verify that the input signal is correct
DIRECTION current, or pressure) control signal: (MDC - binding or and identical in both directions.
broken linkage; EDC - faulty or Adjust, clean, repair, or replace the
inadequate electrical signal; HDC control module as necessary.
- blocked or incorrectly orificed
control lines).
SCR (System Check/Relief ) The SCR valves are malfunctioning Verify that the SCR valves are
valves or improperly set. operating properly. Repair or replace
them as necessary.
Pump control A damaged or biased pump Verify that the pump’s control is
control may be sending a signal functioning properly. Repair or
commanding the pump to stroke replace it as necessary.
only in one direction.
Servo pressure The drain or supply path to one side Verify that the servo supply and
of the servo piston may be blocked. drain paths are unobstructed and
that any orifices are of the correct
size and free of debris. Clean or
repair them as necessary.
Displacement limiters (if The displacement limiters may be Verify that the displacement limiters
equipped) improperly adjusted such that the are adjusted properly.
servo piston is prevented from
moving in one direction.

NEUTRAL DIFFICULT OR Item Description Action

IMPOSSIBLE TO FIND Input control signal (linkage, The pump is receiving a faulty Verify that the input signal is correct
current, or pressure) control signal: (MDC - binding or and identical in both directions.
broken linkage; EDC - faulty or Adjust, clean, repair, or replace
inadequate electrical signal; HDC control module as necessary.
- blocked or incorrectly orificed
control lines).
System pressure With no input signal to the control, Readjust pump neutral setting. Refer
a pressure delta may exist between to adjustment procedure on page 29.
the two sides of the working loop.
Servo pressure With no input signal to the control, Readjust the control neutral setting.
a pressure delta may exist across the Refer to adjustment procedure on
servo piston. page 30.
PCP pressure (EDCs only) With no input signal to the control, a Replace the EDC.
pressure difference may exist across
the control spool.

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Service Manual
Adjustments

OVERVIEW This section offers instruction on how to perform adjustments to the Series 42 pump.
Read through the entire procedure before beginning any service activity. Refer to pages
19 and 20 for location of gauge ports
and suggested gauge size. Displacement limiters
L025
Displacement
limiter seal
L020 lock nut
DISPLACEMENT LIMITER You may adjust displacement limiters to Displacement 13 mm
ADJUSTMENT achieve a desired maximum flow rate. For limiter
20-26 N•m
Series 42 pumps, displacement limiters 4 mm
[15-19 lbf•ft]
are available on one or both sides of the L001
servo piston. Servo
piston
cover
Accurate adjustment of the displacement
limiters requires the use of a test stand
WARNING capable of measuring system flow
The seal nut lock nut output from both the A and B output
must be retorqued after ports.
every adjustment and the
limiter screw must have 1. Mount the pump onto the test stand.
full thread engagement
in the servo piston cover 2. Loosen the displacement limiter seal
to prevent unexpected lock nut (L025), but do not remove it.
changes in operating
conditions and to prevent 3. Start the prime mover and place
external leakage during the pump into full stroke in one
RIGHT SIDE VIEW (M4)
unit operation. direction. Note the system output
flow from either the A or B system M020
Displacement M025
port. limiter Displacement
4 mm limiter seal
4. Adjust the displacement limiter lock nut
13 mm
adjustment screw (L020) until the M001 20-26 N•m
desired output flow is reached. Servo [15-19 lbf•ft]
Turning the displacement limiter piston
cover
adjustment screw clockwise
decreases the maximum output flow
setting. Turning the displacement
limiter adjustment screw counter
clockwise increases the maximum
output flow setting.

The pump achieves overall maximum

flow when the displacement limiter does
not contact the servo piston while the
unit is in full stroke.

One full turn of the displacement limiter E100027E

adjustment screw results in approximate LEFT SIDE VIEW (M5)

flow output changes per the table.
Displacement limiter adjustment
Size Displacement change per turn
28 cm3 3.6 cm3/rev [.22 in3/rev]
41 cm3 5.0 cm3/rev [.31 in3/rev]

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Service Manual
Adjustments

DISPLACEMENT 5. Once you achieve the proper output flow, torque the displacement limiter seal lock
LIMITER ADJUSTMENT nut (L025) to 20-26 N•m [15-19 lbf•ft] while holding the position of the adjustment
(continued) screw (L020).

6. If required, repeat this procedure using the opposite displacement limiter to set the
output flow in the other direction.

Conversions
Changes to the displacement limiter settings are conversions to the pump. Change
the nomenclature on the specification tag to reflect the alterations of the unit. Refer to
520L0637 Series 42 Technical Information Manual, Model Code Supplement, or contact
your Sauer-Danfoss representative for the appropriate nomenclature. Location of the
appropriate module of the nomenclature string appears below:

Pre-blockpoint change
• Displacement limiters - side 1

• Displacement limiters - side 2

Post-blockpoint change
• Displacement limiters - side 1

• Displacement limiters - side 2

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Service Manual
Adjustments

PUMP NEUTRAL Zero output flow from the pump defines the neutral condition. To attain zero output
ADJUSTMENT flow, the pump must achieve both mechanical neutral and control neutral conditions.
Mechanical neutral is the condition when the swashplate is at zero angle without any
signal input from the control. Set mechanical neutral prior to setting control neutral.
WARNING
To prevent injury, disable 1. Disable the control input to the Pump neutral adjustment screw
the machine: raise pump by equalizing the pressures on T060
wheels off the ground both ends of the pump servo piston. Pump mechanical
or disconnect the To accomplish this, connect an neutral adjustment
seal lock nut
mechanism.. SAE-06 hose between servo gauge See table
ports, M4 and M5. See table

2. Install pressure gauges in gauge T015

ports M1 and M2 to measure system Pump neutral
pressure. adjustment screw
See table
See table
3. Start the prime mover and run at
normal operating speed. E100002E

MDC Shown
4. Loosen the pump neutral
adjustment seal lock nut (T060) in Neutral adjustment gauge port readings
the center of the servo cover on the M1 / M2
right side of the pump. M1 / M2

5. Turn the adjustment screw (T015)

clockwise until one of the gauges
registers an increase in system M1 / M2
pressure. Mark the position of the
adjustment screw. Turn the screw
counterclockwise until the other
gauge registers an increase in P101259

system pressure. Mark the position

of the adjustment screw. Turn the adjustment screw clockwise to a position halfway
between the marks. The system pressure gauges should indicate equal pressures.

6. While holding the adjustment screw in position, torque the seal lock nut (T060).
Torque 28 cm3 models with an MDC or an EDC to 20-26 N•m [15-19 lbf•ft]. Torque all
41/51 cm3 models and 28 cm3 models with NFP controls to 31-50 N•m [23-37 lbf•ft].

7. Stop the prime mover and remove the hose between gauge ports M4 and M5.
Remove the pressure gauges in gauge ports M1 and M2. Reinstall the plugs in the
gauge ports.

8. Proceed to the control neutral adjustment section on the next page.

Frame size cm3 28 41/51

Control MDC/EDC NFP MDC/EDC NFP
Lock nut mm 13 17 17 17
Servo adjust screw mm [in] 5 7 7 7
Lock nut torque N•m [lbf•ft ] 20-26 [15-19] 31-50 [23-37] 31-50 [23-37] 31-50 [23-37]

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Service Manual
Adjustments

CONTROL NEUTRAL Control neutral adjustment aligns the Control neutral adjustment screw
ADJUSTMENT FOR MDC pump swashplate and the control spool D014
MDC / EDC neutral
AND EDC so that a zero angle control setting adjustment screw
provides a zero degree swashplate 5 mm
setting. Perform this adjustment
WARNING whenever you adjust or move any part
The following procedure of the control or swashplate mechanism
requires the vehicle/ or after you adjust the pump neutral
machine to be disabled setting.
(wheels raised off the
ground, work function 
disconnected, etc.) while 1. Disconnect the external control
D015
performing the procedure linkage (for MDC) or control signal MDC / EDC neutral
in order to prevent injury input (for EDC) from the pump. adjustment seal lock nut
to the technician and 17 mm
31-50 N•m [23-37 lbf•ft]
bystanders. 2. Install pressure gauges in the servo
gauge ports M4 and M5 to measure E100003E

pressure on the pump servo piston. EDC Shown

3. Start the prime mover and run at Equalization of pressure gauges using
normal operating speed. pump neutral adjustment screw
M3 / M4
4. Loosen the control neutral
adjustment seal lock nut (D015).

5. Turn the adjustment screw (D014) M3 / M4

clockwise until one of the gauges
registers an increase in pressure on
the servo piston. Mark the position of
the adjustment screw.

Turn the screw counterclockwise

until the other gauge registers an M3 / M4
increase in pressure on the servo
P101 270E
piston. Mark the position of the
adjustment screw.

Turn the adjustment screw clockwise so that it is midway between the marks.
Adjustment screw movement produces constant change for both directions, so both
the pressure gauges should indicate nearly equal pressures.

6. While holding the adjustment screw (D014) in position, torque the seal lock nut
(D015) to 31-50 N•m [23-37 lbf•ft].

7. Stop the prime mover and remove the pressure gauges. Remove the plugs in the
gauge ports.

8. Connect the external control linkage (for MDC) or control signal input (for EDC) to
the pump. Reconnect the work function.

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Service Manual
Minor Repair

STANDARD PROCEDURES Remove the pump

Prior to performing certain minor repairs on the Series 42 pump, it may be necessary to
remove the pump from the machine. Chock the vehicle to prohibit movement. Be aware
that hydraulic fluid may be under high pressure and may be hot. Inspect the outside of
the pump and fittings for damage.

Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life, on either new or repaired
units. Clean the outside of the pump thoroughly before disassembly. Take care to avoid
contamination of the system ports. Clean parts using a clean solvent wash and air dry.

As with any precision equipment, keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the pump with a protective layer of plastic.

Inspect for system contamination

Inspect the pump for system contamination. If you find contamination, fully disassemble,
clean, and inspect all components of the pump using 11007277 Series 42 Axial Piston
Closed Circuit Pumps Repair Manual in conjunction with this manual.

Replace the O-rings and gaskets Pump face orientations

Sauer-Danfoss recommends you replace Left face
all O-rings and gaskets. Lightly lubricate
O-rings with clean petroleum jelly prior
to assembly. Front face Top face

Lubricate all moving parts

During reassembly, coat all moving parts
with a film of clean hydraulic oil. This will
help to lubricate these parts during start-
up. For fluid quality requirements, refer to
bulletin 520L0463 Hydraulic Fluids and Bottom face
Lubricants, Technical Information. Rear face

Right face

P101260E

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Service Manual
Minor Repair

SIZE AND TORQUE FOR Plug and fitting sizes appear here. Case drain plug
PLUGS AND FITTINGS Replace O-rings and lubricate with F091 28 cm3 41/51 cm3
petroleum jelly whenever a plug is Internal hex 9/16 in 5/8 in
removed. Torque each as indicated. Torque 95-136 N•m 122-258 N•m
[70-100 lbf•ft] [90-190 lbf•ft]

Size and torque for plugs and fittings

Servo gauge
port M4

L010
11
/16 in
27-47 N•m
[20-35 lbf•ft]

Charge pressure Charge pump

F091 gauge port M3 inlet port S
(see table) (position varies,
Case drain refer to Filtration
port L1 options, page 13)

Servo gauge
port M5

M010
11
/16 in
27-47 N•m
[20-35 lbf•ft]

Case drain
port L2
F091
(see table)

N002
11
/16 in
27-47 N•m
[20-35 lbf•ft]

F093
11
System ports /16 in
System
A and B 27-47 N•m
gauge ports
M1 and M2 [20-35 lbf•ft]

E100001E

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Service Manual
Minor Repair

CHARGE RELIEF VALVE You may remove the charge relief valve for cleaning and installation of new O-rings. You
may change the pressure setting, however, note that the setting will vary for different
charge flows depending on charge pump size and pump speed. The factory setting is set
relative to a specific charge flow at 120°F and 1800 min-1 (rpm) input speed. The actual
charge pressure varies at different speeds.

Shim adjustable style (pre-blockpoint change)

On units manufactured prior to the 1998 block point change, you adjust the charge
pressure relief valve by changing the number or size of shims located behind the charge
pressure relief valve spring.

1. Remove the shim adjustable charge relief valve plug (G040) from the pump housing.
Remove and discard the O-ring (G040A) from the plug.

2. Remove the shims (G041), spring Shim adjustable charge relief valve
(G042), and poppet (G043) from the components
housing. G040
Shim adjustable
charge relief valve plug
3. Inspect the poppet and mating seat 1 in
in the housing for damage or foreign 54-136 [40-100]
material.
G040A
G041
Shims O-Ring
4. If desired, you may change the
charge relief valve setting. The
setting changes approximately G043 G042
Poppet Spring
4 bar [58 psi] per 1.25 mm [0.05 in]
of shim thickness. The actual setting
may vary.

5. Install a new O-ring (G040A) on

the charge relief valve plug (G040).
Reinstall the poppet (G043), spring
(G042), shims (G041), and plug into
the pump housing and torque to 54-
136 N•m [40-100 lbf•ft]. To confirm
the charge relief valve setting,
measure the charge pressure at port
M3. The charge pressure levels off
when it reaches the relief setting.
E100016E

Externally adjustable style

The 1998 block point change Pressure change per shim
discontinued the use of the shim Approximate pressure change Shim thickness
adjustable charge relief valve and made 4 bar [58 psi] 1.25 mm [.050 in]
the externally adjustable charge relief
valve standard. The charge pressure changes by approximately 1.4 bar (20 psi) per
quarter turn of the adjustable charge relief valve plug (this applies to both external and
internal hex style plugs).

1. Mark the adjustable charge relief valve plug (T040), lock nut (T041), and the pump
housing prior to removing the charge relief valve in order to approximately duplicate
the charge pressure relief valve’s original setting upon reassembly.
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Service Manual
Adjustments

CHARGE RELIEF VALVE 2. Loosen the lock nut (T041) and Externally adjustable charge relief valve
(continued) unscrew the adjustable charge relief components
T041
valve plug (T040). Lock nut
1 /16 in
1

3. Remove and discard the O-ring 28 cc: 14-30 N•m

(T040A) from the adjustable charge [10-22 lbf•ft]
41 cc: 28-50 N•m
relief valve plug (T040). [21-37 lbf•ft]
T040A
O-ring T040
4. Remove the spring (T042) and Anti-stall
poppet (T043) from the housing. T040 adjustable charge
Adjustable relief valve plug
charge relief T042
8.5 mm
5. Inspect the poppet (T043) and valve plug Spring
mating seat within the housing for ½ in T040A
T043
damage or foreign material. Replace Poppet O-ring
as necessary.

6. Install the poppet (T043) and spring

(T042) into the housing.

7. Install a new O-ring (T040A) onto the

adjustable charge relief valve plug
(T040).

8. Install the adjustable charge relief

valve plug (T040) and the lock nut
(T041) into the housing, aligning the
marks made prior to disassembly. E100017E

9. On 28 cm3 models, torque the lock nut (T041) to 14-30 N•m [10-22 lbf•ft], and on
41/51 cm3 models, torque the lock nut (T041) to 28-50 N•m [21-37 lbf•ft]. (This may
cause misalignment of the original position marks made earlier).

10. Confirm the charge relief valve setting by measuring charge pressure at the charge
pressure gauge port, (M3). The charge pressure reading should level off when the
relief setting is reached.

Conversions
Changes to the charge relief valve setting are conversions to the pump. Change the
nomenclature on the specification tag to reflect the alterations of the unit. Refer to
520L0637 Series 42 Technical Information Manual, Model Code Supplement, or contact
your Sauer-Danfoss representative for the appropriate nomenclature. Location of the
appropriate module of the nomenclature string appears below:

Pre-blockpoint change
• Charge pump

Post-blockpoint change
• Charge relief setting

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Service Manual
Minor Repair

OPTIONAL SPEED When installing or adjusting the speed Speed sensor replacement
SENSOR sensor on a pump, you must set it to a
specific distance from the speed ring on
the cylinder block. N005
1-1/16 in N002 O-ring plug
13 N•m 11/16 in
Removal [10 lbf•ft] 37 N•m
[27 lbf•ft]
1. Loosen the lock nut using a 1-1/16 in
hex wrench. N005A
N002A

2. Unthread the speed sensor (N005)

from the pump housing. Remove and
discard the O-ring (N005A).

Reassembly
1. Always install a new O-ring before
reinstalling the sensor.

2. Reinstall the speed sensor (with lock

E101 473E
nut and O-ring) into the housing.
Turn the sensor clockwise (CW) by
hand until it contacts the speed ring. Cross section view of speed sensor in
variable pump
3. Turn the sensor counterclockwise
(CCW) 1/2 turn (180°) to establish the
nominal gap of 0.71 mm [0.028 inch].
Gap

4. Then turn the sensor clockwise (CW)

until the wrench flats on sensor body
Speed sensor
are positioned at a 22° angle to the Magnetic speed ring
pump shaft center line. Cylinder block
P104 152E

Most adjustable wrenches have a 22°

handle offset. Positioning speed sensor relative to
pump shaft
5. The final sensor position should be Shaft centerline
1/2 inch wrench flats
between 1/2 (180°) and 1/4 turn (90°)
counterclockwise (CCW) from the 22° 22°

point where the sensor contacts the

speed ring. Speed sensor with Speed sensor with
packard connector turck connector

6. Hold sensor in position with a 1/2 Shaft centerline

1/2 inch wrench flats
inch hex wrench while tightening
the lock nut to 13 N•m [10 lbf•ft].
22° 22°

Speed sensor with Speed sensor with

packard connector turck connector

P104 155E

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Service Manual
Minor Repair

MDC MODULE Removal

The manual displacement control (MDC) actuates the control spool through a connection
to the summing link pin. The following procedure describes how to remove and install the
control. Control spool and linkage removal is explained on pages 40 and 41.

1. Clean external surfaces of the pump.

If necessary, remove the MDC handle Link pin into cam slot
(D017) and disconnect NSS wiring
(D040).

2. Being careful not to lose the

backlash spring (D91), remove the
control spool plugs (D032).

3. Remove the seven (7) control bolts

(D002) that secure the control to the
pump housing. Remove the control
(D070) and gasket (E001) from the
Summing link
pump. Discard the gasket. pin (D011)
MUST enter
the slot in the
4. Ensure that the housing and control control cam
surfaces are clean and free of gasket
material. If necessary, clean the
surfaces with solvent.

Installation E100005E

1. Remove cover plug (D003) from

control housing. MDC module assembly
D003 D019
3
2. Place a new gasket (E001) on the /16 in D016
11-14 N•m D017
control module [8-10 lbf•ft]
D070
Since the control gaskets act as regulating D002
orifices, check the Service Parts Manual T-30
(28 cm3, 520L0590; or 41 cm3, 520L0589) 15-18 N•m D040
[11-13 lbf•ft]
and your order code to confirm you have
the correct control gasket.
E001

WARNING For exact positioning, place D032

D032A
Unintended vehicle/ the MDC alignment tool (see D91
machine movement dimensioned diagram , next page)
hazard. MDC must be over the exposed summing link
aligned to the housing pin. If MDC alignment tool is not
within 0.005 in. Inaccurate available, skip to MDC alignment D032A
alignment may cause without tool (steps 3a-5a). D032
neutral to be off center or
3. Slide the MDC (D070) over the tool
while engaging the tool with the slot
in the MDC cam, and allow it to pass
through the hole on the front of the E100004E

MDC housing.

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Service Manual
Minor Repair

MDC MODULE 4. Install the control screws (D002) and torque to 15-18 N•m [11-13 lbf•ft].
(continued)
5. Remove the alignment tool and install plug (D003); torque to 11-14 N•m [8-10 lbf•ft].

6. Replace the spring (D91) and spool MDC cam

plugs (D032).

7. Adjust control neutral (see page 30).

Point of
contact
MDC alignment without tool. Summing
If the MDC alignment tool is not link pin Imaginary circle
available, it is possible to locate the
approximate position of the pin by
MDC cam
creating an imaginary circle at the
correct location, as indicated in the P101262E

illustration. The point at which the

imaginary circle contacts the slot in the MDC alignment tool
cam is the suggested contact point of 16 mm
the summing link pin. When engaging 6 mm Ø [0.63 in]
[0.236 in]
the pin in the cam slot, you may need to 6.97 mm -0.05 Ø
use a flat tool, such as a screwdriver, to [0.2744 in -0.002]
position the linkage. 20 mm 5.06 mm +0.05 Ø
[0.79 in] [0.1992 in +0.002]
For proper control operation, the ~ 100 mm
summing link must engage the slot on [3.94 in] P101261E

the control module. For exact placement, MACHINED FROM MILD STEEL
use the alignment tool shown.
Torque patterns (MDC and EDC)
3a. Install and hand-tighten the seven TORQUE BOLTS IN ORDER INDICATED
(7) control retaining screws and then
4 3 6
back off each screw one turn.

4a. Adjust the control position so that

1
the summing link pin is aligned as
described above, and torque bolts
7
(D002) to 15-18 N•m [11-13 lbf•ft].
2 5

5a. Replace the cover plug (D003) and

8 Torque this bolt
torque to 11-14 N•m [8-10 lbf•ft]. first & last
P101579

Continue above step 6.

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EDC MODULE The Electric Displacement Control (EDC) actuates the control spool via a connection to
the summing link pin. The following procedure describes how to remove and replace the
control housing.

Removal
1. Clean the external surfaces of the pump. If necessary, remove control input.

2. Being careful not to lose the backlash spring (D91), remove the control spool plugs
(D032).

3. Remove the seven (7) control bolts (D081/D082). Note the position of the different
length screws. Remove the control and control gasket (E001) from the pump.

Replacement
1. Clean the sealing surfaces of the control and the pump housing. Place a new gasket
(E001) in position on the housing.

EDC module assembly

D082
T-30
D081 15-18 N•m
[11-13 lbf•ft]
T-30
15-18 N•m
[11-13 lbf•ft]

Manual override
E001
D032A
D032
Hold D011
(and D090)
in position
Summing
link pin (D011)
MUST enter
D91 the hole in the
control slider
D032A
block
D032

E100006E

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Service Manual
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EDC MODULE (continued) The control orifices are part of the control gasket. Refer to the appropriate Service Parts
List to determine the correct gasket.

WARNING 2.  Hold the summing link pin (D011) in position while installing the control. (The
Failure to properly engage spring on the control spool will tend to push the link to an extreme position.) The
the summing link pin with link pin MUST engage the hole in the control slider block (see diagram on previous
control slider block will page).
result in incorrect control Bolt torque patterns (MDC and EDC)
operation, which may lead Lay the servo piston side of the control TORQUE BOLTS IN ORDER INDICATED
to loss of control of the down first, then watch the link pin
4 3 6
vehicle / machine. engage from the charge pump side of
the pump.
1
3. Install the control bolts (D081/D082),
torque to 15-18 N•m [11-13 lbf•ft].
7
2 5
4. Replace the spring (D91). Install
new O-rings on control spool plugs
8 Torque this bolt
(D032). Install plugs and torque to first & last
41-95 N•m [30-70 lbf•ft]. P101579

5. Adjust the neutral position of the

control as shown on page 30.

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MDC / EDC SPOOL, You may remove the control spool, control linkage, and control neutral adjustment screw
LINKAGE, AND NEUTRAL for cleaning and to change the O-rings or the seal lock nut.
ADJUSTMENT SCREW
Removal
1. Clean the external surfaces of the pump.

2. Remove the MDC or EDC module and the control gasket from the pump housing.
Discard gasket. See pages 36 through 39 for control removal procedure.

3. Remove the summing link (D011), feedback link (D012), and neutral adjustment link
(D013). Note the manner in which the parts are assembled and the way the summing
link engages the control spool (D090).

Remove the summing link by sliding it off the feedback link.

MDC / EDC spool and linkage

D011
D010
Pre-block point change D015
4 mm 17 mm
pumps use a cover plate 8-15 N•m
(F035), gasket (F034), [6-11 lbf•ft]
D012 D014
and two torx-head 5 mm
capscrews (P036) on the D013
D032
filter adapter side of the D91 5
/16 in
pump to contain the spool 41-95 N•m
D90 D090 [30-70 lbf•ft]
assembly. Discard and
replace the gasket when
removing and replacing
the control spool.
D032
5
/16 in
41-95 N•m
[30-70 lbf•ft]

F034

F035

P036
T-30
15-17 N•m
[11-13 lbf•ft]

E100007E

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Service Manual
Minor Repair

MDC / EDC SPOOL, Using a 4mm internal hex wrench, remove the summing link pivot pin (D010).
LINKAGE, AND NEUTRAL Slide the feedback link (D012) towards the servo piston to disengage the neutral
ADJUSTMENT SCREW adjustment link (D013). You can now remove all linkages.
(continued)
4. Remove the two bore plugs (D032). Note the orientation of the control spool (D90)
and which side of the pump the spring (D91) is located (spring is on the opposite
side from the filter adapter).

Prior to the 1998 block point change, the full-featured 28 cm3 housing for the Series 42
pump used a control spool cover (F035), gasket (F034), and two screws (F036) instead of
a bore plug on the control spool’s non-spring side. Discard the control gasket (F034) and
thoroughly clean the mating surface.

5. Remove the control neutral adjustment seal nut (D015) and screw (D014).

Installation
1. Install the control neutral adjustment screw (D014) and seal lock nut (D015). Do not
tighten the nut.

2. Lubricate and install the control spool (D90) and spring (D91), noting proper
orientation. Install the two side bore plugs and torque to 41-95 N•m [30-70 lbf•ft].

3. Replace the summing link, feedback link, and neutral adjustment link.

First combine the center pin of the feedback link (D012) with the mating bore of the
neutral adjustment link (D013). Insert the end of the feedback link into the servo
piston slot. Mate the neutral adjustment link with the control neutral adjustment
screw (D014). Insert the linkage pivot screw (D010) and torque to 8-15 N•m [6-11
lbf•ft]. Install the summing link (D011). It may be necessary to rotate the control
spool so that the summing link fork engages the flats on the control spool.

4. Install the MDC or EDC as described on pages 36 or 39.

Servo piston linkage and control spool Feedback link (D012) must
enter slot in servo piston
D010
? Internal hex nut D091
Backlash spring

?
Fork on summing link
(D011) must engage flats
on control spool (D090
D090
Control
spool Slot in neutral adjust link
(D013) must engage groove
in adjusting screw (D014) E100008E

Internal parts shown with housing removed

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Minor Repair

MDC NEUTRAL START / The Neutral Start Switch (NSS) prevents the engine and pump from starting when the
BACKUP ALARM SWITCH pump control handle is not in neutral. The NSS should be wired in series with the engine
starting circuit. The switch contact is closed at the control handle’s neutral position and
opens when the control handle is rotated 1.5° to 2° from neutral.

The Backup Alarm Switch (BAS) closes when the control handle is in a reverse position.
This switch is normally wired in series with a backup alarm. The switch contact is open
until the control handle is rotated 2.6° to 3.75° in the reverse direction. 

WARNING Top view of NSS showing NSS cam positions

The control handle’s
neutral position must
conform to the pump’s
neutral position for
the NSS/BAS to work
effectively. See page 30 for
control neutral adjustment.
Control Control Control
Yoke cam Yoke cam Yoke cam

NSS cam NSS cam

I. NSS ONLY II. NSS WITH BAS III. NSS WITH BAS
(CW = REVERSE) (CCW = REVERSE)
P100107E

You can configure the NSS/BAS assembly for three different settings:
I. NSS only.
II. NSS with BAS for units where clockwise (CW) handle rotation results in reverse
motion.
III. NSS with BAS for units where counterclockwise (CCW) handle rotation results in
reverse motion.

The setting must be in accordance with the configuration of the unit. See the model
code if uncertain of the type of NSS setting the machine is equipped with.

Adjustment is normally not required unless the function of the NSS is changed (between
I, II, or III).

Adjustment of the NSS or NSS and

BAS requires a special alignment tool. Alignment tool
Dimensions appear at right. The tool 9/16 -18 UNF 2A thread
0.04 x 45°
R 0.125 Ø 0.236 -0.03
positions the cam precisely relative to chamfer
Knurl
the control housing.
35.0
1.250
0.306 0.354
2.000
Material: 0.75 Ø x 3 ETD150 P100108E
(All dimensions in inches)

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Service Manual
Minor Repair

MDC NEUTRAL START / 1. Remove the MDC module from the Side view of NSS and NSS cavity
BACKUP ALARM SWITCH pump housing (see page 36). 23.3 mm D039
(continued) [0.916 in] D038
2. Using a 7/8 in hex wrench, remove 8 mm
the NSS/BAS (D040). 4-7 N•m
1 mm D037
[3-5 lbf•ft]
[0.04 in]
3. Using a screwdriver to pry it out,
remove and discard the NSS cover
(D039). Be careful not to damage the D040
internal hardware. 7/8 in
24-30 N•m
4. Using an 8mm hex socket, remove [18-22 lbf•ft]
the nut (D038). P100109E

5. Pry the cam (D037) off the shaft. Apply locking pliers here.

6. On the underside of the MDC

module, gently clamp a pair of
locking pliers around the spring
contacts of the control cam. Be
careful not to damage the spring
wires. The pliers hold the nub on the
control cam to the pin underneath.
This holds the control cam in neutral
position.

7. Set the NSS cam (D037) in the P101273

proper orientation (I, II, or III). See the

illustration on previous page. NSS assembly on MDC
D040
8. Thread the alignment tool into the (with weatherpack
connector)
NSS cavity to hold the cam in place.
D040
9. Install the nut (D038) onto the cam (with screw
terminals)
and torque to 4-7 N•m [3-5 lbf•ft].

10. Using an appropriate press, press

a new cover (D039) into the cam
cavity. Use a tool with a diameter of NSS Cavity
23.3 mm [0.916 in]. Press the new cover
so that it sits 1 mm [0.04 in] below the
cast surface as illustrated above.

11. Remove the alignment tool and

locking pliers.

12. Lubricate and install a new O-ring on

D037
the NSS (D040) and install the NSS D038
to the MDC. Torque to 24-30 N•m D039
[18-22 lbf•ft]. E100009E

13. Reinstall the MDC module onto the pump housing as shown on pages 36 and 37.
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MDC SOLENOID The solenoid override valve is a safety Solenoid override assembly
OVERRIDE VALVE feature that shunts both ends of the D056B
servo control piston when the solenoid is 3
/4 in
de-energized. The pump will stroke only D056 5-6 N•m
when the vehicle controls energize the [3.5-4.5 lbf•ft]
D056C
solenoid.
D054
The solenoid override with brake release
option allows hydraulic control of a D056D
spring-applied, hydraulically-released D056
brake. When de-energized, the brake D056A?
drains through port X7.
D056F

Removal D056G
1. Using a 3/5 in. hex wrench, remove
the coil nut (D056B) from the valve
D053
stem.

2. Remove the coil (D056) and washer

(D056C).

3. Using snap-ring pliers, remove the

retaining ring (D054) at the base of
the solenoid.

4. Remove the valve stem (D056D),

plunger (D056G), spring (D056F), and
spool (D053).

5. Remove the O-ring (D056A) from the

stem, and discard it.

Installation
Port X7
1. Lubricate and install a new O-ring E100011E

(D056A) on the valve stem (D056D).

2. Place the spring (D056F) and the plunger (D056G) inside of the stem.

3. Attach the spool (D053) to the plunger (D056G).

4. Insert the solenoid/spool assembly into the solenoid override cavity.

5. Using snap-ring pliers, install the retaining ring (D054).

6. Install the washer (D056C) onto the valve stem.

7. Install the coil (D056) and coil nut (D056B) and torque to 5-6 N•m [3.5-4.5 lbf•ft]. Do
not over torque coil nut.

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Service Manual
Minor Repair

FNR, NFPE, AND NFPH The FNR, NFPE, and NFPH are non-feedback type controls. The FNR and NFPE controls
CONTROLS consist of external, solenoid-actuated spool valves mounted on the pump housing. The
pump receives hydraulic input for NFPH through ports on the pump’s control surface
(9/16–18 SAE O-ring boss port). These ports connect directly to the servo piston.

You may remove the FNR and NFPE controls to clean the ports and replace the O-rings,
however they are not serviceable. The gasket (E074) contains control orifices. Orifice
plugs (E051) for NFPH pumps are beneath the servo covers (see page 57). You may clean
or replace them.

Removal of FNR and NFPE modules

1. Clean the pump and module control FNR and NFPE assembly
D081
housings. 4 mm
5.5-7.5 N•m
2. Remove the four (4) screws (D081) [4-5.5 lbf•ft]
retaining the module to the housing,
D004
and remove the module (D004) from
the pump housing.

3. Remove and discard the four O-rings E074

D004A
from the control ports. Examine the
ports for cleanliness.

Installation of FNR and NFPE modules

1. Clean the sealing surfaces.

2. Using petroleum jelly to retain them,

install new O-rings in the bottom of
the control.

3. Replace the bolts (D081) and torque E100013E

to 5.5-7.5 N•m [4-5.5 lbf•ft].

Bolt torque patterns

TORQUE BOLTS IN THE ORDER INDICATED

2 3 2 3

4 1
4 1

P101581 P101580

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FNR, NFPE, AND NFPH Conversions

CONTROLS Changes to the control and control response options are conversions to the pump. You
(continued) must change the nomenclature on the specification tag to reflect the alterations of the
unit. Refer to 520L0637 Series 42 Technical Information Manual, Model Code Supplement,
or contact your Sauer-Danfoss representative for the appropriate nomenclature. Location
of the appropriate module of the nomenclature string is shown appears below:

Pre-blockpoint change
• Control

• Control response

Post-blockpoint change
• Control

• Control response

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SYSTEM CHECK RELIEF The System Check Relief valve assembly System check relief valve components
(SCR) VALVES (HIGH performs the charge check, high pressure K007
PRESSURE RELIEF, relief, and loop bypass functions. You 1 in
40-95 N•m WITH
CHARGE CHECK, AND may remove this assembly for cleaning [30-70 lbf•ft] BYPASS
BYPASS VALVES) and replacement of O-rings. The model WITHOUT
code specifies which configuration of BYPASS K008
SCR valves your pump uses. K009
K007
K010
/16 mm
5

1. Using a 1 in. hex wrench or a 5/16 41-95 N•m K008

in. internal hex wrench, remove the [30-70 lbf•ft] K009
K010 J005
valve seat plugs (K007) from the
pump housing. Remove and discard
the O-rings and backup rings (K008,
H005
K009, and K010).

2. Remove the check poppet/relief

valve assemblies (H05/J05) from the
pump housing.

3. Inspect the valves and mating seats

in the valve seat plugs (K007) for
damage or foreign material.

The SCR valves (H05/J05) are non-

serviceable; replace as a complete unit.

4. Install new outer O-ring (K008),

backup ring (K009), and inner O-ring
(K010) on each valve seat plug.

5. Verify that the conical springs are E100015E

properly retained on the check

poppets/relief valves (H005/J005). Install the check poppet/relief valve assemblies
into the pump housing. Ensure that the valve assembly moves freely in its bore.

6. Using a 1 in. hex wrench or a 5/16 in. internal hex wrench, install the valve seat
plugs or valve seat/bypass plugs into the pump housing and torque to 41-95 N•m
[30-70 lbf•ft].

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SYSTEM CHECK RELIEF Conversions

VALVES (HIGH PRESSURE Changes to the SCR and bypass options are conversions to the pump. You must change
RELIEF, CHARGE CHECK, the nomenclature on the specification tag to reflect the alterations of the unit. Refer to
AND BYPASS VALVES) 520L0637 Series 42 Technical Information Manual, Model Code Supplement, or contact
(continued) your Sauer-Danfoss representative for the appropriate nomenclature. Location of the
appropriate module of the nomenclature string appears below:

Pre-blockpoint change
• System relief - port A

• System relief - port B

• Bypass valve

Post-blockpoint change
• System relief - port A

• System relief -port B

• Bypass valve

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Minor Repair

FILTRATION ADAPTERS Filter-related pump hardware

Filtration systems for Series 42 pump include full flow suction filtration, pressure
filtration, and partial flow pressure filtration. Sauer-Danfoss provides a filtration adapter
for each configuration. If filtration is provided elsewhere in the hydraulic circuit, the
pump may not have a filtration adapter.
Housing with filtration adapter
Pumps housings without filtration R043
adapters have an unused and plugged Pre 1998: 7/8 in
construction bore next to the charge Post 1998: 11/16 in
37 N•m
relief valve. When these pumps use [27 lbf•ft]
suction filtration, the factory plugs x7
external charge inlet.
R042
T30
Pump housings with filtration adapters R040
15-18 N•m
have an appropriate adapter and gasket. [11-13 lbf•ft]
The position of the M3 gauge port
varries depending on filtration type. R041

Pumps manufactured after 1998 have

filter adapter screws that are 10 mm
[0.39 in] longer than the screws used on
pre-1998 pumps. The longer screws are
only compatible with post-1998 pumps.

Removal
1. Clean the exterior of the pump.

2. Remove any hoses or piping from

the filter adapter.
E100025E

3. Using a T30 Torx driver, remove the

six screws (R042) securing the filter Housing without filtration adapter
adapter to the housing.
F035
4. Remove the filter adapter (R040).

5. Remove the gasket (R041) and

discard. Thoroughly clean all mating
surfaces.

R045
5/8 in
37 N•m
[27 lbf•ft]
P101628E

Suction Filtration Only

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Minor Repair

FILTRATION ADAPTERS Replacement

(continued) 1. Install a new gasket (R041) and place the filter adapter (R040) on the housing.

2. Using a T30 Torx driver, install the six bolts (R042) and torque to 15-18 N•m
[11-13 lbf•ft].

Bolt torque patterns

TORQUE BOLTS IN THE ORDER INDICATED
3
6
5

1
2
8
4 Torque this bolt 7
first and last
P101582

Conversions
Changes to filtration options are conversions to the pump. Change the nomenclature
on the specification tag to reflect the alterations of the unit. Refer to 520L0637 Series 42
Technical Information Manual, Model Code Supplement, or contact your Sauer-Danfoss
representative for the appropriate nomenclature. Location of the appropriate module of
the nomenclature string appears below:

Pre-blockpoint change
• Housing

Post-blockpoint change
• Filtration

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AUXILIARY PAD/CHARGE Use the following procedure to install a new gasket (F106) or to change the auxiliary pad
PUMP COVER option. Pads are available for SAE A and SAE B auxiliary pumps, or for options with no
auxiliary pad.

The charge pump cover integrates the auxiliary mounting pad. When no auxiliary pump
is present on an SAE A or SAE B style pad, the pad includes a shipping plate (U085) and
O-ring (U080).

Removal of charge pump cover/auxiliary pad

1. Orient the pump so that the charge pump cover or pad (U040) is facing up.

2. If present, remove the auxiliary pump or cover (U085) by removing the two screws
(U090). Discard the O-ring (U080).

3. Remove the six or seven screws (U035) retaining the charge pump cover/pad.
Remove the charge pump cover/pad (U040) and gasket (U030). You may reuse the
gasket. Clean all mating surfaces.

4. Remove charge pump seal (G023) and discard. Leave the alignment pins (U025) in
the housing.

If you are installing or replacing a different auxiliary pad, any charge pump components,
or drive coupling, follow the instructions on pages 51 and 52. Also refer to page 9 for
more information on interchangeability of charge pump components.

Auxiliary pad options and components

U040
No pad charge
U035 pump cover
T-45
43-46 N•m
[32-34 lbf•ft] U025

U090
9 x7
/16 in
37-50 N•m
[27-37 lbf•ft] x7
G023
U035
U080 U025
U085
U030

U040
SAE-A pad

U090 U035
3
/4 in
91-111 N•m x 6
[67-82 lbf•ft]

U040
SAE-B pad
U080
U085 E100022E

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CHARGE PUMP COVER Bolt torque patterns

(continued) TORQUE BOLTS IN ORDER INDICATED
Installation
1. Inspect the charge pump cover/pad
gasket (U030) and mating surfaces. 2 4
If undamaged, you may reuse the
gasket. Replace the gasket if you
suspect leakage. Install the gasket.

2. Install a new charge pump cover/pad

seal (G023).

3. Install the charge pump cover/pad

(U040) Using a T45 Torx driver torque 3 1
the six or seven bolts (U035) to 43-46
N•m [32-34 lbf•ft] using the pattern 6 5
at the right. 7
Torque this bolt first and last.
4. Replace the O-ring (U080) and cover P101583

plate (U085) or auxiliary pump.

Install and torque the two mounting 6 4
screws (U090). For SAE A pads, torque
the mounting screws to 37-50 N•m
[27-37 lbf•ft]. For SAE B pads, torque
the mounting screws to 91-111 N•m
[67-82 lbf•ft]. 2

The threaded screw holes in the auxiliary

pump mounting pad in early production
pumps with the SAE A pad option go
clear through the charge pump cover. 3 1
Use M8x1.25 internal hex set-screws to
plug any holes not used to attach the 5 7
cover plate or auxiliary pump. Install 8
hand tight to prevent the entrance of Torque this bolt first and last
foreign material into the pump. P101584

Conversions
Changes to the charge pump cover or auxiliary mounting pad options are conversions
to the pump. Change the nomenclature on the specification tag to reflect the
alterations of the unit. Refer to 520L0637 Series 42 Technical Information Manual, Model
Code Supplement, or contact your Sauer-Danfoss representative for the appropriate
nomenclature. Location of the appropriate module of the nomenclature string appears
below:

Pre-blockpoint change
• Charge pump

Post-blockpoint change
• Auxiliary mounting pad

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Minor Repair

CHARGE PUMP You may disassemble the charge pump to inspect, clean, or to change the auxiliary shaft
drive coupling (U015). Post 1998 pumps contain a number of non-interchangeable parts
within the charge pump system:

• Pre-1998 pumps have a gerotor drive coupling with a drive pin for the gerotor
element, while post 1998 release pumps will contain a coupling with a parallel drive
key. This change also results in a change to the gerotor set. When servicing the
gerotor, these two elements must be placed in combination. A service kit is available
for pre-1998 charge pumps. Refer to service bulletin 1997-029.

• Post 1998 release pumps also contain a coupling with a retaining ring to positively
locate the coupling in the assembly. This change eliminated the need for a coupling
spacer.

• The outer step on the gerotor cover Charge pump components

G023
has been removed on the post 1998
release pumps.
G020
See page 55 for units without integral
charge pumps.
G015
Disassembly Pre block-point
change, replace U015
1. Remove the charge pump cover/pad with service kit
and gasket as described on page 51.
Use feeler
Remove the two charge pump cover gauge
alignment pins (U025)
G005

2. Remove the gerotor cover assembly Keyway

(G020/G015). Remove the two G010
gerotor cover O-ring (G023) and G006
U025
discard (early production SAE A pad G065 U025
models may contain two or three
seals: only the inner G023 seal is
required).

3. Remove the drive coupling (U015)

and gerotor gear set (G010). Remove
the retaining ring (G006) holding the
inner gear onto the coupling.

4. Remove the gerotor drive pin or key

(G005). Remove the gerotor cover
locating pin (G065).

5. Inspect the gerotor assembly (G010). E101024E

Ensure the upper and lower surfaces

of the gerotor are free of nicks and grooves. The mating surfaces of the inner and
outer gears should fit snugly and create a tight seal. Inspect the keyway for major
wear. It is normal to find a small impression from the drive pin (G005). Measure
gerotor tip clearance for wear (illustrated above). Seat the gerotor assembly into the
gerotor cover and align the assembly so that one of the tips of the inner gear fully
engages a valley in the outer gear. Using a feeler gauge, measure the clearance of the
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Service Manual
Minor Repair

CHARGE PUMP opposite tip. Clearance should be 0.127 mm [0.005 in.] or less. Replace the gerotor if
(continued) necessary. The gerotor assembly is machined as a matched pair.

6. Inspect the drive pin or key (G005) to ensure that the edges are not rounded and
that the drive coupling’s internal splines are straight and free of damage on both
ends. Check for wear on the top and bottom surfaces. Replace the drive pin or key if
worn.

7. Inspect the gerotor cover (G020). It should be free of nicks and scratches. The drive
coupling journal bearing (G015) is on the inside diameter of the small bore of the
aluminum gerotor cover. The drive coupling should fit the journal bearing with
a relatively close fit. If the coupling has worn through the bearing and into the
aluminum gerotor cover, replace the gerotor cover and drive coupling. If the fit is
excessively loose and the drive coupling has not worn into the gerotor cover, remove
the old journal bearing from the gerotor cover and press a new journal bearing into
the cover from the cavity side. Press the bearing to a depth of 12.88 mm [0.507 in]
from the bottom (cavity side) of the gerotor cover.

Assembly
1. Install the two charge pump cover/ Determining charge pump orientation
pad alignment pins (U025). looking inside of gerotor pump cover
G020
2. Install the gerotor cover locating pin
12.88 mm
(G065). G015 [0.507 in]

3. Install the 41 cm3 spacer (not shown)

if previously removed. (Spacers exist
on the older 41 cm3 models.)

4. Install the drive pin or key (G005)

into the drive coupling. Use CW CCW
petroleum jelly to hold it in place. P100110E

5. Lubricate and install the gerotor set (G010) onto the drive coupling (U015). Align the
notch in the inner gear with the drive pin or key (G005).

6. If present, install the retaining ring (G006) onto the drive coupling.

7. With the smaller end of the drive coupling (U015) facing up, install the drive coupling
and gerotor onto the shaft.

Different drive couplings are used with different charge pump covers.

8. Place the gerotor cover assembly (G020/G015) over the gerotor assembly and rotate
until the cover engages the orientation pin. The cover fits flat.

9. Lubricate the new gerotor cover O-ring (G023) with petroleum jelly and place it on
the gerotor cover (G020). Early production A pad models may contain two or three
seals.

10. Install the charge pump cover gasket, charge pump cover, and auxiliary pump as
described on page 51.
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Service Manual
Minor Repair

CHARGE PUMP Units without integral charge pump

(continued) Variable pumps without an integral charge pump have a spacer (G010) in the location
where the gerotor assembly goes. A steel O-ring plug (G004) blocks the charge pump
inlet port. Pumps without an integral charge pump that are not machined to accept
a filtration adapter, contain a charge pump defeat plug (R020) in the gerotor cavity
outlet. An O-ring (R020A) holds this plug in place. Later models have an M6 thread in the
exposed end of the plug for easier removal. Replace the O-ring when removing the plug.

Pumps without an integral charge pump that are machined to accept a filtration adapter,
do not contain a charge pump defeat plug. Pumps in this configuration use a full-flow
pressure filtration adapter with a steel O-ring plug (R086) in the charge flow outlet port.
The suction filtration adapter does not suit this configuration; neither does the partial-
flow pressure filtration adapter. It bypasses the charge relief valve.

Conversions

No charge pump option components

G023

G015

G020

U015

G010
#

G006
R020
R020A

Charge inlet
Charge inlet
To filter
N004

N004

R086

E100024E
Housing with filtration adapter Housing without filtration adapter

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CHARGE PUMP Changes to the charge pump are conversions to the pump. Change the nomenclature
(continued) on the specification tag to reflect the alterations of the unit. Refer to 520L0637 Series 42
Technical Information Manual, Model Code Supplement, or contact your Sauer-Danfoss
representative for the appropriate nomenclature. Location of the appropriate module of
the nomenclature string appears below:

Pre-blockpoint change
• Charge pump

Post-blockpoint change
• Charge pump

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Minor Repair

SERVO PISTON COVERS You can remove the servo piston covers to change the gasket or to inspect/change the
AND NFPH CONTROL NFPH control orifices.
ORIFICE
Disassembly
1. Remove the neutral adjustment seal locknut (T060) from the right side servo cover.

2. Using a T-30 Torx driver, remove the servo cover bolts (L005/M005). Post 1998 release
pumps have cover bolts that are 10 mm [0.39 in] longer than pre-1998 pumps. The
longer bolts are only compatible with post-1998 pump housing.

3. Remove the servo piston covers (L001/M001).

To remove the right side servo cover turn the neutral adjustment screw (T015)
clockwise (inward) far enough for the servo cover to clear the nearby case drain port.
Then pull the cover away from the housing and turn the cover counterclockwise to
remove it from the adjustment screw.

4. Remove the gaskets (L002/M002). Clean gasket the surfaces.

5. NFPH control orifice plugs (E051 and E052) are located beneath the servo covers. If
necessary, remove and clean the orifices.

Servo piston cover components

SERVO PISTON COVER – RIGHT SIDE SERVO PISTON COVER – LEFT SIDE
T060 L005
Lock nut M005
T-30
see table T-30
15-18 N•m
15-18 N•m
[11-13 lbf•ft]
L001 [11-13 lbf•ft]
E051 x5
x5
NFPH orifice M001
M002
3 mm L001
2-4 N•m (Non-feedback E052
[1.5-3 lbf•ft] controls only)
NFPH orifice
L002 3 mm
2-4 N•m
T015 [1.5-3 lbf•ft]
Neurtal adjust
screw
see table

E100026E

Frame size cm3 28 41/51

Control MDC/EDC NFPE/NFPH MDC/EDC NFPE/NFPH
Lock nut 13 mm 17 mm 17 mm 17 mm
Servo adjust screw 5 mm 7 mm 7 mm 7 mm

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Minor Repair

SERVO PISTON COVERS Assembly Bolt torque patterns

AND NFPH CONTROL 1. Replace the NFPH control orifice plugs TORQUE BOLTS IN ORDER INDICATED
ORIFICE (E0 51, E052) if they were removed.
2 3
(continued)
2. Install new gaskets (L002/M002).

WARNING 3. On the right side, thread the servo

Unintended vehicle piston cover (L001) onto the neutral
movement hazard: adjustment screw. Then, while
4 1
When you remove the holding the cover, turn the neutral
right side servo piston adjustment screw (T015) counter-
cover, you must set neutral clockwise to run the cover down the
and control neutral. Refer screw threads. 6
Torque this
to pages 29 and 30. bolt first and
4. Using a T30 Torx driver, install 5
last
the servo piston cover screws
(L005/M005). Torque to 15-18 N•m P101585

[11-13 lbf•ft] in the pattern shown.

5. Install a new seal lock nut (T060) onto the neutral adjustment screw (T015). Do not
torque at this time.

6. Perform pump neutral adjustment and control neutral adjustment procedures. Refer
to pages 29 and 30. 

Removal of the servo covers may change the position of the displacement limiters;
readjust if necessary (see page 27).

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Service Manual
Minor Repair

LOOP FLUSHING AND The loop flushing function consists of the Loop flushing valve and loop flushing
LOOP FLUSHING RELIEF loop flushing shuttle valve and the loop defeat components
VALVE flushing relief valve. You may remove the Q050
11
assemblies for cleaning and installation /16 in Q060
of new O-rings. You may exchange 27-47 N•m 5
/8 in
Q050 [20-35 lbf•ft]
the relief valve poppet for one with a 1
/4 in 20-34 N•m
[15-25 lbf•ft]
different flow rating. Take notice, though, 4-7 N•m
pre 1998 models contained relief shims, [3-5 lbf•ft] Q060A
do not change these shims unless Sauer- Q050A Q050A
Danfoss specifically instructs you to do Q061
Q051
so. You may also defeat the loop flushing
function by installing a defeat spool. Q062

Series 42 pumps built prior to 1998 Q051

use unique loop flushing spools. Post
1998 release pumps use a common
loop flushing spool. They are not
interchangeable.

Loop flushing valve

1. Remove the loop flushing plug
(Q050). Discard the O-ring (Q050A).

2. Remove the loop flushing spool

assembly (Q051) from the housing.

3. Inspect the parts for damage or

foreign material. Ensure the washer
securely retains the centering spring. E100018E

4. Install the loop flushing valve spool assembly (Q051) into its bore. Install a new
O-ring (Q050A) on the loop flushing plug (Q050); torque to 27-47 N•m [20-35 lbf•ft].

Loop flushing relief valve

Two styles of loop flushing relief valve plugs exist. The style of plug is depends on the
charge pressure specification. If the charge pressure is greater than or equal to 18 bar
[260 psi]: the plug has two identification grooves. If the charge pressure is less than 18
bar [260 psi]: the plug has a single identification groove.

1. Remove the loop flushing relief valve plug (Q060). Discard the O-ring (Q060A).

2. Remove the spring (Q061) and poppet (Q062) from the housing.

3. Do not alter the shims between the spring and plug, or interchange parts with
another valve. Inspect the poppet and mating seat in the housing for damage or
foreign material. Inspect the orifice in the valve poppet.

4. Install a new O-ring (Q060A) on the plug (Q060). Install the poppet (Q062), spring
(Q061), shims, and plug into the pump housing, torque to 15-34 N•m [15-25 lbf•ft].

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LOOP FLUSHING VALVE Defeating loop flushing

(continued) 1. Remove the loop flushing plug (Q050). Discard the O-ring (Q050A).

2. Remove the loop flushing spool assembly (Q051) from the pump housing.

3. Install the defeat spool (Q051) into the spool bore with tapped end facing outwards.
Install the standard plug with O-ring into the housing and torque to 27-47 N•m
[20-35 lbf•ft].

4. Remove the loop flushing relief plug (Q060). Discard the O-ring (Q060A).

5. Remove the loop flushing relief valve components (Q061/Q062).

6. Install the loop flushing relief plug (Q060) with a new O-ring (Q060A) into the
housing and torque to 15-34 N•m [15-25 lbf•ft].

Conversions
Changes to the loop flushing valve are conversions to the pump. Change the
nomenclature on the specification tag to reflect the alterations of the unit. Refer to
520L0637 Series 42 Technical Information Manual, Model Code Supplement, or contact
your Sauer-Danfoss representative for the appropriate nomenclature. Location of the
appropriate module of the nomenclature string appears below:

Pre-blockpoint change
• housing

Post-blockpoint change
• Loop flushing

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Minor Repair

SHAFT SEAL, ROLLER Series 42 pumps use a lip type shaft seal. You can replace the seal and/or shaft without
BEARING, AND SHAFT major disassembly.
REPLACEMENT
Seal removal
1. Position the pump with the shaft facing up.

If the unit is positioned horizontally when the shaft is removed, the cylinder block could
move out of place, making shaft installation difficult.

2. Remove the case drain plug (F091) to relieve any vacuum that may be present on the
shaft (C005) and seal carrier assembly (C020).

3. Remove the spiral retaining ring (F096) from the housing. Using a screwdriver, pry
the end of the ring free and unwind the remainder of the ring out of the groove.

4. Remove the seal carrier assembly (C020). Loosen it from the unit by prying on the
raised surface of the seal carrier with a screwdriver.

5. Remove the O-ring (C017) from the seal carrier (C020); discard.

6. Pry or press the lip seal (C018) from

the seal carrier (C020); use caution Shaft seal components
to avoid damaging the seal carrier.
Discard the seal.
F096
7. Inspect the seal carrier (C020) for
damage. C020

8. Press the new seal (C018) into the

C017
shaft bearing side of the seal carrier
(C020). Be careful to only press on
the outside diameter of the lip seal.
Orient the seal as shown in the F091
see table
illustration. Be careful not to damage see table
the seal.

E100019

Installation of shaft seal

C017

C018

Seal carrier shown

C020 with the inside
facing up

Press seal to bottom of the carrier

E100020E

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Minor Repair

SHAFT SEAL, ROLLER Shaft removal Case Drain Plug

BEARING, AND SHAFT 1. Grip the shaft assembly (C005) by Frame Size 28 cm3 41/51 cm3
REPLACEMENT the splines or keyed end and remove Internal Hex 9/16 in 5/8 in
(continued) from the pump. Torque 95-136 N•m 122-258 N•m
[70-100 lbf•ft] [90-190 lbf•ft]
2. Inspect the shaft for damage (C001).
Ensure the shaft and splines are
straight and free of damage or heavy Shaft seal, roller bearing, and shaft
wear. Inspect the surface where the replacement
rear shaft bearing contacts the shaft.
If spalling is present, replace the
shaft and rear shaft bearing. Refer
to 11007277 Series 42 Axial Piston
Closed Circuit Pumps Repair Manual. If
necessary, clean the sealing area with
a nonabrasive material. Lubricate the
shaft with a light coating of hydraulic
fluid.

Replacement of shaft rear bearing is

a major repair and violates the unit’s
warranty policy unless performed by an
authorized Sauer-Danfoss Global Service F096
Partner.
C020
3. Inspect the shaft bearing (C003)
for damage and rotate to ensure
smoothness. If you suspect C017
contamination or damage, clean with
solvent and lubricate with hydraulic
fluid. Replace if necessary.

If you are not replacing the shaft or

bearing, proceed with reassembly.

Shaft bearing replacement

1. Remove the retaining ring (C002)
using snap ring pliers.

2. Observe the orientation of the

chamfer on the bearing (C003). Press E101029

the bearing off of the shaft (C001).

3. Verify the chamfer on the bearing

is facing toward the pump. Press
the new bearing (C003) onto the
shaft (C001) and secure it with the
retaining ring (C002). Press only on
the inner race of the roller bearing.

4. Using snap-ring pliers, install the

retaining ring (C002).
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Minor Repair

SHAFT SEAL, ROLLER Reassembly Shaft seal, roller bearing, and shaft
BEARING, AND SHAFT 1. Ensure that the cylinder kit and rear replacement
REPLACEMENT bearing are aligned. Insert the shaft
(continued) assembly (C005) into the pump. It
may be necessary to grip the splined F096
end of the shaft and twist to align it
with the block splines and properly
C020
seat it into the rear bearing.

If you change from or to a 19 tooth shaft, C017

change the seal carrier. Refer to the
service parts manual.

2. Lubricate a new O-ring (C017) with

petroleum jelly and seat it into the
housing, on top of the bearing.

3. Cover the splined or keyed end of

the shaft (C001) with an assembly
sleeve (bullet) or a layer of thin
plastic to prevent damage to the lip
seal during installation. Lubricate
the inside diameter of the shaft E101029

seal carrier assembly (C020) with

petroleum jelly.

4. Slide the seal carrier assembly

(C020) over the shaft (C001) and into
the housing. Press the seal carrier
against the O-ring (C017). It may be
necessary to use a large socket to
straddle the shaft and press the seal
carrier down completely.

5. Wind the spiral retaining ring (F096)

into the groove in the housing.

Conversions
Changes to the input shaft are conversions to the pump. Change the nomenclature on
the specification tag to reflect the alterations of the unit. Refer to 520L0637 Series 42
Technical Information Manual, Model Code Supplement, or contact your Sauer-Danfoss
representative for the appropriate nomenclature. Location of the appropriate module of
the nomenclature string appears below:

Pre-blockpoint change
• Input Shaft

Post-blockpoint change
• Input Shaft

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Appendix A - Torques

TORQUE TABLE Torques

Sequence Part Description Tool Type Tool Size Torque
Number N•m [lbf•ft]
D002 MDC bolts Torx wrench T-30 15-18 [11-13]
D003 Cover plug Internal hex wrench 3
/16 in 11-14 [8-10]
D010 Linkage pivot screw Internal hex wrench 4 mm 8-15 [6-11]
D015 MDC/EDC neutral adjustment seal External hex wrench 17 mm 31-50 [23-37]
lock nut
D032 Control spool bore plugs Internal hex wrench 5/16 in 41-95 [30-70]
D038 Control nut External hex wrench 8 mm 4-7 [3-5]
D040 Neutral start switch External hex wrench 7/8 in 24-30 [18-22]
D056A Retaining nut External hex wrench 3/4 in 5-6 [3.5-4.5]
D081 FNR/NFPE bolts Internal hex wrench 4 mm 5.5-7.5 [4-5.5]
D081/D082 EDC bolts Torx wrench T-30 15-18 [11-13]
E051 NFPH orifice Internal hex wrench 3 mm 2-3.8 [1.5-2.5]
F091 Case drain plug (28 cm3) Internal hex wrench 9/16 in 95-136 [70-100]
F091 Case drain plug (41/51 cm3) Internal hex wrench 5/8 in 122-258 [90-190]
F093 System gauge ports M1 and M2 plugs External hex wrench 11/16 in 27-47 [20-35]
G040 Shim adjustable charge relief valve External hex wrench 1 in 54-136 [40-100]
plug
K007 Valve seat plug External hex wrench 1 in 40-95 [30-70]
(with bypass)
K007 Valve seat plug Internal hex wrench /16 in
5
41-95 [30-70]
(without bypass)
L005/M005 Servo piston cover bolts Torx wrench T-30 15-18 [11-13]
L010/M010 Servo gauge plug External hex wrench 11/16 in 27-47 [20-35]
L025/M025 Displacement limiter seal lock nut External hex wrench 13 mm 20-26 [15-19]
N002 Port N plug External hex wrench 11/16 in 27-47 [20-35]
P036 Control spool cover screws Torx wrench T-30 15-17 [11-13]
(pre-block point change)
Q050B Loop flushing plug Internal hex wrench /4 in
1
4-7 [3-5]
(pre-block point change)
Q050B Loop flushing plug External hex wrench 11
/16 in 27-47 [20-35]
(post-block point change)
Q060B Loop flushing relief valve plug External hex wrench /8 in
5
20-34 [15-25]
R042 Filtration adapter bolts Torx wrench T-30 15-18 [11-13]
T041 Lock nut (28 cm3) External hex wrench 1 1/16 in 14-30 [10-22]
T041 Lock nut (41/51 cm3) External hex wrench 1 1/16 in 28-30 [21-37]
T060 Pump mechanical neutral adjustment External hex wrench 13 mm 20-26 [15-19]
seal lock nut (28 cm3, MDC/EDC)
T060 Pump mechanical neutral adjustment External hex wrench 17 mm 31-50 [23-37]
seal lock nut (28 cm3, NFP control and
41/51 cm3, all controls)
U035 Charge pump cover bolts Torx wrench T-45 43-46 [32-34]
U090 Auxiliary pump screws External hex wrench 9/16 in 37-50 [27-37]
(SAE-A pad)
U090 Auxiliary pump screws External hex wrench /4 in
3
91-111 [67-82]
(SAE-B pad)

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Appendix B - Specification Tags

PRE-BLOCK POINT
CHANGE Ames, Iowa, U.S.A. Neumünster, Germany
Model Code
42L28 - C - ANN1 - 01 -
ANA - 2CNB - NN - NN - N - Model code
N - N - NNN - NNN
Model No. Ident Nr
4282051
A 97 23 67890
Serial No. Fabr Nr

MADE IN U.S.A.
Serial no.
{ X XX
Location Year
XX
Week
XXXXX
Sequence
number

POST-BLOCK POINT Name plate

CHANGE

Model
428 2051
number
Model-No./Ident-No.
Model Model Code 42L28 C ANN1 01 ANA
code 2CNB NN NN N N N
NNN NNN Serial
A 97 14 67890
number
Serial-No.

Made in USA

P100438E Place of manufacture

Specifications
tag

P101263

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Appendix C - Nomenclature

PRE-BLOCK • Series
POINT CHANGE
NOMENCLATURE • Rotation

• Frame Size

• Input Shaft

• Control

• Control Response

• Housing

• Charge Pump

• System Relief - Port A

• System Relief - Port B

• Bypass Valve

• Displacement Limiters - Side 1

• Displacement Limiters - Side 2

• Special Hardware

• Special Features

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Appendix C - Nomenclature

POST-BLOCK • Series
POINT CHANGE
NOMENCLATURE • Rotation

• Frame Size

• Input Shaft

• Control

• Control Response

• Housing

• Loop Flushing

• Filtration

• Charge Pump

• Charge Relief Setting

• Special Drive Features

• Auxiliary Mounting Pad

• System Relief - Port A

• System Relief - Port B

• Bypass Valve

• Displacement Limiters - Side 1

• Displacement Limiters - Side 2

• Special Hardware

• Special Features

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OUR PRODUCTS Sauer-Danfoss Hydraulic Power Systems

– Market Leaders Worldwide

Hydrostatic transmissions Sauer-Danfoss is a comprehensive supplier providing complete

Hydraulic power steering systems to the global mobile market.

Electric power steering Sauer-Danfoss serves markets such as agriculture, construction, road
building, material handling, municipal, forestry, turf care, and many
Closed and open circuit axial piston others.
pumps and motors
We offer our customers optimum solutions for their needs and
Gear pumps and motors develop new products and systems in close cooperation and
partnership with them.
Bent axis motors
Radial piston motors Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
Orbital motors total system design.

Transit mixer drives Sauer-Danfoss provides comprehensive worldwide service for its
Planetary compact gears products through an extensive network of Global Service Partners
strategically located in all parts of the world.
Proportional valves
Directional spool valves Local address:

Cartridge valves

Hydraulic integrated circuits

Hydrostatic transaxles
Integrated systems
Fan drive systems
Electrohydraulic controls Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Digital electronics and software Ames, IA 50010, USA Phone: +45 7488 4444
Phone: +1 515 239-6000 Fax: +45 7488 4400
Battery powered inverter Fax: +1 515 239-6618
Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD
Sensors Postfach 2460, D-24531 Neumünster Sannomiya Grand Bldg. 8F
Krokamp 35, D-24539 Neumünster, Germany 2-2-21 Isogami-dori, Chuo-ku
Phone: +49 4321 871-0 Kobe, Hyogo 651-0086, Japan
Fax: +49 4321 871 122 Phone: +81 78 231 5001
Fax: +81 78 231 5004

www.sauer-danfoss.com
520L0638 • Revision BA • July 2007

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Moteurs hydrauliques
MS
Hydraulic motors
Réparations
Repairs

02 03 05 08 11 18
MS ! ! ! ! ! !
MSE ! ! ! ! ! !

Dépannage
Trouble shooting

Interventions
Maintenance

Réparations
Repairs
5767
Pièces de rechange
Spare parts

5763 5765
0549 5766 0545

5764
0550 0547

Ref : 677777845L POCLAIN HYDRAULICS Industrie

B.P. 106
REPAR MS2-18 F/GB 60411 VERBERIE CEDEX - FRANCE POCLAIN HYDRAULICS
Tel.: 33 3 44 40 77 77
Rev : B - Avr 01
Fax: 33 3 44 40 77 99
Certifié ISO 9001
www.poclain-hydraulics.com

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POCLAIN HYDRAULICS
Ce document s'adresse aux constructeurs des machines qui intè- This document is provided to machine manufacturers integrating
grent les produits POCLAIN-HYDRAULICS. II préconise les proces- POCLAIN-HYDRAULICS products.. It suggests processes that
sus que les constructeurs peuvent mettre en oeuvre pour réparer ces manufacturers may utilize to repair products after the warranty period.
produits à l'issue de la période de garantie.
It is recommended that all operations be performed by technicians
Il est recommandé que toutes les opérations soient effectuées par trained accordingly. The technicians should read and understand the
des techniciens ayant bénéficié de la formation adéquate. Les tech- information given in this document and be authorized by the machine
niciens doivent avoir lu et compris les informations figurant dans ce manufacturer.
document et avoir été habilités par le constructeur de la machine. It is essential that the technicians comply with safety instructions to
Ces techniciens devront impérativement observer les directives de prevent injury.
sécurité et de protection contre les accidents.
Ce document inclut des remarques importantes concernant la sécuri- This document includes major safety warnings announced in this way:
té. Elles sont mentionnées de la manière suivante:

! Remarque de sécurité.
! Safety warning.

Ce document inclut également des instructions essentielles au fonc- Additionally, this document includes instructions essential to product
tionnement du produit ainsi que des informations générales. Elles function as well as those providing general information. Both are an-
sont mentionnées de la manière suivante: nounced similar to the following examples:

Instruction essentielle. Essential instruction.

Information générale. General information.

POCLAIN HYDRAULICS est concepteur de produits que ses clients POCLAIN HYDRAULICS designs products that are integrated by its
intègrent aux machines qu'ils conçoivent. De ce fait, POCLAIN HY- customers in the machines they design. Subsequently POCLAIN
DRAULICS ne peut être tenu pour responsable des conséquences HYDRAULICS disclaims liability for consequences of improper inte-
liées à la mauvaise intégration de ses produits, ni des conséquences gration of its products and of improper set-up of adjustable devices.
pouvant résulter du mauvais paramétrage de leurs dispositifs régla- In the same way, POCLAIN HYDRAULICS may not be liable for in-
bles. De la même manière, POCLAIN HYDRAULICS ne peut être complete or improper operating and maintenance instructions pro-
tenu pour responsable d'instructions d'utilisation et de maintenance vided to the end user by the machine manufacturer nor for failures
erronées ou incomplètes qui auraient été communiquées par les resulting from operations performed by any person using these sug-
constructeurs de machines aux utilisateurs finaux ni d'incidents gested procedures.
qu'aurait engendrés quiconque ayant appliqué les processus préco-
nisés dans ce document. A re-certification of the machine may be required for every change in
Toute modification de paramétrage des dispositifs réglables peut né- set-up of adjustable devices.
cessiter une nouvelle homologation des machines.
In order to offer the best quality service, POCLAIN HYDRAULICS
Dans le but d’offrir le meilleur service, POCLAIN HYDRAULICS re- recommends to its customers to have applications approved by PO-
commande à ses clients de lui faire approuver chaque application. CLAIN HYDRAULICS.
L'ouverture des produits conduit à la perte de la garantie. N'utilisez Opening of products voids the warranty contract.
que des pièces de rechange d'origine POCLAIN HYDRAULICS. Le Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
montage de pièces d'origine différente pourrait nuire au fonctionne- from different sources could reduce the performance of the product
ment du composant et du système et à la sécurité. and pose a safety hazard..

Soucieux d’améliorer ses fabrications, POCLAIN HYDRAULICS se In accordance with its policy of continuous improvement, POCLAIN
réserve le droit d’apporter sans préavis, toutes les modifications qu’il HYDRAULICS reserves the right to modify the specifications of all
jugerait utile aux produits décrits dans ce document. products described herein without prior notice.
Ce document contient des sections en langue Française et des sec- This document contains sections written in French and sections
tions imprimées en italique constituant leur traduction en langue An- printed in italics composing the English translation of the French sec-
glaise. En cas de contestation, les sections en langue Française fe- tions. The French sections will be the reference in case of dispute.
ront foi. Les mesures sont exprimées en unités métriques. Les All measures are expressed in metric units. Converted values to
correspondances à d’autres systèmes de mesure (notamment anglo- other systems (notably US and UK) are given for reference only.
saxons) sont données à titre indicatif.

Les illustrations ne sont pas contractuelles The illustrations for information only.
POCLAIN HYDRAULICS Industrie 1998. POCLAIN HYDRAULICS Industrie 1998.
La marque POCLAIN HYDRAULICS est la propriété de POCLAIN The trademark POCLAIN HYDRAULICS is the property of POCLAIN
HYDRAULICS S.A. HYDRAULICS S.A.
Ce document est la propriété de POCLAIN HYDRAULICS Industrie. This document is the property of POCLAIN HYDRAULICS Industrie.
Il est strictement confidentiel. Il ne doit pas être utilisé, reproduit, co- It is strictly confidential. It must not be used, duplicated, copied or
pié ou divulgué à un tiers en totalité ou en partie sans notre accord disclosed to a third party in full or in part without our prior written con-
écrit préalable. sent.
FACOM est une marque déposée de FACOM SA. FACOM is FACOM SA registered trademark.
LOCTITE est une marque déposée de LOCTITE SA. LOCTITE is LOCTITE SA registered trademark.
AUTO-TOP est une marque déposée de AGIP SPA. AUTO-TOP is AGIP SPA registered trademark.

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Sommaire Contents

SECURITE ET QUALITE................................................4 SAFETY AND QUALITY ................................................4

AVANT TOUTE INTERVENTION .............................................4 BEFORE SERVICING ...........................................................4
DURANT L'INTERVENTION ...................................................4 DURING SERVICING............................................................4
APRES INTERVENTION........................................................4 AFTER SERVICING..............................................................4
IDENTIFICATION DU COMPOSANT ........................................5 IDENTIFICATION OF THE COMPONENT ..................................5
DEPANNAGE..................................................................6 TROUBLE SHOOTING...................................................7

INTERVENTIONS ...........................................................8 MAINTENANCE..............................................................8

REMPLACEMENT DU MOTEUR .............................................8 REPLACING THE MOTOR .....................................................8
DEFREINAGE MECANIQUE ..................................................9 MECHANICAL BRAKE RELEASE ............................................9
DESACTIVATION DU FREINAGE MECANIQUE DES MOTEURS A MECHANICAL BRAKE DEACTIVATION OF THE MOTORS WITH
PALIERS DYNA+. ............................................................10 DYNA+ BEARING SUPPORT .............................................10
CONTROLE DE L'EFFICACITE DE FREIN DE PARKING. ..........11 CHECKING THE PARKING BRAKE EFFICIENCY. ....................11
REPARATIONS. ...........................................................12 REPAIRS. .....................................................................12
REPARATION DU FREIN. ...................................................12 REPAIR OF THE BRAKE.....................................................12
REPARATION DU PALIER (070) .........................................27 BEARING SUPPORT (070) REPAIR .......................................27
REMPLACEMENT DU PALIER DYNA +................................44 REPLACEMENT OF THE DYNA + BEARING SUPPORT..........44
REMPLACEMENT DES MACHOIRES DE FREIN ......................50 The big chamfers oriented towards bearing support .48
REMPLACEMENT DE LA CAME (026) ..................................57 REPLACING THE BRAKE SHOES.........................................50
REMPLACEMENT DU BLOC CYLINDRE EQUIPE (010) ...........58 REPLACEMENT OF THE CAM (026) ....................................57
REMPLACEMENT DE LA GLACE (047). ...............................59 REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)58
REMPLACEMENT DU JOINT (045) DE LA PLAQUE DE REPLACEMENT OF THE VALVING (047)..............................59
FERMETURE. ...................................................................62 REPLACEMENT OF THE END COVER O-RING (045) .............62
REMPLACEMENT DU CAPTEUR (OPTION) ...........................64 REPLACING THE SENSOR (OPTIONAL) ...............................64
RECAPITULATIF OUTILLAGE ....................................66 TOOLING INVENTORY................................................66

RESUME DES COUPLES DE SERRAGE ...................69 TIGHTENING TORQUE SUMMARY ............................69

LISTE DES PIECES......................................................73 SPARE PARTS LIST ....................................................73

MOTEURS AVEC PALIER DYNA + .......................................75 MOTOR WITH DYNA+ BEARING SUPPORT ........................75
MOTEURS A 1 CYLINDREE ................................................76 SINGLE DISPLACEMENT MOTORS ......................................76
MOTEURS A 2 CYLINDREES ..............................................78 DUAL DISPLACEMENT MOTORS .........................................78

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Sécurité et Qualité Safety and Quality

Avant toute intervention Before servicing
• Prendre toutes les dispositions de sécurité nécessai- • Be extremely careful to prevent personal injury and
res (hommes et matériel) en se conformer aux ré- to avoid damage to material. Comply with all safety
glementations de sécurité en vigueur. regulations.
• Engager le frein de parking et immobiliser la ma- • Apply the parking brake and prevent the machine
chine avec des cales. from rolling with tire blocks.
• Stopper le générateur d'énergie (moteur) du système • Stop the hydraulic system power source (engine)
hydraulique et déconnecter l'alimentation électrique. and disconnect the battery.
• Le cas échéant, délimiter le périmètre de sécurité. • If necessary, block off the safety area.
• Nettoyer l'extérieur des composants pour en retirer • Wash dirt and grease from exterior of the compo-
toute trace de boue et de graisse. nents.
• Attendre le refroidissement et la dépressurisation complète • Await the complete cooling down and depressurization of
du système hydraulique (décharger les accumulateurs). the hydraulic system (accumulators must be purged).
L'huile chaude ou sous pression peut provo- Hot or pressurized hydraulic fluid may cause se-
! quer des brûlures graves avec infection.
Consulter un médecin en cas d'accident. ! rious burns & infections to the human body.
Consult a physician in case of accident.

Durant l'intervention During servicing

• Certains composants sont très lourds. Les soutenir • Some hydraulic components are very heavy. Se-
au moyen d'un dispositif de levage de capacité adé- cure them with a lifting device of adequate capacity
quate pour les déposer du châssis. when removing from the machine frame.
• La propreté est essentielle au fonctionnement des com- • Cleanliness is essential to functioning of the hydrau-
posants hydrauliques. La plupart des pièces peuvent être lic components. Most of the parts may be cleaned with a
nettoyées au moyen d'un solvant propre. clean solvent.
• Durant les manutentions, protéger toutes les surfaces • During handling, protect all sensitive surfaces from
sensibles contre les chocs (centrages, parties frottantes, ap- shocks (piloting and interface surfaces, thrust & bear-
puis, portées des joints et des roulements, etc...). ings surfaces, seal races, etc...)
• Nettoyer ces surfaces avant remontage. • Clean up these surfaces before reassembling.
• Toujours remonter des joints neufs en éliminant • Always install new O-rings, seals & gaskets discard-
systématiquement les joints démontés. Nous recom- ing the old ones. We recommend lubricating all seals
mandons de graisser tous les joints avant montage. prior to assembly.
• Huiler toutes les surfaces frottantes en y déposant • Lubricate all surfaces which have relative motion
un film de fluide hydraulique propre qui assurera une lu- between parts by coating them with a film of clean hy-
brification correcte lors du premier (re)démarrage.
draulic fluid to assure lubrication at first start.
• Ne jamais chauffer le fluide hydraulique qui peut
• Never heat hydraulic fluid, as it may flame at high
s'enflammer à haute température. Certains solvants
temperature. Some solvents are also flammable.
sont également inflammables. Ne pas fumer durant l'in-
Do not smoke during servicing.
tervention.
Après intervention After servicing
Réinstaller les composants et remettre le système hy- Reinstall the components and restart the hydraulic sys-
draulique en service selon les instructions figurant dans tem according to instructions defined in the following
les documents suivants: documents:
• INSTALLATION MS F/GB (ref. 677777844K) • INSTALLATION MS F/GB (ref. 677777844K)
• INSTALLATION CIRCUITS F/GB (ref. 677777831V) • INSTALLATION CIRCUITS F/GB (ref. 677777831V)

Ne pas surtarer les soupapes de sécurité.

! ! Do not overset relief valves.

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Identification du composant Identification of the component

MS18-2-D11-F19-2A10-K000
B
D
000143896J

C
001 40712
0349

A : Désignation commerciale : A: Commercial description:

Ex : MSE18-2-D11-F19-2A10-K000 E.g : MSE18-2-D11-F19-2A10-K000

B : Code :Code Article B: Code:Part number.

Ex : 000143896J E.g : 000143896J

C : Série :Numéro de fabrication C: Series: Manufacturing batch number.

Ex : 001 E.g : 001

D : Num : Numéro d’ordre chronologique D: Num: Chronological serial number.

Ex : 40712 E.g : 40712

Le Code article et le numéro d’ordre doi- The part number and the chronological
vent être indiqués pour toute commande serial number must be specified to order
de pièces de rechange. spare parts.

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Dépannage
DETERIORATION LIMAILLE DETECTION PAR LES FILTRES PREVENTIF……

Pannes Causes Remèdes

Ronronnement Palier usagé Procéder au remplacement du
régulier palier
À vide
Desserrage des fixations,
Vibrations Resserrer au couple
des tuyauteries
MOTEUR BRUYANT
Contrôler le tarage et l'état de
Pression de gavage trop
Claquement la soupape de contre-
faible
En charge pression.
Fuites internes trop impor- Remplacer le bloc cylindre et
Cavitation
tantes la distribution

Le moteur n'est pas ali- Contrôler l'entraînement de la

menté pompe et son alimentation
Le circuit ne monte pas en Contrôler l'état de la soupape
LE MOTEUR NE pression de sécurité (régulateur)
TOURNE PAS Fuites internes trop impor- Remplacer le bloc cylindre et
tantes la distribution
Contrôler le circuit de pilotage
Le frein reste serré du frein

Le débit de la pompe est Contrôler la vitesse d'entraî-

insuffisant nement et l'état de la pompe
LE MOTEUR NE
TOURNE PAS A SA Fuites internes trop impor- Vérifier l'état du bloc cylindre
VITESSE NORMALE tantes et de la distribution
EN CHARGE
La pression de fonction- Contrôler le tarage de la sou-
nement est trop basse pape de sécurité (régulateur)

LE MOTEUR Le débit est irrégulier Contrôler le débit de la pompe

TOURNE IRREGU- Vérifier l'état du bloc cylindre
LIEREMENT Fuites trop importantes
et de la distribution

Pression carter trop élevée Vérifier le circuit de drainage,

et l'état du filtre
FUITES D'HUILE EX- Joints détériorés Remplacer les joints
TERNES
Contrôler le serrage des vis
Montage défectueux d'assemblage, des vis de
purge et raccordements

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Trouble shooting
DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION……

Troubles Causes Remedies

Regular rum- Worm bearing support Replace the bearing support
Without bling
load Mountings and/or hydraulic
Vibrations Tighten to torque
piping becoming loose
NOISY MOTOR
Check the setting and condi-
Clattering Boost pressure too low
tion of counter-pressure valve
Under load Replace the cylinders- block
Cavitation Excessive internal leaks and distribution valve assem-
bly

Check pump drive and pump

No supply to the motor
inlet
The circuit does not reach Check condition of safety
THE MOTOR DOES working pressure valve (regulator)
NOT REVOLVE Replace the cylinders block
Excessive internal leaks and distribution valve assem-
bly
The brake stays engaged Check the brake pilot circuit

Check drive speed and condi-

Pump flow is too low
tion of the pump
THE MOTOR DOES
Check condition of cylinders-
NOT REVOLVE AT
Excessive internal leaks block and distribution valve
ITS NORMAL SPEED
assembly
UNDER LOAD
Working pressure is too Check safety valve setting
low pressure (regulator)

Irregular flow Check the pump flow

THE MOTOR RE-
VOLVES IRREGU- Check condition of cylinders-
LARLY Excessive leaks block and distribution valve
assembly

Too high casing pressure Check the leakage circuit and

filter condition
EXTERNAL OIL Seals damaged Replace seals
LEAKS
Check tightening of mounting
Incorrect assembling screws, bleed screws and un-
ions

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Interventions Maintenance
Remplacement du moteur Replacing the motor

Dépose Removal

• Éliminer la pression dans le circuit d'alimentation. • Release the pressure in the supply circuit.
• Débrancher la tuyauterie de drainage au niveau du • Disconnect the drain line at the tank level to avoid
réservoir afin d'éviter le siphonnage de celui-ci. its siphoning.
• Débrancher et boucher les tuyauteries ou flexibles • Disconnect and plug the pipes or hoses connected
raccordés sur le moteur. to the motor.
• Débrancher le connecteur du capteur tachy • Disconnect the speed sensor.
• Démonter les vis de fixation, puis déposer le mo- • Disconnect the mounting screws, and remove the
teur. motor.
• Vidanger le carter. • Drain the casing.

Repose Installation

Reprendre les opérations de dépose dans l'ordre in- Execute the removal operations in the reverse order.
verse.
Veuillez vous reporter aux documentations suivantes: Please refer to the following documentation brochures:
• INSTALLATION MS F/GB (ref: 677777844K) • INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS F/GB (réf: . 677777831V) • INSTALLATION CIRCUITS F/GB (réf: . 677777831V)

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Défreinage mécanique Mechanical brake release

(sauf moteur avec palier DYNA+) (except motor with DYNA+ bear-
ing support)

Dans certains cas de dépannage, il In certain service situations, it may

peut être nécessaire que le moteur be necessary to release the motor
soit défreiné. brake.

• Extraire et éliminer le bouchon • Extract and release the plug 142

(142) de la coiffe de frein. (142) from the brake cover.

6499

• Serrer la vis dans le piston • Tighten the screw in the piston

6556

• Puis serrer l'écrou jusqu'à ce • And tighten the nut until the mo-
que l'arbre du moteur tourne libre- tor shaft turns freely.
ment.

6555

Freins Brakes Effort N Force [lbf] Couple équivalent N.m Equivalent torque [lbf.ft] Ecrou Nut
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

Après le défreinage, monter un bouchon After brake release, mount a new plug
! (142) neuf. ! (142).

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Désactivation du freinage mécanique des Mechanical brake deactivation of the mo-

moteurs à paliers DYNA+. tors with DYNA+ bearing support

• Se reporter aux brochures caractéristiques pour obtenir • See the characteristics brochures to obtain the nec-
les volumes nécessaires pour défreiner et pour freiner. essary volumes to release the brake or to brake.

Cette opération peut être nécessaire lors du montage This operation can be necessary to do during the mo-
du moteur ou dans certains cas pour déplacer une ma- tor’s assembly or to move a machine during a break-
chine lors d'un dépannage. down.

• Dévisser et démonter la soupape d'irrigation des • Unscrew and remove the irrigation valve of the mo-
moteurs à palier DYNA+.(D+). tors with DYNA+ bearing support (D+).

• Monter en lieu et place l'obturateur M18x1.5 équipé. • Install the M18x1.5 plug assembly (Part number
(Code article 003037414M). 003037414M).

• À l'aide d'une tuyauterie flexible, relier les orifices de • Using a flexible piping, connect the break release
défreinage (X) des paliers DYNA+ à une pompe ma- ports (X) of DYNA+ bearing supports to a manual
nuelle (M) équipée d'un réservoir (0.5 l [30.5 cu.in] pump (M) equipped with a tank (0.5 L [30.5 cu.in]
minimum), ainsi qu'une soupape de sécurité (S) tarée minimum), as well as a safety valve (S) calibrated at
à 30 bar [435 PSI] maxi, d'une vanne de vidange (V), 30 bar [ 435 PSI ] maximum, a blow off valve (V), a
d'un clapet anti-retour en sortie de pompe et d'un check valve at the pump output and a manometer
manomètre (M) (0-100 bar [0 – 1450 PSI]). (M) (0-100 bar [ 0 – 100 bar [1450 PSI ]).

• Actionner la pompe à main (M) pour désactiver le • Activate the hand pump to release the mechanical
frein mécanique. brake.

• Pour réactiver le frein mécanique, actionner la • To reactivate the mechanical brake, activate the
vanne de vidange (V), puis procéder aux opérations blow off valve (V), then execute the operations in
inverses. the reverse order.

• Après l'intervention, remonter les soupapes d'irriga- • After the intervention, reinstall the irrigations valves.
tions.

! "

( -. /)0 12 1 %
!# * +$ %, - +./ )

4
&
3
' ( )* + ,
!" # $ %& ' ()
! " # $
7852

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Contrôle de l'efficacité de frein de parking. Checking the parking brake efficiency.

Pour un engin roulant, effectuer ce test sur un For a rolling machine, make the test on a
! sol horizontal. ! horizontal ground.

Pression de pilotage du frein: mini 12 bar Pilot brake pressure : Minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]

• S'assurer que la pression d'alimentation du frein est • Make sure that the brake supply pressure is zero,
nulle,
• Effectuer la purge du frein par la vis (112) située au • Purge the brake using the screw (112) located at
niveau le plus haut, the highest level,
• Alimenter le moteur jusqu'à la pression de tarage, • Supply the motor up to the setting pressure.

• L'arbre du moteur ne doit pas tourner sinon il est • The motor shaft must not turn, otherwise it is nec-
nécessaire de procéder au remplacement du frein: essary to replace the brake :

! Ne pas roder les freins multidisques. ! Do not run multidisc brakes in.

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Réparations. Repairs.
Réparation du frein. Repair of the brake.
(sauf moteur avec palier DYNA+) (except motor with DYNA+ bear-
ing support)
Démontage Disassembly

Prévoir la fourniture de la Plan to supply a cover

(141) as it will be de-
! coiffe(141) car elle sera
détruite au démontage. ! stroyed during disas-
sembly.

• Déposer le moteur. • Remove the motor.

• Mettre le moteur en appui sur le • Place the motor on the bearing
support palier. support.

Protéger les goujons en Protect the studs by re-

! remontant les écrous ! installing the nuts

• Démonter et éliminer la coiffe • Remove and discard the brake

de frein.(141) cover.(141) 141

6500

• Extraire et éliminer le joint tori- • Extract and discard the O-ring 143
que (143). (143).

6501

• Comprimer la rondelle élastique • Compress the spring washer

(108): (108).
• À l'aide du mandrin et de l'ex-
tracteur (voir outillage page 66) (fig • Using a mandrel and an extrac-
6502) tor (see tools page 66) (fig 6502)
• À l'aide du mandrin et d'une vis • Using a mandrel and a screw
de classe 12.9 (voir outillage page class 12.9 (see tools page 66)
66) • Using a mandrel and a press 6502
• À l'aide du mandrin et d'une (fig 6503). Respect the force F (see
presse (fig 6503). Respecter la table page 9)
force F (voir tableau page 9)

Mark the mounting direc-

Repérer le sens de mon- tion of the snap ring.
tage de l'anneau élastique.

6503

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• Démonter l'anneau d'arrêt (109) • Remove the snap ring (109) us-
à l'aide d'une pince à anneaux d'ar- ing internal snap ring pliers. (see
rêt intérieur.(voir outillage 66) tools 66)

• Extracteur et pince (fig 6504 et • Extractor and pliers (fig 6504 6504 6505
6505) and 6505)
• Presse et pince (fig 6506 et • Press and pliers (fig 6506 and
6507) 6507)

6506 6507
Ne pas mettre le palier en If you use the press do
! appui sur les goujons lors
de la mise sous la presse.
! not place the bearing
support on the studs.

• Extraire la rondelle élastique • Extract the spring washer (108).

(108).

108

6508

• Extraire le piston de frein (107). • Extract the brake piston (107)

6513

• Eliminer le joint torique (106). • Discard the O-ring (106).

106

6511
• Démonter et éliminer les vis • Remove and discard the screws
(102). (102). 102

7145

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• Démonter le corps de frein • Remove the brake housing

101
(101). (101).

7146

• Extraire le calage (105) et les • Extract the shims (105) and the
103-104
disques de frein (103-104). brake discs (103-104).

6647

• Si le moteur est à 2 cylindrées, • If motor with dual displacement

démonter le tiroir de changement de (two speed) : remove the two speed
cylindrée (053). shift spool (053).
053

7147

• Eliminer le joint torique (045). • Discard the O-ring (045).

045

7148

• Si le moteur est à deux cylin- • If motor with dual displacement,

drées, éliminer le joint (057). discard the O-ring (057).
057

7149

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Remontage. Reassembly.

Avant le remontage, il est impératif Before reassembling, it is necessary

de s'assurer de la propreté de tou- to ensure that all parts, the surface
tes les pièces, des portées de joint conditions of the piston seal and the
et des gorges. grooves are clean.

Toute trace de rouille,

All traces of rust, mud,
! boue, eau doit être sup-
primée.
! water must be removed.

S’assurer également que le corps Also make sure that the brake
de frein présente bien des chan- housing has proper chamfers
freins dans les trous de passage around the mounting screws
des vis de fixation sur le corps de holes.
frein.

Enduire de graisse anti-oxydante Coat with anti-oxidizing grease (see

(voir outillage page 66), les gorges, tools page 66), the grooves, the top
le dessus du piston de frein, la ron- of the brake piston, the spring
delle élastique, l'anneau d'arrêt, et washer, the snap ring and the piston 7150
la portée du joint de piston dans le seal contact surface in the brake
corps de frein. housing.
Montage du corps de frein : Brake housing mounting :
st
De type 1 : collé 1 type : glued
nd
De type 2 : non collé 2 type : not glued
rd
De type 3 : à fixation à billes 3 type : balls fixing

Type 1 Type 1
• Contrôler l’absence de colle sur • Check there is no dried glue on
la face de liaison du couvercle. the mating face of the valving
Eliminer toute trace de colle à l’aide cover. Scrape off all glue residues
d’une spatule. with a blade.

NE PAS TOILER LA FACE DE DO NOT FILE OR EMERY THE

LIAISON AFIN DE CONSERVER SA MATING SURFACE AS THE
RUGOSITE ORIGINALE. ORIGINAL SURFACE FINISH MUST
BE MAINTAINED

• Essuyer la face de liaison en • Wipe the mating face with a lint-

faisant des mouvements vers free moist rag, stroking the valving
l’extérieur à l’aide d’un chiffon hu- cover from the inside to the outside.
mide ne présentant pas de particu-
les détachables. 7152
• Dégraisser la face de liaison à • Degrease the mating face us-
l’aide d’alcool isopropylique. ing isopropyl alcohol.

• Contrôler l’absence de colle sur • Check there is no dried glue on

la face de liaison du corps de frein. the mating face of the brake hous-
Éliminer toute trace de colle à l’aide ing. Scrape off all glue residues of
d’une spatule. the brake housing.

NE PAS TOILER LA FACE DE DO NOT FILE OR EMERY THE

LIAISON AFIN DE CONSERVER SA MATING SURFACE AS THE
RUGOSITE ORIGINALE. ORIGINAL SURFACE FINISH MUST
BE MAINTAINED.

677777845L REPAR MS2-18 F/GB 15

5/20112 635
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Essuyer la face de liaison en • Wipe the mating face with a

faisant des mouvements vers moist lint-free rag, stroking the
l’extérieur à l’aide d’un chiffon hu- brake housing from the inside to the
mide ne présentant pas de particu- outside .
les détachables.
• Dégraisser la face de liaison à • Degrease the mating face us-
l’aide d’alcool isopropylique. ing isopropyl alcohol.

7154

LE DEGRAISSAGE TERMINE, LES

AFTER DEGREASING, DO NOT
MAINS ET LES DOIGTS DE
TOUCH THE MATING SURFACES
L’OPERATEUR DE DEVRONT
WITH HANDS NOR FINGERS.
PLUS ETRE EN CONTACT AVEC
LES FACES A ASSEMBLER.

• Déposer un film d’activateur • Using a clean brush apply a film

Loctite 7471 (voir tableau page 66) of Loctite 7471 activator (see table
à l’aide d’un pinceau propre sur la page 66) on the valving cover sur-
surface du couvercle qui doit être en face which should be in contact with
contact avec le corps de frein, et at- the brake housing, and wait 2 min-
tendre 2 minutes. utes.

NE PAS APPLIQUER D’ACTIVATEUR SUR DO NOT APPLY ANY ACTIVATOR ON

L’ARBRE. THE SHAFT.
7151

• Monter le joint torique neuf • Install the new O-ring (045), and
(045) et si le moteur est à 2 cylin- if motor with dual displacement, in- 045
drées, le joint (057) neuf. stall the new O-ring (057).

057
DO NOT TOUCH THE MATING
NE PAS TOUCHER LA SURFACE
SURFACE AFTER COATING IT
RECOUVERTE D’ACTIVATEUR.
WITH THE ACTIVATOR.

7155

• Déposer sur le corps de frein un • Place a continuous bead of

cordon continu d’adhésif LOCTITE LOCTITE 638 glue (see page 66)
638 (voir page 66) suivant la ligne on the brake housing following the
moyenne des centres de trous de median line of the mounting screw
passage des vis de fixation (voir hole centers (see drawing).
dessin).
• Veiller à raccorder les cordons • Make sure the bead of glue is
sans discontinuité. continuous (no gaps).

7156
NE JAMAIS DEPOSER
NEVER APPLY THE ACTIVATOR
D’ACTIVATEUR SUR LA FACE
ON THE SAME SURFACE AS THE
RECEVANT LE CORDON ADHE-
BEAD OF GLUE.
SIF.

16 REPAR MS2-18 F/GB 677777845L

636 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Ligne moyenne des centres de

Largeur du cordon : trous de passage des vis de fixa-
5 à 10 mm [0.2 to 0.4 in] tion
Width of bead : Median line of the mounting
5 à 10 mm [0.2 to 0.4 in] screws centerline.

Absence d'adhésif dans la gorge

No adhesive in the groove.

LES OPERATIONS SUIVANTES THE FOLLOWING STEPS MUST

DOIVENT ETRE EFFECTUEES AU BE ACHIEVED IN 10 MINUTES
MAXIMUM 10 MINUTES APRES MAXIMUM AFTER THE GLUE AP-
LE DEPOT DU CORDON. PLICATION.

Type 1 et 2 Type 1 et 2
• Présenter les pièces à assem- • Position the parts to be assem-
bler en montant quelques vis neu- bled by installing some new screws
ves (classe 12.9) (cl 12.9)

7157

• Monter et serrer toutes les vis • Install and tighten all new
neuves (102) au couple préconi- screws (102) to the required 057
sé.(voir page 69). torque.(see page 69)

7158

677777845L REPAR MS2-18 F/GB 17

5/20112 637
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Type 1 Type 1

LA LIAISON COLLEE DEMEURE FRAGILE DURANT UNE THE GLUED CONNECTION REMAINS FRAGILE SIX HOURS
PERIODE DE 6 HEURES APRES COLLAGE. AFTER BEING GLUED.

Durant cette période : During this time :

NE PAS CHOQUER les pièces collées, AVOID ANY SHOCK to the glued parts,
NE PAS UTILISER OU TESTER le frein ou le DO NOT USE OR TEST the brake nor the mo-
moteur. tor

Type 3 Type 3

• Monter les 6 billes (123) sur le • Install the 6 balls (123) on the " 3 !
% & ' ( ) ( * +,- ( . ,/ 011( .
couvercle (041). cover (041). ! " ##$ %& ' ( $ )* +

! # $

! " !
8155
" 2 !

• Monter un joint torique neuf • Install a new O-Ring (045) in the

(045) dans le couvercle (041). cover (041).

" 2 !

" 2 4

! ! "

18 REPAR MS2-18 F/GB 677777845L

638 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Assembler le corps de frein • Install the brake housing (101) •

(101) sur le couvercle (041) en pre- on the cover 041). Take care to
nant soin de présenter les loge- place the housings in front of the
ments en face des billes (123). balls (123).
• Monter et serrer toutes les vis • Install and tighten all the screws
(102) au couple préconisé. (102) to the required torque :

! " !

! " #

! # $
8157
" 2 4

677777845L REPAR MS2-18 F/GB 19

5/20112 639
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

REGLAGE DU FREIN. ADJUST THE BRAKE.

TOUTE TRACE DE ROUILLE, ALL TRACES OF RUST, MUD,

BOUE, EAU, COLLE, DOIT ETRE WATER OR GLUE, MUST BE RE-
SUPPRIME. MOVED.

• Monter le calage de compensa- • Install the torque reduction

tion de couple (115) suivant version shims (115) according to the ver-
(voir dessin 6736). sion (see drawing 6736).
• Huiler les disques neufs (utiliser • Oil the new discs (use hydraulic
du fluide hydraulique). fluid).

• Commencer par monter un dis- • Start by installing one external

que extérieur (103), puis un disque brake disc (103), then one internal
intérieur (104), puis alternativement brake disc (104), then alternately
(103) et (104). (103) et (104).
104
103
• Le dernier disque à monter est • The last brake disc must be an
un disque extérieur (103). external disc (103).

7159

! " $ ! " 2 ! " 2 ! " $

! " !
! " 5
! ! 4
! " :

! " 4

! " 9

! " 3
! ! "
! 2 #

! " #

! ! ! ;2 ! 2 !
! ! ! ;$
! ! ! ;!

! 2 $
6 ," 7!
" "
! ! !
5 3 $ 5

20 REPAR MS2-18 F/GB 677777845L

640 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

REP. ITEM DÉSIGNATION DESCRIPTION

101 Corps de frein Brake housing
102 Vis de fixation Mounting screw
103 Disque de frein extérieur External brake disc
104 Disque de frein intérieur Internal brake disc
105 Calage Shims
106 Joint de piston de frein Brake piston O-ring
107 Piston de frein Brake piston
108 Rondelle élastique Spring washer
109 Anneau d'arrêt Snap ring
115 Calage de compensation de couple Torque reduction shim
141 Chapeau de frein Brake cover
142 Bouchon Plug
143 Joint torique O-ring

• Enduire de graisse antioxydante • Coat the piston seal contact

(réf. AUTO-TOP 2000 origine AGIP surface in the brake housing with
ou Mobil XHP222) la portée du joint anti-oxidizing grease (ref. AGIP
de piston dans le corps de frein AUTO-TOP 2000 or Mobil XHP222).
(101).
• Monter un joint torique (106) • Install a new O-ring (106) on the
neuf sur le piston (107). piston (107). 107

Le joint doit être serré sur The ring should be tight

! le piston et non vrillé. ! on the piston and not
twisted.

106

7160

• Monter le piston de frein (107) • Install the brake piston (107) in

dans le corps de frein (101). the brake body (101). 107

Attention au passage du Be careful when pass-

! joint sur la gorge de l'an-
neau d'arrêt.
! ing the seal over the
snap ring groove.

101 7161

• Monter la rondelle élastique • Install the spring washer (108)

(108) sur le piston de frein (107). on the brake piston (107).
108

7162

677777845L REPAR MS2-18 F/GB 21

5/20112 641
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Appliquer l’effort F (voir tableau • Using a press or an extractor

ci-dessous) à l’aide de la presse ou (FACOM U20B) apply the compres-
avec l’extracteur (FACOM U20B) sive force F (see table here below) 109
pour monter l’anneau d’arrêt (109). to install the snap ring (109).

6505

• Alimenter le frein en pression • Supply the pressure to the

(voir tableau ci-dessous) et mesurer brake (see table here below) and
la course du piston à l’aide d’un measure the brake piston stroke us-
comparateur. ing a dial gauge.

7163

• Calculer alors la valeur pour le • Calculate the shimming (105)

calage (105) afin de respecter la value in order to respect the stroke
course C indiquée dans le tableau C indicated in the table here below.
ci-dessous.

TAILLE COURSE EFFORT F (N) NBRE DE DISQUES* PRESSION DE REGLAGE

SIZE STROKE FORCE F [LBF] NUMBER OF DISCS* SETTING PRESSURE
mm in N lbf 103 104 bar PSI
BRAKE WITH SINTERED DISCS
FREINS A DISQUES FRITTES

+0.32 +0.012
F02 MSE02 0.65 -0.14 0.025 -0.005 10 10
+0.32 +0.012
F04 MSE02 0.75 -0.14 0.029 -0.005 50000 11200 14 14 17 246
+0.32 +0.012
F02 MS02 0.65 0.025 11 10
-0.14 -0.005
+0.4 +0.016
F05 0.55 0.021 11 11 14 203
-0.3 -0.012
+0.4 +0.016
F05 0.55 0.021 70000 15700 11 11
-0.3 -0.012
+0.4 +0.016
F07 0.8 0.031 15 15
-0.3 -0.012
+0.32 +0.016 17 246
F11 0.65 0.025 10 10
-0.25 -0.012
+0.35 +0.016 100000 22500
F18 1 0.039 17 17
-0.25 -0.012

F03 095 +0.32 0.037 +0.012 50000 1124 21 19

NI-
FREINS A DISQUES

-0.14 -0.005
+0.45 +0.018
F04 0.87 0.034 70000 1573 19 18
NITRURES

WITH

-0.25 -0.01
TRIDED DISCS

+0.4 +0.016 17 246

F09 0.85 0.033 90000 2023 19 18
-0.3 -0.012
+0.42 +0.017
BRAKE

F12 0.90 0.035 20 19

-0.3 -0.012
+0.35 +0.014
100000 2250
F19 1.4 -0.25
0.055 -0.01
33 32

*Dans certains cas, on peut réparer un frein équipé d'ori- *In certain cases it's possible to repair a brake system
gine en disques frittés avec des disques nitrurés. Pour equipped with genuine sintered discs with nitrided discs.
connaître l'ordre spécifique du montage des disques, pren- To know the specific order of brake discs mounting,
dre contact avec les services techniques de POCLAIN contact POCLAIN HYDRAULICS technical depart-
HYDRAULICS. ments.
22 REPAR MS2-18 F/GB 677777845L

642 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Appliquer à nouveau l’effort F • Reapply the compressive force

pour dégager l’anneau d’arrêt (109). F to remove the snap ring (109).

109

6505

• Démonter la rondelle élastique • Remove the spring washer

(108). (108).

108

6508

• Démonter le piston de frein • Remove the brake piston (107).

(107).
107

6509

• Installer le calage nécessaire • Install the proper shimming

(105) sur le dernier disque de frein, (105) on the last disc, the thickest 105
la cale la plus épaisse côté piston shim towards the brake piston.
de frein.

MINIMIZE THE NUMBER OF

MINIMISER LE NOMBRE DE CA-
SHIMS OF THICKNESS 0.2 mm
LES D’EPAISSEUR 0.2 mm
[0.0079 inch]
7164

• Remonter le piston de frein • Reinstall the brake piston (107),

(107), la rondelle élastique (108). the spring washer (108). 108

108

7162

677777845L REPAR MS2-18 F/GB 23

5/20112 643
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Appliquer l’effort F pour monter • Apply the compressive force F

l’anneau d’arrêt (109) et relâcher to install the snap ring (109) and re-
l’effort. lease the compressive force.
109

6505

• Alimenter à nouveau le frein en • Supply the pressure to the

pression pour vérifier la course du brake piston again to check the pis-
piston de frein. ton stroke.

7163

• Monter un joint torique neuf • Install a new O-ring (143) 143

(143) enduit de graisse anti- coated with antioxidizing grease
oxydante (voir outillage page 66) (see tool page 66 ) in its groove.
dans sa gorge.

6515

• Placer la coiffe neuve (141) sur • Install a new cover (141) on the
le chanfrein d’entrée. entry chamfer. 109

6516

• L’encliqueter à l’aide du man- • Click it into place using the cor-

drin correspondant (voir outillage responding mandrel (see tools page
page 66). 66).

S’ASSURER QUE LE BORD EX- MAKE SURE THAT THE OUTER

TERIEUR DE LA COIFFE EST EN EDGE OF THE BRAKE COVER IS
PRISE DANS SA GORGE. ENGAGED IN THE GROOVE

6517

24 REPAR MS2-18 F/GB 677777845L

644 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter un bouchon neuf (142). • Install a new plug (142).

142

6518

• Reposer le moteur. • Install the motor.

ATTENDRE SIX HEURES APRES

WAIT SIX HOURS AFTER GLUING
LE COLLAGE AVANT DE SOLLICI-
BEFORE USING THE BRAKE OR
TER LE FREIN OU D’UTILISER
ENGAGING THE POWER FUNC-
LES FONCTIONS DE PUISSANCE
TIONS OF THE MOTOR
DU MOTEUR.

• Vérifier l’efficacité du frein. • Check brake effectiveness.

677777845L REPAR MS2-18 F/GB 25

5/20112 645
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

5767

8144

" 3 9
Etanchéité TYPE 1 : " 3 9 Etanchéité TYPE 2 : Etanchéité TYPE 3 :
Bague d’étanchéité Bague d’étanchéité joint glace
faciale à lèvre radiale à lèvre Sealing TYPE 3:
Sealing TYPE 1: Sealing TYPE 2: Mechanical seal
Facial lip seal $ ! 4 :
Radial lip seal " 9 4 $ ! 3170
3 "
" 3 : $ ! 5 "

26 REPAR MS2-18 F/GB 677777845L

646 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Réparation du palier (070) Bearing support (070) repair

(Type 1, 2 et 3, sauf moteur MS02 (Type 1, 2 et 3, except MS02 motor
avec palier "1340".et palier DYNA with1340 DYNA+ bearing support)
+)
Démontage Disassembly

• Déposer le moteur. • Remove the motor.

• Disposer le moteur en appui sur • Place the motor on the brake or
le frein ou sur la plaque de fermeture on the end cover (motor without
(moteur sans frein) brake)

6519

• Repérer la position de la came • Mark the position of the cam 070

(026) par rapport au couvercle dis- (026) in relation to the valving cover
tributeur (040). (040).
025

040

6519

• Démonter les vis (042). • Remove the screws (042).

042

6520

• Démonter le palier (070), en uti- • Remove the bearing support

lisant un palan. (070), using a lifting tackle.
070

6521

677777845L REPAR MS2-18 F/GB 27

5/20112 647
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Déposer la came (026). • Remove the cam (026).

026

6524

• Eliminer le joint torique (027) du • Discard the O-ring (027) from the
couvercle (041). valving cover (041). 027

041

6525

• Eliminer le joint torique (027) du • Discard the O-ring (027) from the
support palier (071). bearing support (071) 027

071

6522

• Installer le palier posé sur • Position the bearing support

l’arbre (090) sous une presse ou sur placed on the shaft (090) under a
un support pour éviter tout effort sur press or on a support to avoid any
les goujons. force on the studs.
090

7925

• Comprimer les roulements à • Compress the roller bearings us-

l’aide d’un mandrin, Effort F (voir ta- ing a mandrel, force F (see table
bleau page 72), puis démonter page 72), then remove the snap ring
l’anneau d’arrêt (077) à l’aide d’une (077) using external snap ring pliers 077
pince à anneaux d’arrêt extérieurs (see tools page 66).
(voir outillage page 66).

6838

28 REPAR MS2-18 F/GB 677777845L

648 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Relâcher l’effort F de la presse, • Release the press force F and

puis enlever le mandrin. remove the mandrel.
• Démonter la bague d’appui • Remove the thrust ring (076) 075
(076) et les cales de réglage (075) and the shims (075)

REPERER L’ORDRE DE MON- MARK THE MOUNTING ORDER OF

! TAGE DES CALES (075)
! THE SHIMS (075)

6844
6839

• Fixer sur le support palier la • Fix a right contact plate on the

plaque d’appui correspondante. bearing support.

6840

• Positionner la plaque d’appui • Position the contact plate on the

sur des supports sous la presse. supports under the press.

DISPOSER SOUS LE PALIER UN PLACE UNDER THE BEARING

MATERIAU SOUPLE (BOIS) POUR SUPPORT A PLIANT MATERIAL
! AMORTIR LA CHUTE DE L’ARBRE ! (WOOD)TO ABSORB THE SHAFT
DOWNFALL
6841

• Chasser l’arbre (090) • Press out the shaft (090)

CHAUFFER LEGEREMENT LA IF NECESSARY, HEAT SLIGHTLY

BAGUE INTERIEURE DU ROULE- THE INNER RING OF THE
MENT SI NECESSAIRE. LE ROU-
! LEMENT SERA DETRUIT PEN- ! ROLLER BEARING. THE BEAR-
ING WILL BE DESTROYED BY
DANT CETTE OPERATION THIS OPERATION
6842
PAR MESURE DE SECURITE, SE AS A SAFETY MEASURE, STAY
TENIR ELOIGNE DU MONTAGE APART FROM THE ASSEMBLY
! PENDANT
L’ARBRE
LA DESCENTE DE
! DURING THE SHAFT FALLING
DOWN

Dans le cas de TYPE 3: If TYPE 3 :

• Extraire la partie (078.2) du joint • Using a flat screwdriver remove
glace (côté support-palier) à l’aide the part (078.2) of the mechanical
d’un tournevis plat. seal (on the bearing support side).

7873
" 3 9 ;#
Pour tous types For all types :

• Démonter la bague intérieure du • Remove the internal bearing

roulement (074.1) cage (074.1)

6843

677777845L REPAR MS2-18 F/GB 29

5/20112 649
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Extraire la bague extérieure du • Extract the bearing outer race

roulement (074.2). Utiliser un ex- (074.2) using a two legs extractor
tracteur à deux branches à prise ex- (see tools page 66) and a cutting
térieure (voir outillage page 66) et tool lying flat to have a central sup-
074.2
un burin posé à plat pour obtenir un port point for the extractor.
point d’appui centrale. Finir Finish extracting the race using a
d’extraire la bague à l’aide d’un jet casing and a hammer.
et d’un marteau. 6844

Pour tous types sauf TYPE 3 : All types except TYPE 3 :

• Chasser l’ensemble d’étanchéité • Press out the sealing assembly
(072). (072). 072

ATTENTION DE NE PAS ENDOM-

BE CAREFUL NOT TO DAMAGE

! MAGER LE LOGEMENT DE LA
BAGUE ETANCHE. ! THE SEAL’S HOUSING

6846

• Eliminer l’ensemble d’étanchéité • Discard the sealing assembly

(072). (072). 072

6847

• Extraire la bague extérieure du • Extract the bearing outer race

roulement (073) (voir outillage page (073) (see tools page 66).
073
66). Finish extracting the race using a
Finir d’extraire la bague à l’aide d’un casing and a hammer.
jet et d’un marteau

6845

Dans le cas du TYPE 3 : If TYPE 3 :

• Extraire la partie (078.1) du joint • Remove the part (078.1) of the
glace à l’aide d’un tournevis plat. mechanical seal using a flat screw-
driver.

" 3 9 ;!
5767

Pour tous types : For all types :

• Détruire cage à rouleaux du • Destroy the bearing cage (073)
roulement (073) à l’aide d’un burin using a cutting tool by sectioning it
073
en la sectionnant en quatre points in four points above the rollers.
au-dessus des rouleaux.

DO NOT DAMAGE THE SEAL

NE PAS ENDOMMAGER LA POR-

! TEE DE JOINT SUR L’ARBRE

! CONTACT SURFACE ON THE
SHAFT
6848

NE JAMAIS TRONÇONNER DANS NEVER TRUNCATE IN THE

L’ATELIER POUR EVITER TOUTE
! POLLUTION ! WORKSHOP TO PREVENT POL-
LUTION

30 REPAR MS2-18 F/GB 677777845L

650 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Ecarter la cage avec un tournevis et • Separate the cage using a

éliminer cage et rouleaux. screwdriver then discard the 078
cage and the rollers.
Pour tous types sauf TYPE 3 All types except TYPE 3 :
• Palier équipé de la bague • If bearing support fitted with
d’étanchéité type 1 (078). Découper type 1 seal (078), cut it using a cut-
celle-ci à l’aide d’un burin. L’extraire ting tool. Extract it using a flat 6849
avec un tournevis plat. screwdriver.
• Palier équipé de la bague • If bearing support fitted with
d’étanchéité type 2 (078). Ecraser type 2 seal (078), use a flat chisel.
celle-ci à l’aide d’un burin plat.

Pour tous types : All types :

• Extraire la bague intérieure du • Extract the bearing inner race 074
roulement (074) (voir outillage). (074) (see tools).

CHAUFFER LEGEREMENT SI NE-

IF NECESSARY HEAT SLIGHTLY.
CESSAIRE : LA BAGUE
THE LIP SEAL (078) WILL BE
! D’ETANCHEITE (078) SERA DE-
TRUITE PAR CETTE OPERATION
! DESTROYED BY THIS OPERATION
6850

Pour TYPE 1 : TYPE 1:

• Extraire le déflecteur (079) à • Extract the deflector (079) with
l’aide d’un tournevis plat. a flat screwdriver. 079

6851

677777845L REPAR MS2-18 F/GB 31

5/20112 651
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage. Reassembly
(TYPE 1 ou 2) (TYPE 1 or 2)

• Contrôler la portée de la bague • Check the lip seal (072) contact

d’étanchéité (072) sur l’arbre (090) surface on the shaft (090), the
l’état des cannelures, la portée de la splines conditions, the lip seal (078)
bague (078) sur le palier (071). contact surface on the bearing sup-
port (071)
• Monter la bague d’étanchéité • Install the lip seal (072) in the
(072) dans le support palier à l’aide bearing support using the right
du mandrin correspondant voir outil- mandrel – see tools.
lage.
ENLEVER LE RESSORT POUR
TAKE OFF THE SPRING TO POSI-
! POSITIONNER LA BAGUE ETAN-
CHE (072) ! TION THE LIP SEAL (072)

• S'assurer visuellement que la • Check visually that the lip seal

bague soit bien en place au fond de is properly placed in the bottom of 7878
son logement. its groove
• Monter la bague extérieure du • Install the bearing outer race
roulement (074) dans le corps du (074) in the bearing support housing
support palier en la mettant en bu- up to the stop (see tools page 66)
tée. (voir outillage page 66).
• Contrôler visuellement la bonne • Check visually the right position
position de la bague dans son lo- of the race in its groove.
gement.

7836

• Retourner le support palier et • Return the bearing support and

l’équiper de la bague extérieure du install the bearing outer race (073)
109
roulement (073) en la mettant en up to the stop (see tools page 66)
butée (voir outillage page 66).

NE PAS OUBLIER DE REMONTER

DO NOT FORGET TO INSTALL
! LE RESSORT
D’ETANCHEITE.
DE LA BAGUE
! THE LIP SEAL SPRING.

• Contrôler visuellement la bonne • Check visually the right position 7837

position de la bague dans son lo- of the race in its groove.
gement.
• Enduire de graisse (LG EP2) la • Coat with grease (LG EP2) the
bague extérieure du roulement bearing external race (073). 073
(073)

7832

32 REPAR MS2-18 F/GB 677777845L

652 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the
lèvres de la bague d’étanchéité lips of the lip seal (072).
(072).

072

7933

• Enduire de graisse (LG EP2) le • Coat with grease (LG EP2) the
roulement (073). bearing (073).

073

7931

• Monter le roulement (073) (voir Install the bearing (073) (see tools
outillage page 65) dans sa bague page 65) inside its external race.
extérieure.

073
7930

677777845L REPAR MS2-18 F/GB 33

5/20112 653
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

MONTAGE TYPE 1 : TYPE 1 ASSEMBLY:

• Monter la bague (078) à l’aide • Install the seal (078) using a tef-
d’une plaque de téflon de diamètre lon plate with upper diameter and a
supérieur et d’un maillet jusqu’au mallet up to the contact of the plate
contact de la plaque sur le support with the bearing support, then finish
palier et finir le montage à la main. the assembly manually.

7875

• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the 078
lèvres de la bague type 1. (078) lips of the type 1 seal.(078)

7927

• Monter le déflecteur (079) sur • Install the deflector (079) on the

l’arbre (090). shaft (090) 079 090

7877

MONTAGE TYPE 1 : TYPE 1 ASSEMBLY :

(1) <! =
• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the
lèvres (1) de la bague type 2 (078). lips (1) of the type 2 seal (078).

3 9 3 #

• Monter manuellement la bague • Install manually the type 2 seal " 3 9

type 2 (078) dans le support palier (078) into the bearing support up to
et mettre en butée sur le roulement the stop on the bearing (074)
(074).

ATTENTION AU SENS DE MON- BE CAREFUL ABOUT THE TYPE 2

(078)
! TAGE
2.(078)
DE LA BAGUE TYPE
! SEAL
TION.
MOUNTING DIREC-

LES LEVRES NE DOIVENT PAS SE THE LIPS SHOULD NOT TURN IN-

! RETOURNER VERS L’INTERIEUR.

! SIDE. $ ! 3159
4 :

34 REPAR MS2-18 F/GB 677777845L

654 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

DANS TOUT LES CAS : ALL CASES :

• Sous une presse, poser l’arbre • Under press, place the shaft on
sur un support pour éviter tout effort a support to avoid any force on the
sur les goujons. studs.

7840

• Positionner le support palier sur • Install the bearing support on

l’arbre the shaft

ATTENTION AU PASSAGE DES TAKE CARE WHEN PASSING THE

! CANNELURES SUR LA BAGUE

D’ETANCHEITE (072). ! SPLINES THROUGH THE LIP SEAL
(072).

7843

• Positionner le roulement (074) • Install the bearing (074) in its

dans sa bague extérieure. outer race
074

7844

• Appliquer l’effort F (voir tableau • Using the right mandrel (see

page 69) sur le roulement (074) à tools page 65) press with F force
090
l’aide du mandrin correspondant (see table page 69) on the bearing
(voir outillage page 65). (074)

7845

• Relâcher l’effort F (voir tableau • Release the F force (see table

page 69) jusqu'à obtenir page 69) up to 20 000 N [4500 Ibf]
20 000 N.[4500 lbf].et s’assurer de and check the bearings position by
la mise en place des roulements par turning the bearing support (mini-
la rotation du palier (5 tours mini à mum 5 rev. to the right and left)
droite et à gauche) • Using a mandrel press again
• Appliquer à nouveau l’effort F with F force (see table page 69) on
(voir tableau page 69) sur le roule- the bearing (074)
ment (074) à l’aide d’un mandrin.
7846

677777845L REPAR MS2-18 F/GB 35

5/20112 655
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Relâcher l'effort F, et monter la • Release the F force, and install

bague d’appui (076) the thrust ring (076)
076

7847

• Monter l’anneau d’arrêt (077) en • Remove the snap ring (077) us-
utilisant une pince à anneaux d’arrêt ing external snap ring pliers 077
extérieurs

7848

• Appliquer l’effort F (voir tableau • Apply the F force (see table

page 69) sur le roulement (074), page 69) on the bearing (074), then
puis mesurer le jeu entre la bague measure the clearance between the
d’appui (076) et l’anneau d’arrêt thrust ring (076) and the snap ring
(077). (077).
• Déterminer le calage (075) afin • Determine the shimming (075)
d'obtenir le couple de rotation (C) in order to obtain the rotational
correspondant (voir tableau page torque (C) (see table page 69) (Ap-
69). (valeur approximative du ca- proximate shimming value = meas-
lage = mesure + S) ure + S). 7849

• Relâcher l’effort F. Démonter • Stop the F force. Remove the

l’anneau d’arrêt (077) et la bague snap ring (077) and the thrust ring
(076). (076).
• Monter le calage (075) • Install the shimming (075)

LA CALE LA PLUS EPAISSE DOIT THE THICKEST SHIM SHOULD BE

! ETRE
MENT
MONTEE COTE ROULE-
! MOUNTED TOWARDS THE BEAR-
ING

• Remonter la bague (076). • Install the thrust ring (076). 7850

• Monter l’anneau d’arrêt (077) • Install the snap ring (077) (the
(l'angle vif opposé à la bague d'ap- sharp corner opposite to the thrust
pui (076)) en utilisant l’effort F initial ring (076) using the initial F force
(voir tableau page 69) (see table page 69).
S’ASSURER : CHECK : 074 075 076 077
• De l'impossibilité de tourner la • that it is not possible to turn the
bague (076) d’appui manuellement. thrust ring (076) manually
• Visuellement que le diamètre de • visually that the snap ring (077)
l’anneau d’arrêt (077) n'est pas plus diameter is not larger then the thrust
grand que celui de la bague d’appui ring (076) diameter.
(076).

2050

36 REPAR MS2-18 F/GB 677777845L

656 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

ETANCHEITE RENFORCEE REINFORCED SEALING

• Equiper le support de la bague • Install the lip seal on its support

d'étanchéité à l'aide du mandrin using the right mandrel (see tools
correspondant (voir outillage page page 66)
66).

ENLEVER LE RESSORT POUR

TAKE OFF THE SPRING TO POSI-

! POSITIONNER LA BAGUE ETAN-

CHE (072) ! TION THE LIP SEAL (072) 7880

• Contrôler visuellement la bonne • Check visually the right position

position de la bague d'étanchéité. of the lip seal.

7881

• Appliquer un cordon de Loctite • Coat with Loctite 542 (see tools

542 (voir outillage page 63) sur le page 63) the external diameter of
diamètre extérieur du support équi- the lip seal support assembly.
pé de la bague d'étanchéité.

7882

• Monter le support équipé à • Using a mandrel (see tools

l'aide du mandrin (voir outillage page 66) install the lip seal support
page 66) dans le support palier. assembly into the bearing support.

7878

• Contrôler visuellement la bonne • Check visually the right position

position du support équipé dans le of the lip seal support assembly in
support palier the bearing support

NE PAS OUBLIER D'ESSUYER DO NOT FORGET TO CLEAN THE

! L'EXCEDENT DE LOCTITE.
! LOCTITE EXCESS

7885

677777845L REPAR MS2-18 F/GB 37

5/20112 657
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Remonter le ressort de la bague • Reinstall the lip seal spring.

d'étanchéité.

7886

• Appliquer un cordon de loctite • Coat with Loctite 542 (see tools

542 (voir outillage page 63) sur le page 63) the back-up ring support.
support de contre-joint.

7887

• Monter le support de contre- • Using a mandrel (see tools

joint à l'aide du mandrin (voir outil- page 66) install the back-up ring
lage 66) support

ATTENTION AU SENS DE MON- BE CAREFUL ABOUT THE

! TAGE.
! MOUNTING DIRECTION.

• Essuyer l'excédent de Loctite. • Clean the Loctite excess.

7884

• Monter le joint torique. • Install the O-ring.

7888

• Monter le contre-joint. • Install the back-up ring.

7889

38 REPAR MS2-18 F/GB 677777845L

658 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage (TYPE 3) Reassembly (TYPE 3)

• Contrôler les portées de joint et • Check the lip seal contact sur-
l’état des cannelures. face and the splines conditions.

SHAFT PART EXCEPT IF THERE

ARBRE NU SAUF SI DEFLECTEUR
IS A DEFLECTOR WITH TYPE 1
! AVEC UNE BAGUE TYPE 1
! SEAL

7830

• Monter les éléments de la partie • Install the first component of the

er
(78.1) du joint glace. Ici 1 élé- mechanical seal part (78.1) 090
ment.

7831

ème
• Ici 2 élément. • Install the second component

7833

• Vérifier le positionnement du • Check visually at four points the

joint (085) visuellement en quatre seal’s positioning (085).
points.

7834

• Positionner la bague intérieure • Install the bearing inner race 073

du roulement (073) sur l’arbre (073) on the shaft

7835

677777845L REPAR MS2-18 F/GB 39

5/20112 659
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter la bague extérieure du • Install the bearing outer race

roulement (074) dans le corps du (074) into the bearing support hous-
support palier, en la mettant en bu- ing up to the stop. (see tools page
tée.(voir outillage page 66) 66)

7836

• Retourner le support palier et • Turn the bearing support and

monter la bague extérieure du rou- install the bearing outer race (073) 073
lement (073) en la mettant en butée. up to stop.

7837

• Positionner la partie (78.2) du • Place the mechanical seal part

joint glace sur l’outil (voir outillage (78.2) on the tool (see tools page 078.2
page 66). 66)

7838

• Monter le joint glace sur le pa- • Install the mechanical seal on

lier. the bearing support.
• Vérifier que le joint soit bien po- • Check visually at four points the
sitionné visuellement en quatre seal’s positioning.
points.

7839

• Poser l’arbre sur un support • Place the shaft on a support to

pour éviter tout effort sur les gou- avoid any force on the studs
jons

S’ASSURER QU’IL N’Y AIT AU- MAKE SURE THERE ARE NO IM-

! CUNE IMPURETE SUR LES DEUX

PARTIES DU JOINT GLACE ! PURITIES ON THE TWO PARTS OF
THE MECHANICAL SEALS

7840

40 REPAR MS2-18 F/GB 677777845L

660 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Huiler une des portées du joint • Lubricate one of the sealing sur-
glace. faces

7841

• Appliquer un film huile sur le • Apply an oil film on the seal

joint.

PROCEDER AVEC PRECAUTION, BE CAREFUL NOT TO CUT

! RISQUE DE COUPURE.
! YOURSELF

7842

• Positionner le support palier sur • Position the bearing support on

l’arbre the shaft

7843

• Positionner le roulement (074). • Position the bearing (074)

074

7844

• Puis suivre les instructions dé- • Then follow the mounting in-
crites de la page 35 à la page 36 structions on pages 35 - 36 about
concernant le calage du palier. the bearing support shimming.

677777845L REPAR MS2-18 F/GB 41

5/20112 661
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage du palier sur le moteur. Reassembling of the bearing

support on the motor.

Avant le remontage, il est impératif de Before reassembling it is necessary

s'assurer de la propreté de la gorge. to ensure that the groove is clean

Toute trace de rouille,

All traces of rust, mud,
! boue, eau doit être sup-
primée.
! water must be removed

• Monter un joint torique neuf • Install a new O-ring (027) coated 027
(027) enduit de graisse anti- with anti-oxidizing grease (see tools
oxydante (voir outillage page 66) page 66) in the groove of the bear-
dans la gorge du support palier ing support (071).
(071).

071

6523

• Monter un joint torique neuf • Install a new O-ring (027) coated

(027) enduit de graisse anti- with anti-oxidizing grease (see tools
oxydante (voir outillage page 66) page 66) in the groove of the valv-
dans la gorge du couvercle (041). ing cover (041).

041

6525

• Monter la came (026) sur le cou- • Install the cam (026) on the valv-
vercle, suivant les repères établis ing cover, in line with the marks 026
au démontage. made during disassembly.

The big chamfers ori-

Gros chanfreins orientés
! côté palier ! ented towards bearing
support

• Centrer la came à l'aide de deux • Center the cam using two 6526
vis (042) diamétralement opposées. screws (042) diametrically opposite.

42 REPAR MS2-18 F/GB 677777845L

662 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter le palier en utilisant un • Install the bearing support, using

palan. a lifting tackle.

Pour les moteurs paliers For shaft motors the

les orifices doivent être ports must be perpen-
! perpendiculaires à l'axe
de fixation du moteur. (Fig
! dicular to the mounting
axis of the motor. (Fig
6527) 6527)
6521

>

>

6527

• Monter et serrer les vis de fixa- • Install and tighten the mounting
tions (042) au couple indiqué. (voir screws (042) to the right torque.
tableau page 71). (see table page 71).

042

6520

• Reposer le moteur. • Install the motor.

677777845L REPAR MS2-18 F/GB 43

5/20112 663
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement du palier Replacement of the DYNA +

DYNA + bearing support.
Démontage. Disassembly.

Les étapes suivantes sont impé- The following steps are manda-
ratives si le joint (045) fuit sinon tory if there are leaks on the seal
commencer le démontage des vis (045) level, if not start removing
(042) page 45 the screws (042) page 45
• Disposer le moteur en appui sur • Place the motor on the bearing
le palier et desserrer les vis (066). support and unscrew the screws 066
(066).

7666

• Démonter les vis (066) puis la • Remove the screws (066) and 065
plaque de fermeture (065). the end cover (065).

7667

• Démonter le tiroir (053) • Remove the valve spool (053).

053

7668

• Éliminer le joint torique (057). • Discard the O-ring (057).

090

7669

44 REPAR MS2-18 F/GB 677777845L

664 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Éliminer le joint torique (045). • Discard the O-ring (045).

045

7670

• Desserrer les vis (042). • Unscrew the screws (042).

042

7671

• Démonter le couvercle (040) • Remove the valving cover (040)

équipé de la glace. equipped with the valving.

Repérer la position de la Mark the location of the

! glace (047) par rapport au
couvercle (041). ! valving (047) in relation to
the valving cover (041).

6758

• Démonter la came (025). • Remove the cam (025). 025

7672

• Démonter le bloc cylindre équi- • Remove the cylinders block

pé (010). assembly (010). 010

7673

677777845L REPAR MS2-18 F/GB 45

5/20112 665
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Éliminer le joint torique (027). • Discard the O-ring (027).

027

7674

46 REPAR MS2-18 F/GB 677777845L

666 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage. Reassembly.

• Avant le remontage, il est impé- Before reassembling it is necessary

ratif de s'assurer de la propreté de to ensure that the groove is clean
la gorge.

Toute trace de rouille, All traces of rust, mud,

! boue, eau doit être sup-
primée.
! water must be removed

• Monter un joint torique (027) • Install a new O-ring (027) in the

neuf dans la gorge du support palier groove of the bearing support (071).
(071).

Monter le joint sans Install the O-ring without

! l’enduire de graisse. ! greasing it.

7674

Les 2 étapes suivantes ne sont The 2 following steps are not 027
pas nécessaires si la plaque de necessary if the end cover (065)
fermeture (065) n’a pas été dé- was not removed.
montée.
• Install a new O-ring (027)
• Monter un joint torique neuf coated with anti-oxidizing grease
(027) enduit de graisse anti- (see tools page 66) in the groove of
oxydante (voir outillage page 66) the valving cover (041).
dans la gorge du couvercle (041).
7670

• Monter un joint torique neuf • Install a new O-ring (057) 090

(057) enduit de graisse anti- coated with anti-oxidizing grease
oxydante (voir outillage page 66) (see tools page 66) in the groove of
dans la gorge du tiroir (053). the valve spool (053).

7669

• Monter le bloc cylindre équipé • Install the cylinders-block as-

010
(010). sembly (010).

7673

677777845L REPAR MS2-18 F/GB 47

5/20112 667
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter la came (025). • Install the cam (025).

Gros chanfreins orientés The big chamfers ori-

! côté palier ! ented towards bearing
support 025

7672

• Huiler avec du fluide hydrauli- • Lubricate with hydraulic fluid the

que le dessus du bloc-cylindres. top of the cylinder-block.

7675

• Monter le couvercle équipé sur • Install the valving cover assem-

l'ensemble. Utiliser les 2 piges de bly on the unit. Use 2 positioning
positionnement. pins.

7676

• Monter et serrer au couple les • Install and tighten the screws

vis (042). (042). 042
Puis retirer les piges de positionne- Then remove the positioning pins.
ment.

7671

Les 3 étapes suivantes ne sont The 3 following steps are not

pas nécessaires si la plaque de necessary if the end cover was 053
fermeture n’a pas été démontée. not removed.

• Monter le tiroir (053). • Install the valve spool (053).

7668

48 REPAR MS2-18 F/GB 677777845L

668 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter la plaque de fermeture • Install the end cover (065).

(065). 065

7667

• Monter et serrer au couple les • Install and tighten the screws

vis (066).(voir tableau page 69) (066).(see table page 69) 066

7666

677777845L REPAR MS2-18 F/GB 49

5/20112 669
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement des mâchoi- Replacing the brake shoes.

res de frein

Avant démontage il est possible de Before disassembling it is possible

contrôler visuellement l'usure des to make a visual checking of the
garnitures de frein par les trous de brake pads wear via the inspection
visite. ports.

2055

Démontage Disassembly

Le remplacement des mâ- The same repairs should

choires et des tambours be made on each motor of
! doit être effectué sur cha-
que moteur d'un même
! the same axle when re-
placing shoes and brake
essieu drums.

• Débloquer les écrous de fixation • Loosen the wheel rim retaining

de la jante. nuts.
• Lever l'engin à proximité de la • Raise the machine on the side of
jante à déposer. the wheel rim to be removed.
• Déposer la jante (pneu). • Remove the wheel rim (tyre).
• Desserrer le frein mécanique. • Release the mechanical brake.

• Extraire le tambour (096) • Extract the drum (096).

Contrôler l'état de la sur- Check the friction sur-

face de frottement du face condition of the
tambour qui ne doit com- drum which should
porter aucune rayure pro- show no deep scratches
! fonde (0,2 mm maxi) ni
d'usure anormale sinon
! (deeper than 0,2 mm
[0.0078 in]) nor abnormal
096

procéder à son rempla- wear. Otherwise, the

brake drum should be 6528
cement. (Ra 1,6 à 3,2)
replaced. (Ra 1.6 to 3.2)

50 REPAR MS2-18 F/GB 677777845L

670 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Démonter le ressort de rappel • Remove the return spring

(154.a). (154.a).

154.a
6529

6530

• Démonter les ressorts de main- • Remove the retention springs

tien (154.b). (154.b). 1

154.b
2
6531

• Libérer les mâchoires du méca- • Release the brake shoes from

nisme de réglage . the regulating mechanism.

6532

• Démonter les ressorts de rappel • Remove the return springs

(154.c). (154.c).

154.c

6533

677777845L REPAR MS2-18 F/GB 51

5/20112 671
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Déposer la mâchoire (154.1) • Remove the brake shoe (154.1)

154.1
6534

• Déposer la mâchoire (154.2) en • Releasing the mechanical brake

libérant le levier de freinage méca- control lever from its cable, remove
nique de son câble. the brake shoe (154.2)
154.2

6535

6536

52 REPAR MS2-18 F/GB 677777845L

672 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage Reassembly

Dépoussiérer l'ensem- Remove all dust from the

ble, s'assurer de l'étan- whole assembly. Make
! chéité du cylindre de ! sure there are no leaks at
the wheel cylinder.
roue.

Contrôler l'état de la surface de frot- Check the friction surface condition

tement du tambour qui ne doit com- of the drum which should show no
porter aucune rayure profonde (su- deep scratches (deeper than 0.2 6549
périeure à 0.2 mm) ni d'usure mm) [0.0078in] nor abnormal wear.
anormale sinon procéder à son Otherwise, the brake drum should
remplacement. be replaced.

• Monter la mâchoire (154.2), en • Attaching the control lever on

accrochant le levier de commande the brake cable (098), install the
sur le câble de frein (098). brake shoe (154.2)
098

154.2

6536

6535

677777845L REPAR MS2-18 F/GB 53

5/20112 673
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Monter la plaque de renvoi sur • Mount the return plate on the

la mâchoire (154.2) brake shoe (154.2)

6537

6538

• Monter la mâchoire (154.1) • Install the brake shoe (154.1)

154.1

6539

• Positionner les mâchoires sur le • Position the brake shoes on the

mécanisme de réglage. regulating mechanism.

6532

• Monter les ressorts de rappel • Install the return springs (154.c)

(154.c)

154.c

6533

54 REPAR MS2-18 F/GB 677777845L

674 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Mettre en place les mâchoires • Install the brake shoes in the

dans le mécanisme de réglage regulating mechanism

6532

• Monter les ressorts de maintien • Install the retention springs

(154.b) (154.b)
1

154.b
2 6531

• Monter le ressort de rappel • Install the return spring (154.a)

(154.a)

154.a
6530

• Mesurer le diamètre D de frot- • Measure the brake drum friction

tement du tambour puis celui des diameter D and that of the brake
mâchoires en place shoes, which have been installed.

Diamètre D diameter
6529

677777845L REPAR MS2-18 F/GB 55

5/20112 675
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

• Ajuster le diamètre des mâchoi- • Adjust the brake shoes diame-

res pour obtenir le jeu entre garni- ter to obtain correct clearance be- " . 6 -7
ture et tambour à l'aide de la roue tween the brake padding and the
dentée (156.1) pour les freins équi- " . 6 -8 " . 6 -'
drum using the adjusting wheel
pés d'un dispositif de réglage mé- (156.1) for brakes equipped with
canique ou des deux roues dentées mechanical adjustment system or
(156.2 et 156.3) pour les freins two adjusting wheels (156.2 and
équipés d'un dispositif de rattrapage 156.3) for brakes equipped with + +
de jeu automatique. Dans ce cas, automatic clearance adjustment. In
l'action sur les roues dentées doit this case, the adjusting wheels 6540
être symétrique (a). Dégager légè- should be adjusted symmetrically
rement le levier (156.4) pour per- (a). Release the lever slightly
mettre cette opération. (156.4) to enable this operation to
take place.

Diamètre tambour (mm)

Drum diameter [in] Jeu total (mm)
Freins Brake
Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70] 0.80 [0.03]
325 x 80 325 [12.79] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]

• Monter le tambour, contrôler sa • Install the drum, check that it

libre rotation. can turn freely.

6528

• Purger le cylindre de roue si né- • Bleed the wheel cylinder, if nec-

cessaire. essary.
• Remonter la jante. • Install the wheel rim.
Voir brochure INSTALLATION • See brochure INSTALLATION
MS F/GB (ref. 677777844K) MS F/GB (ref 677777844K)

56 REPAR MS2-18 F/GB 677777845L

676 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement de la came Replacement of the cam

(026) (026)

Démontage Disassembly

Effectuer les opérations décrites à Do operations described in chapter

la rubrique "démontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 27 port" section "disassembly" page 27

Remontage Reassembly

Effectuer les opérations décrites à la Do operations described in chapter

rubrique "remontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 28. Il port" section "reassembly" page
est nécessaire de respecter la position 28.The angular position of the cam
angulaire de la came dans le cas des must be respected on dual dis-
moteurs à 2 cylindrées dont le rapport placement motors with a displace-
de cylindrée est différent de 2 ment ratio different from 2.

Exemple : Moteur MS18, cylindrées Example : Motor MS18 with dis-

1747-1049-698 placement 1747-1049-698.
3 3
Petite cylindrée : 698 cm lettre P Small displacement : 698 cm
[42.59 cu.in] letter P
3 3
Moyenne cylindrée : 1 049 cm lettre M Medium displacement : 1049 cm
[64.01 cu.in] letter M.
La lettre P ou M doit être située The letter P or M must be located in
dans l’axe et vers le tiroir de chan- the axis and towards the displace-
gement de cylindrée, le trou borgne ment change spool, with the blind
côté fixation de la came sur le pa- hole towards the fixing of the cam
lier. on the bearing support.

M P

M P
MS08
MSE08
A R A R
MS18
MSE18

P M

M P

A R A R
MS11
MSE11

P M 2035

677777845L REPAR MS2-18 F/GB 57

5/20112 677
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement du bloc cy- Replacement of the cylin-

lindre équipé (010) ders block assembly (010)

Démontage Disassembly

Effectuer les opérations décrites à Do operations described in chapter

la rubrique "démontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 27 port" section "disassembly" page 27

• Après avoir démonter la came, • After removing the cam, re-

démonter le bloc cylindre. move the cylinders block.

6541

Remontage Reassembly

• Monter un joint torique neuf • Install a new O-ring (027) 027

(027)

6542

• Monter le bloc cylindre équipé • Install the cylinders block as-

(010) sembly (010) 010

6541

• Effectuer les opérations décrites • Do operations described in

à la rubrique "remontage" du chapi- chapter "replacement of the bearing
tre "remplacement du palier" page support" section "reassembly" page
28. 28.

58 REPAR MS2-18 F/GB 677777845L

678 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement de la glace Replacement of the valving

(047). (047).
Démontage Disassembly

• Effectuer les opérations décrites • Do operations described in

à la rubrique "démontage" du chapi- chapter "replacement of the cylin-
tre "remplacement du bloc cylindre ders bloc assembly (010)" section
équipé (010)" page 58. "disassembly" page 58.

Mark location to the

Repérer le position de la valving (047) in relation
glace (047) par rapport au
! couvercle (041) (moteur à ! to the valving cover
(041) (Dual displace-
deux cylindrées). ment motor).

• Déposer la glace (047) du cou- • Separate the valving (047) from

vercle (041) en faisant levier au ni- the cover (041) by levering at the
veau des doigts d'indexage ou de la indexing pins or at the flange.
collerette.
2031

Protéger la glace de Protect the valving from

! toute poussière. ! dusts.

• Extraire les ressorts (052). • Remove the springs (052).

• Extraire et éliminer les joints et • Remove and discard the seals
contre joints (048) du couvercle and back-up rings (048) from the
(041). cover (041).

Remontage Reassembly
Toute trace de rouille,
boue, eau doit être sup- All traces of rust, mud,
!primée. ! water must be removed.

• Huiler, puis monter des joints • Lubricate and install new seals
toriques et contre joints neufs (048) and back-up rings (048), ensuring
048
en déformant les contres joints au the back up rings are twisted as little
minimum. as possible.

1135
• Placer les ressorts (052) dans • Place the springs (052) in their
leur logement préalablement rempli housings, previously filled with
de graisse. grease.
• Huiler les portées de joints de la • Lubricate the faces of the seals
glace (047). of the valving (047).
• Enfoncer la glace (047) dans le • Press the valving (047) into the
couvercle (041). cover (041).

677777845L REPAR MS2-18 F/GB 59

5/20112 679
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Respecter le sens de Respect the assembly

montage de la glace sense of the valving
! (047) par rapport au ! (047) in relation to the
cover (041).
couvercle (041).

Ne pas forcer lors du Do not force when in-

!
montage de la glace
(047) dans le couvercle ! stalling the valving (047)
into the cover (041).
(041).

Montage glace version 1C. Valving assembly type sin-

gle displacement motor.
• Pas de sens de montage parti- • No particular assembly sense.
culier.

041 047 2031

Montage glace version 2C. Valving assembly type Dual

displacement motor.
• Mettre la lettre choisie indiquant • Place the chosen letter indicate
le sens de rotation en face du tiroir the rotation sense in front of the
de pilotage (053). displacement change spool (053).

POSITIONNEMENT DE LA GLACE VALVING POSITIONING

G/L Gauche G/L Left

041

" 4 $ 047
? % 053

6758

! 053 9 $ # # 3

60 REPAR MS2-18 F/GB 677777845L

680 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

D/R Droite D/R Right

047

041
" 4 $
? %
6757

! 053 9 $ # # 9

• Si il n'y a pas de lettre, réaliser • If there is no letter, do the indexing

l'indexage suivant les repères établis according to the marks made during
au démontage. disassembly.

• Effectuer les opérations décrites • Do operations described in chapter

à la rubrique "remontage" du chapi- "replacement of the cylinders block"
tre "remplacement du bloc cylindre section "reassembly" page 58.
"page 58.

Cas des moteurs SE02 et S05 : Situation of SE02 and S05 motors :

Moteur SE02 :
SE02 Motor :
G/L Gauche D/R Droite
G/L Left D/R Right

6959
5 : 4 :
Moteur S05 :
S05 Motor : G/L Gauche D/R Droite
G/L Left D/R Right
053

5 : 2 9
6948

677777845L REPAR MS2-18 F/GB 61

5/20112 681
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement du joint Replacement of the end

(045) de la plaque de ferme- cover O-ring (045)
ture.
Démontage Disassembly

• Disposer le moteur en appui sur • Place the motor on the bearing

le palier (écrou montés pour proté- support (fitted with nuts for studs
ger les goujons) protection)
• Démonter les vis (066) • Remove the screws (066)
066

6543

• Démonter la plaque de ferme- • Remove the end cover

ture

6544

• Eliminer le joint torique (045) • Discard the O-ring (045)

045

6545

• Eliminer le joint torique (057) si • Discard the O-ring (057) if the 057
le moteur est un 2 cylindrées motor has 2-displacement

6546

62 REPAR MS2-18 F/GB 677777845L

682 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage Reassembly

• Monter un joint torique (045) • Install a new O-ring (045).

neuf.
045

6547

• Monter un joint torique (057) • Install a new O-ring (057) if the 057
neuf si le moteur est un 2 cylindrées motor has 2-displacement. If not go
sinon passer à l'étape suivante to the next section

6548

• Monter la plaque de fermeture • Install the end cover

6544

• Monter et serrer les vis (066) au • Install and tighten the screws
couple correspondant (voir tableau (066) to the right torque (see table 066
page 71) page 71)

6543

677777845L REPAR MS2-18 F/GB 63

5/20112 683
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement du capteur Replacing the sensor (op-

(option) tional)
Démontage Disassembly

• Débrancher le connecteur • Disconnect the connector

(161.3) (161.3) 161.3

6550

• Desserrer et démonter la vis • Unscrew and remove the screw

(165) (165) 165

6551

• Extraire le capteur (161) avec le • Extract the sensor (161) with its
166
support (166) support (166)

161

6552

64 REPAR MS2-18 F/GB 677777845L

684 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remontage Reassembly

S'assurer de la propreté Make sure that the seal

de la portée de joint mounting surface (164)
! (164) sur le couvercle ! on the valving cover
(041) is clean
distributeur (041)

• Monter la rondelle frein (163) • Install the new brake washer

neuve et le joint (164) neuf sur le (163) and the new seal (164) on the
capteur (161) équipé de sa pastille sensor (161) fitted with its adjusting
de réglage (167) sticker (167).
• Engager le capteur équipé dans • Push the sensor assembly into
le support (166) jusqu'à ce que le the support (166) until the seal (164)
joint (164) soit dans son logement is in its housing

6552

• Enfoncer le capteur dans le • Push the sensor into the valving

couvercle distributeur (041) jusqu'à cover (041) until it comes in contact
venir en contact sur le bloc cylindre with the cylinders block (011).
(011).

2064
l'encoche du capteur doit être orien- the notch of the sensor should be
tée vers le centre du moteur. oriented towards the center of the
motor. " . : )0 + ; 1

" . : )0 + ; 1
6558

• Monter et serrer la vis (165) au • Install and tighten the screw

165
couple de serrage correspondant (165) to the right torque (see table
(voir tableau page 38). page 38).

6551

• Rebrancher le connecteur • Reconnect the connector

(161.3) (161.3) 161.3

6550

677777845L REPAR MS2-18 F/GB 65

5/20112 685
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Récapitulatif outillage Tooling inventory

Outillage standard Standard tools
• Clé hexagonale pour Hollow head
5 6 8 10 12 14
vis six pans creux wrench
• Clé hexagonale pour
Hex head wrench 13 17 19 22 24
tête hexagonale
• Clé dynamométrique FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Clé dynamométrique FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Clé dynamométrique FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
Auto-top 2000
Anti-oxidizing Couleur vert fluo / fluorescent
• Graisse anti-oxydante origine AGIP ou Mo-
grease green color
bil XHP 222
du commerce
• Alcool isopropylique isopropyl alcohol
commercial
du commerce
• Pinceau standard Standard brush
commercial
• Activateur LOCTITE 7471 T Activator
Anaerobic adhe-
• Adhésif anaérobie LOCTITE 638
sive
• Adhésif LOCTITE 542 Adhesive

• Pince à anneau Internal snap ring

FACOM 499.32
d’arrêt intérieur pliers

0761
• Extracteur

FACOM U 20 B Extractor

6553

• Extracteur FACOM U.52T Extractor

• Clé hexagonale pour
Hex head wrench 13 17 19 22 24
tête hexagonale
• Clé dynamométrique FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Clé dynamométrique FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Clé dynamométrique FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]

66 REPAR MS2-18 F/GB 677777845L

686 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Outillage à réaliser Special tools

@ ,>
@ ,A

E
D

F
• Mandrin pour remonter
• Mandrel for reassembling the
la coiffe de frein ou pour
brake cover or to compress the
comprimer la rondelle
spring washer. @ ,B
élastique
@ ,C

0759

ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.3] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 195 [7.67] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21

,3 .5 6 1 %4 )" 2
Tube pour immobiliser le
Tube to immobilize the motor
@ ,# 4

moteur @ ,! 5
,3 .0 - 1 %4 )" 2

4 4
,- ./ 0 12

H ! # ,,I ,! # " H ! 5 ,I ,! # "

G 1;,! " ;:
J ,H ! # J ,H ! 5
K ,! # L

9 < )8 ( ( 9 < )8 = ( >

Outillage pour défreinage E " # E ! !
Tools for mechanical brake release
mécanique. E " $ E ! #
E " 2 E ! 9
E " 4 E ! : @ ,! 5 ;4
E " 3 E # ! ,3 .0 7 2
E " 9
E " :
5 " ,I ,$ " 4 " ,I ,4

677777845L REPAR MS2-18 F/GB 67

5/20112 687
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Mandrin pour roulement de palier et Mandrel for bearing support and

bague d'étanchéité sealing ring

Taille de moteurs ØA ØB L
Size of motors mm in mm in mm in
MS02 45 1.78 55 2.16 110 4.33
MSE02
MS05
60 2.36 70 2.75 120 4.72
MSE05
MS08
75 2.95 85 3.35 140 5.51
MSE08
MS11
85 3.35 95 3.74 160 6.3
MSE11
MS18
100 3.94 110 4.33 200 7.87
MSE18
Tolérances générales : ± 0.25 mm General tolerances : ± 0.001 in

Tube Ø 5x10
pipe 0.197 dia x
0.393

Outillage pour montage joint-glace Tools for mechanical seal mounting

Taille de moteurs ØA ØB ØC
Size of motors mm in mm in mm in
MS05
101 3.97 94 3.70 88 3.46
MSE05
MS08
150 5.9 142 5.6 135 5.31
MSE08
MS11
155 6.1 148 5.82 139.5 5.49
MSE11
MS18
169 6.65 162 6.38 155 6.1
MSE18
Tolérances générales : ± 0.25 mm General tolerances : ± 0.001 in

68 REPAR MS2-18 F/GB 677777845L

688 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Mandrin pour les bagues extérieures

Mandrel for bearing outer race : Ø1
des roulements de palier :
Ø2
Ø 1 for bearing 073
Ø 1 pour roulement 073
Ø 2 for bearing 074
Ø 2 pour roulement 074
50 mm
[1.97 in]
Taille de moteurs Ø1 Ø2
Size of motors mm in mm in
MS02 C 75 2.95 75 2.95
MS02
89 3.5 84 3.3
MSE02
MS05C
89 3.5 89 3.5
MSE05C
MS05
109 4.29 99 3.9
MSE05
MS08C
119 4.68 109 4.29
MSE08C
MS08
139 5.47 124 4.88
MSE08
MS11C
MSE11C 129 5.07 124 4.88

MS11
159 6.26 139 5.47
MSE11
MS18C
159 6.26 144 5.67
MSE18C
MS18
189 7.44 169 6.65
MSE18

Résumé des couples de

Tightening torque summary
serrage

Remplacement du Replacement of the 145±14 N.m 107±10 lbf.ft

palier (070) MS02 bearing support (070)
MS05 MS08 MS02 MS05 MS08
Vis (042) Page 43 Screw (042) page 43

Remplacement du Replacement of the 355±35 N.m 262±26 lbf.ft

palier (070) MS11 bearing support (070)
MS18 Vis (042) MS11 MS18
Page 43 Screw (042) page 43

677777845L REPAR MS2-18 F/GB 69

5/20112 689
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Remplacement du Replacement of the 355±35 N.m 262±26 lbf.ft

palier DYNA + DYNA + bearing
Page 48 support page 48

End cover MS02

Plaque de fermeture
MS05 49±5 N.m 36±4 lbf.ft
MS02 MS05 moteur
motor without brake
non freiné
Screw (066) page 63
Vis (066) page 63
DYNA+ bearing sup-
Palier DYNA+ page49)
port page 49)

Plaque de fermeture 86±9 N.m 63.4±6 lbf.ft

End cover MS08
MS08 moteur non
motor without brake
freiné
Screw (066) page 63
Vis (066) page 63

Plaque de fermeture End cover MS11 210±21 N.m 155±15 lbf.ft

MS11 MS18 moteur MS18
non freiné motor without brake
Vis (066) page 63 Screw (066) page 63

Corps de frein sur 85+(0/-16) N.m 63 (+0/-12) lbf.ft

rake housing on
couvercle (MS02
alving (MS02 MS05)
MS05)
crews (102) page 17
Vis (102) page 17

Corps de frein sur rake housing on 145+(0/-30) N.m 107 (+0/-22) lbf.ft
couvercle (MS08) alving (MS08)
Vis (102) page 17 crews (102) page 17

Corps de frein sur 355+(0/-70) N.m 262 (+0/-52) lbf.ft

rake housing on
couvercle (MS11
alving (MS11-MS18)
MS18)
crews (102) page 17
Vis (102) page 17

Remplacement du Replacing the sensor. 35 ± 3.5 N.m 26±2.6 lbf.ft

capteur. screws (165)
Vis (165) Page 65 Page 65

70 REPAR MS2-18 F/GB 677777845L

690 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Couples de serrage Standard tightening

standard en N.m ± 10% torques in [lbf.ft] ± 10%
(Suivant norme DIN 912) (According to the standard DIN 912)

Taille Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509

677777845L REPAR MS2-18 F/GB 71

5/20112 691
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

POCLAIN HYDRAULICS

Tableau de valeur pour réparation palier Table of repair support bearing values.

Standard Industriel Graisse

Moteurs Types Standard Industrial Grease

Motors Types F (N) S(mm) C (N.m) F (N) S C N.m (cm3)

F [lbf] S[in] C [lbf.ft] F [lbf] mm C [lbf.ft] [cu.in]

MS02 1..0 20000 [4496.4] 0 4 [2.9] 30 [1.83]
45000 [10117] 0,10 [0.0039] 10 [7.3]
MSE02 13.0 - - - - - - -
MS05 1..0 0,12 [0.0047] 25000 [5620.5] 60 [3.66]
70000 [15737.4] 23 [16.9] 0 9 [6.6]
MSE05 13.0 0,18 [0.0070] 18000 [4046.7] 25 [1.52]
MS08 1..0 0,15 [0.0059] 40000 [8992.8] 90 [5.49]
100000 [22482] 31 [22.8] 0 12 [8.8]
MSE08 13.0 0,20 [0.0078] 28000 [6295] 30 [1.83]
MS11 1..0 0,17 [0.0066] 45000 [10117] 65 [3.96]
120000 [26978.4] 37 [27.2] 0 12 [8.8]
MSE11 13.0 0,25 [0.0098] 31000 [6969.4] 25 [1.52]
1..0 [13489.2
MS18 13.0 60000 180 [10.98]
170000 [38219.4] 0,20 [0.0078] 70 [51.6] ] 0 28 [20.6]
MSE18 42000 150 [9.15]
14.0 [9442.4]

1..0 73 [53.8] 75000 [16861.5 29 [21.3] 150 [9.15]

13.0 60 [44.2] 52000 ] 24 [17.6] 140 [8.54]
MS25 210000 [47212.2] 0,20 [0.0078] 0
[11690.6
]
1..0 280000 [62949.6] 0,25 [0.0098] 108 [95.8] [13489.2 43 [31.7] - -
MS35 60000 0
13.0 170000 [38219.4] 0,20 [0.0078 75 [55.3] ] 30 [22.1] 180 [10.98]
1..0 320000 [71942.4] 0,30 [0.0118] 120 [88.4] [16861.5 48 [35.3] -
MS50 75000 0
13.0 210000 [47212.2] 0,20 [0.0078] 110 [81.1] ] 44 [32.4] 150 [9.15]
1..0 350000 [78687] 0,30 [0.0118] 208 [153] 100000 [22482] 83 [61.2]
MS83 13.0 250000 [56205] 0,20 [0.0078] 180 [132.7 75000 [16861.5 0 72 [53] - -
]
1..0 350000 [78687] 0,30 [0.0118] 170 [125.3] 100000 [22482] 68 [50.1]
MS125 0 - -
.4.. 250000 [56205] 0,20 [0.0078] 180 [132.7] 75000 72 [53]

1. .0 : Palier Moteur Roue Standard 1. .0 : Standard wheel motor bearing support

Types 13.0 : Palier Moteur Roue Courte. Types 13.0 : Short wheel motor bearing support
4 .. : Palier Moteur Compact 4 .. : Compact wheel motor bearing support
Graisse (901) : ELF EPEXA RN 2 Grease (901) : ELF EPEXA RN 2

72 REPAR MS2-18 F/GB 677777845L

692 5/2012
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POCLAIN HYDRAULICS

Liste des pièces Spare parts list

Repère Désignation Item Description
001 Pochette de joints 001 seals kit

010 Bloc cylindres équipé 010 Cylinders-block assembly

026 Came équipée 026 Cam assembly

027 Joint torique 027 O-ring

040 Couvercle équipé 040 Valving cover assembly

041 Couvercle 041 Valving cover part
042 Vis 042 Screw
043 Rondelle d'étanchéité 043 Seal washer
044 Vis 044 Screw
045 Joint torique 045 O-ring
047 Glace équipée 047 Valving
050 Bouchon 050 Plug
053 Tiroir 053 Valve spool
054 Rondelle 054 Washer
055 Anneau d'arrêt 055 Snap ring
056 Ressort 056 Spring
057 Joint torique 057 O-ring

065 Plaque de fermeture équipée 065 Cover plate assembly

066 Vis 066 Screw
067 Bague d'étanchéité 067 Sealing ring

070 Palier assemblé 070 Bearing support assembly

071 Support palier 071 Bearing support part
072 Bague d'étanchéité 072 Radial lip seal
073 Roulement 073 Roller bearing
074 Roulement 074 Roller bearing
075 Jeu de cales 075 Set of shims
076 Bague 076 Thrust ring
077 Anneau d'arrêt 077 Snap ring
078 Bague d'étanchéité 078 Lip seal
079 Déflecteur 079 Deflector
081 Support de joint 081 Seal support
085 Joint glace 085 Mechanical seal
087 Clavette 087 Key
088 Kit étanchéité renforcée 088 Reinforced seal kit
090 Arbre 090 Shaft
091 Jeu de goujons 091 Set of studs
096 Tambour de frein 096 Drum brake
097 Vis 097 Screw
098 Câble 098 Brake cable
099 Anneau d'arrêt 099 Snap ring
154 Mâchoire équipée 154 Brake shoe sub-assembly
155 Cylindre équipé 155 Brake cylinder sub-assembly
156 Réglage 156 Brake adjustment

677777845L REPAR MS2-18 F/GB 73

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POCLAIN HYDRAULICS

Repère Désignation Item Description

100 Frein équipé 100 Brake assembly
101 Corps de frein 101 Brake body
102 Vis 102 Screw
106 Joint torique 106 O-ring
107 Piston 107 Brake piston
108 Rondelle élastique 108 Spring washer
109 Anneau d’arrêt 109 Snap ring
110 Arbre de frein 110 Brake shaft
111 Joint équipé 111 Seal
112 Vis 112 Screw
113 Rondelle d’étanchéité 113 Sealing ring
135 Kit frein 135 Brake kit
141 Coiffe 141 Protector
142 Bouchon 142 Plug
143 Joint torique 143 O-ring

150 Prédisposition Tachy 150 Speed sensor predisposition

152 Rondelle 152 Washer
153 Rondelle 153 Washer

160 Capteur équipé 160 Speed sensor assembly

161 Capteur 161 Speed sensor part
163 Rondelle 163 Washer
164 Joint 164 Seal
165 Vis 165 Screw
166 Support 166 Support

Pièce non vendue séparément Part no sold singly

Sous-ensemble vendu en kit Sub-assembly sold assembled
Pièce vendue séparément Part sold singly
Pièce vendue exclusivement en lot. Part sold per batch

74 REPAR MS2-18 F/GB 677777845L

694 5/2012
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POCLAIN HYDRAULICS

Moteurs avec palier Dyna +

Motor with DYNA+ Bearing support

8162

677777845L REPAR MS2-18 F/GB 75

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POCLAIN HYDRAULICS

Moteurs à 1 cylindrée
Single displacement motors

8158

76 REPAR MS2-18 F/GB 677777845L

696 5/2012
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POCLAIN HYDRAULICS

8159

677777845L REPAR MS2-18 F/GB 77

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POCLAIN HYDRAULICS

Moteurs à 2 cylindrées
Dual displacement motors

8158

78 REPAR MS2-18 F/GB 677777845L

698 5/2012
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POCLAIN HYDRAULICS

8161

677777845L REPAR MS2-18 F/GB 79

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China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies Gran Via Carlos III no84 – 1o 3a
No.8 Beichendong St. 08028 BARCELONA
BEIJING 100101 ESPAÑA
CHINA Tel.: 349 3 409 54 54
Tel.: 86 10 6499 3988 Fax: 349 3 490 21 79
Fax: 86 10 6499 3979

eská Republika France

POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kšírova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
ESKÁ REPUBLIKA FRANCE
Tel.: 420 5 43217830 Tel.: 33 3 44 40 77 77
Fax: 420 5 43217818 Fax: 33 3 44 40 77 91

Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422

Italia United Kingdom

POCLAIN HYDRAULICS SRL POCLAIN HYDRAULICS LTD
Via Remesina int, 190 Nene Valley Business Park
41012 CARPI (MODENA) Oundle
ITALIA PETERBOROUGH, Cambs PE8 4HN
Tel.: 390 59 65 50 528 ENGLAND
Fax: 390 59 65 50 544 Tel.: 44 1832 273773
Fax: 44 1832 274990

Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
Tel.: 31 76 5021152 USA
Fax: 31 76 5012279 Tel.: 1 262 554 6739
Fax: 1 262 554 4860

POCLAIN HYDRAULICS INDUSTRIE S.A.S. au capital de 85 124 000 Francs

B.P. 106 Siège social: Route de Saint Sauveur
60411 VERBERIE CEDEX - France VERBERIE (OISE)
Tel.: 33 3 44 40 77 77 R.C.S. Senlis B 414 781 823
Fax: 33 3 44 40 77 99 Siret 414 781 823 00011
www.poclain-hydraulics.com

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Series 51

Bent Axis
Variable Motors
Service Manual

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Bent Axis Variable Displacement Motors Series 51

General Description
Series 51 Variable Displacement Motors are bent Motors equipped with controls normally start at maxi-
axis design units, incorporating spherical pistons. mum displacement. This provides maximum starting
torque (high acceleration).
These motors are designed primarily to be combined
with other products in closed circuit systems to trans- The controls may utilize externally or internally sup-
fer and control hydraulic power. plied servo pressure. They may be overridden by a
pressure compensator which functions when the
Series 51 Motors have a large maximum / minimum motor is operating in motor and pump modes. A
displacement ratio (5 to 1) and high output speed defeat option is available to disable the pressure
capabilities. SAE flange and cartridge motor configu- compensator override when the motor is running in
rations are available. pump mode.

The pressure compensator option features a low

pressure rise (short ramp) to provide optimal power
A complete family of controls and regulators is avai-
utilization throughout the entire displacement range
lable to fulfill the requirements of a wide range of
applications. of the motor. The pressure compensator is also
available as a stand-alone regulator.

The Series 51 - Advanced Technology Today

The Most Technically Advanced Hydraulic Units in the Industry

SAE Flange and Cartridge Motors

Cartridge Motors designed for Direct Installation in Compact

Planetary Drives

Large Displacement Ratio (5:1)

Complete Family of Control Systems

Proven Reliability and Performance

Optimum Product Configurations

Compact, Lightweight

Front page: Option - hydraulic two-position control

Copyright 1992-1997, Sauer-Sundstrand Company.
All rights reserved. Contents subject to change. Printed in U.S.A. 0992H
2

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Bent Axis Variable Displacement Motors Series 51

Contents

Introduction ......................................................................................................................................................4
Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 Variable Displacement Motors ..............................................................5
Functional Description ......................................................................................................................................6
Technical Specifications and Data - Variable Displacement Motors .............................................................. 20
Safety Precautions .........................................................................................................................................21
Gauge Installation ..........................................................................................................................................23
Start-Up Procedure and Maintenance ............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting ............................................................................................................................................. 37
Exploded View of the Series 51 Variable Motor .............................................................................................41
Minor Repair and Replacement - Variable Motor ........................................................................................... 51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) .................................................................................................... 52
Shaft Seal (Cartridge Configuration) .........................................................................................................53
Loop Flushing Shuttle Valve (Option)........................................................................................................54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover .................................................................................................................... 55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57
Electric 2-Position Controls (Type S1) ......................................................................................................58
Hydraulic Proportional Control (Type HZ) .................................................................................................59
Hydraulic Proportional Control (Type HS) .................................................................................................60
Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61
Two Connection Hydraulic Proportional Control (Type HP) ......................................................................62
Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) ...............................64
Electrohydraulic Proportional Control (Types EP and EQ)........................................................................68
Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ........................................................................................... 76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torques ................................................................................................................................77

0-1 3

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Bent Axis Variable Displacement Motors Series 51

Introduction
The purpose of this manual is to provide information Dirt or contamination is the greatest enemy of any
necessary for the normal servicing of the Series 51 type of hydraulic equipment. The greatest possible
family of variable displacement hydrostatic motors. cleanliness is necessary when starting up the sys-
tem, changing filters, or performing any other service
This manual includes unit and component descrip- procedure.
tion, troubleshooting, adjustments, and minor repair
procedures. By following the procedures in this For Technical Information on Series 51 motors, refer
manual, inspections and minor repairs may be per- to publication BLN-10042 or 368753.
formed without affecting the unit warranty.
For Fluid Quality Requirements, refer to publication
A Series 51 motor does occasionally require servic- BLN-9987 or 697581.
ing, and these units are designed to meet this require-
ment. Sauer-Sundstrand provides a complete repair serv-
ice for its products. Contact any Sauer-Sundstrand
Many repairs or adjustments can be completed with- Authorized Service Center for details. Sauer-Sund-
out removing the unit from the vehicle or machine, strand Authorized Service Center locations are listed
provided the unit is accessible and can be thoroughly in publication BLN-2-40527 or 698266.
cleaned before beginning any procedures.

Basic Hydraulic Circuits

CASE Closed Circuit
DRAIN
LINE The main ports of the pump are connected by hydrau-
lic lines to the main ports of the motor. Fluid flows in
either direction from the pump to the motor then back
to the pump in this closed circuit. Either of the hydrau-
INPUT PV MV OUTPUT lic lines can be under high pressure. The direction
and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the
machine load.

FLOW (BI-DIRECTIONAL) Open Circuit

RESERVOIR The outlet port of the pump is connected by a hydrau-
51000001 lic line to a directional control valve. The working ports
Fig. 0-1 - Basic Closed Circuit of this valve are connected to the main ports of the
motor. When the valve is actuated, fluid flows first
FLOW FLOW from the pump to the valve. The valve then directs the
(UNI-DIRECTIONAL) (BI-DIRECTIONAL) fluid to the motor in either direction. The direction of
fluid flow (and motor output shaft rotation) depends
CONTROL VALVE

on the direction the control valve is shifted. The speed

INPUT PUMP of fluid flow (and motor output shaft speed) depends
MV OUTPUT on pump output volume and the distance the control
valve is shifted. The system pressure is determined
by the machine load.
CASE Fluid returning from the motor is routed through the
DRAIN
RESERVOIR LINE
control valve to the reservoir. Additional components
may be necessary to provide dynamic braking and to
51000002 deal with over-running loads.
Fig. 0-2 - Basic Open Circuit

4 0-2

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Bent Axis Variable Displacement Motors Series 51

General Description of the Series 51 Variable Displacement Motors
The Series 51 variable displacement hydraulic mo- Various hydraulic and electrohydraulic controls may
tors use spherical pistons and piston rings. The angle be mounted on the motor end cap to control the servo
between the cylinder block and the output shaft can piston and the motor displacement. Servo pressure
be set between 32° and 6°, providing a 5 to 1 oil may either be supplied internally from the motor, or
maximum to minimum displacement ratio. externally.

At maximum displacement, the motor will provide a For all controls except the N2 and PC, servo pressure
certain maximum output shaft torque and minimum oil is supplied to a four (4) way spool valve in the motor
speed corresponding to the pressure and flow sup- end cap. When a combination of pilot pressure (or
plied to the motor. Under the same input conditions force) from an external control assembly and internal
but at minimum displacement, the shaft speed will be spring force shifts this valve, servo pressure is routed
approximately five (5) times faster while the available to move the servo piston and change the motor’s
output torque will decrease to approximately one-fifth displacement.
(1/5) the full displacement value. The displacement
is changed by a servo piston which is connected to A synchronizing shaft, with spherical rollers, synchro-
the valve segment. nizes the rotation of the output shaft and the cylinder
block. The ball end of each piston runs in a socket
bushing, pressed into the output shaft. There are no
other parts used to connect the pistons to the shaft.
Two tapered roller bearings support the output shaft.
Minimum
Displacement Limiter
Hydraulic Pressure Compensator
Proportional Override
Control Valve Segment
Control
Pressure Bearing Plate
Port

Tapered Roller Bearings

Synchronizing
Piston Shaft

Servo Piston
Cylinder

Charge Pressure
Relief Valve
P001 196
Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange
Configuration) with Hydraulic Proportional Control

10 - 1 5

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Bent Axis Variable Displacement Motors Series 51

Functional Description

Loop Flushing
Series 51 motors used in closed circuit applications
incorporate an integral loop flushing valve as stan-
dard equipment. Installations that require additional
fluid to be removed from the main hydraulic circuit
because of fluid cooling requirements, or circuits
requiring the removal of excessive contamination
from the high pressure circuit, can benefit from loop
flushing. Series 51 motors used in open circuit appli-
51000003 51000004
Fig. 10-2 - Loop Fig. 10-3 - Loop cations may have the optional loop flushing defeat
components installed.
Flushing Flushing Defeat
Components Components Series 51 motors equipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor charge relief valve
affects the function of the flushing circuit. Higher
motor charge relief settings reduce the loop flushing
flow and increase the flow over the pump charge
pressure relief valve when the circuit is operating.
Lower motor charge relief settings increase the loop
flushing flow and may increase the motor case pres-
sure when the circuit is operating.

An appropriate combination of pump and motor charge

pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all condi-
tions of operation to maintain pump control perfor-
mance in closed loop systems.

NOTE: An optional orifice may be installed between

the motor charge relief and the motor case to
limit the maximum flushing oil flow.

6 10 - 2

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Displacement Limiters
All Series 51 motors incorporate mechanical dis-
placement limiters. The minimum displacement of
the motor can be limited within the standard range by
a set screw in the motor housing. The maximum
displacement can be limited with spacers installed on
the servo piston.

51000005
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)

51000006
Fig. 10-5 - Maximum Displacement Limiter
Screw

Controls - General
A wide range of control options is available for the
Series 51 motors. These include pilot operated
Electrohydraulic 2-Position Controls, Hydraulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportional Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.

The Series 51 variable motor servo piston (except 5100007

when equipped with N2 control or the PC regulator) Fig. 10-6 - Internal Servo Pressure Supply
may be operated either by servo pressure oil supplied Screen with Multi-function Block and/or
internally from the main ports of the motor, or by servo Control Removed (Plug for External
pressure oil supplied from an external source. (The Supply)
N2 control uses servo pressure supplied by an exter-
nal control valve. The PC regulator obtains servo
pressure from the main ports of the motor.)

Orifice plugs are installed in the control spool sleeve

in the end cap to regulate the flow of oil from the servo
piston to the motor housing. Orifice plugs may be
installed in the end cap to regulate the flow of servo
pressure supply oil to the control valve, and to regu-
late the flow of oil from the control valve to the servo
piston. 51000008
Fig. 10-7 - External Servo Pressure Supply
Fitting (Plug for Internal Supply)
10 - 3 7

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Hydraulic 2-Position Control (Type N2)
This is a two (2) position (maximum - minimum
displacement) control, consisting of a cover plate
mounted on the end cap. An external control valve
supplies servo pressure from an external source
directly to the servo piston. PCOR is not available
with the N2 control.

When servo pressure is supplied to port “Y1,” the

51000009 setting piston moves to the maximum motor displace-
Fig. 10-8 - Series 51 Motor with N2 Control ment position. When servo pressure is supplied to
port “Y2,” the setting piston moves to the minimum
motor displacement position.

Orifices may be installed in the external control valve

or its connections to regulate the speed of servo
piston movement.

51000010
Fig. 10-9 - N2 Control Components

L2 M6 (M4) Y1 Y2 (M3)

A
M1

max.
disp.

U4 (opt.)

M2
B

L1
51000011
Fig. 10-10 - N2 Control Schematic

8 10 - 4

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Electrohydraulic 2-Position Control (Types
E1•E2 and F1•F2)
A 12 or 24 VDC solenoid valve, mounted on the multi-
function block, connects the end of the control valve
spool in the end cap with pilot pressure (provided by
the shuttle spool in the multi-function block) or with
the motor case. The control valve in the end cap is
biased by a threshold spring, and controls oil flow to
the ends of the servo piston. Servo pressure may be
51000012
supplied from an external source or internally by the Fig. 10-11 - Series 51 Motor with E1•E2 or
shuttle spool in the multi-function block. PCOR is F1•F2 Control
available with these controls.

With the E1 and E2 controls, energizing the solenoid

will cause the motor to shift to minimum displace-
ment. When the solenoid is not energized, the motor
is held at maximum displacement.

With the F1 and F2 controls, energizing the solenoid

causes the motor to shift to maximum displacement.
When the solenoid is not energized, the motor is held
at minimum displacement.
51000013
Fig. 10-12 - E1•E2 and F1•F2 Control
Components

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
E1•E2
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M8 M7
F1•F2

51000014
Fig. 10-13 - E1•E2 and F1•F2 Control
Schematic

10 - 5 9

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Electric 2-Position Control (Type S1)
A 12 VDC solenoid valve, mounted on the multi-
function block, directly operates the control valve
spool in the end cap. The control valve in the end cap
is biased by a threshold spring, and controls oil flow
to the ends of the servo piston. Servo pressure may
be supplied from an external source or internally by
the shuttle spool in the multi-function block. PCOR is
available with this control.
51000162
Fig. 10-14 - Series 51 Motor with S1 Control With the S1 control, energizing the solenoid causes
the motor to shift to maximum displacement. When
the solenoid is not energized, the motor is held at
minimum displacement.

51000163
Fig. 10-15 - S1 Control Components

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
S1
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
51000085
Fig. 10-16 - S1 Control Schematic

10 10 - 6

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Hydraulic Proportional Control (Type HZ)
The HZ control consists of a cover plate mounted
directly on the end cap. A ball type shuttle valve
provides internal servo pressure supply to the control
valve in the end cap. PCOR is not available with the
HZ control.

Feedback springs (single spring for 060, 080 and

110) and a threshold spring are installed in the end
cap. The feedback springs and threshold spring 51000015

provide a force on the end of the control spool. The Fig. 10-17 - Series 51 Motor with HZ
force of the threshold spring is externally adjustable Control
with an adjusting screw. The feedback spring is
positioned between the control spool and a feedback
lug attached to the servo piston. The force of the
feedback spring increases as the motor’s displace-
ment decreases.

Pilot oil pressure from an external source is applied to

the end of the control spool opposite the feedback
and threshold springs. An increase in pilot pressure
(above the threshold pressure and within the modu-
lating pressure range) will result in a decrease in 51000016
motor displacement, while a decrease in pilot pres- Fig. 10-18 - HZ Control Components
sure will result in an increase in motor displacement.

L2 M6 M4 M3

A
M1

max.
disp.

U4 (opt.) T3

T2

T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
B
Servo
Pressure
internal L1

X1 M7
51000017
Fig. 10-19 - HZ Control Schematic

10 - 7 11

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the multi-function block.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

The function of the HS control is identical to the

function of the HZ control.
51000018
Fig. 10-20 - Series 51 Motor with HS
Control

51000019
Fig. 10-21 - HS Control Components
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 HS

H1•H2
M7 X1

K1•K2
M7 X1
51000022
Fig. 10-22 - HS, H1•H2, and K1•K2 Control
Schematic

12 10 - 8

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Hydraulic Proportional Control with
Electric Override (Types H1•H2 and K1•K2)
The function of the H1•H2 and K1•K2 controls is
similar to the function of the HS control. A 12 or 24
VDC solenoid valve is installed between the external
pilot pressure source and the control spool.

With the H1•H2 controls, energizing the solenoid

allows the control to function as an HS control. When
the solenoid is not energized, pilot pressure is blocked 51000020

and the end of the control spool is drained to the motor

Fig. 10-23 - Series 51 Motor with H1•H2
case, causing the motor to shift to maximum displace- Control
ment.

With the K1•K2 controls, energizing the solenoid

blocks pilot pressure and drains the end of the control
spool to the motor case, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control functions as an HS control.

51000167
Fig. 10-24 - Series 51 Motor with K1•K2
Control

51000021
Fig. 10-25 - H1•H2 and K1•K2 Control
Components

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)

Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mounted on the multi-function block.
The valve block incorporates a shuttle spool and a
pilot piston with centering springs. A pin transmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
51000023
080, and 110) and a threshold spring are installed in
Fig. 10-26 - Series 51 Motor with HP the end cap. These springs function similar to the HS
Control control. Servo pressure may be supplied from an
external source or internally by the shuttle spool in the
multi-function block. PCOR is available with this
control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback spring,
and the lower pressure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

51000024 An increase in the difference between the pilot pres-

Fig. 10-27 - HP Control Components sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment.
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Press,
internal
L1

X2 X1
51000025
Fig. 10-28 - HP Control Schematic

14 10 - 10

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Two Line Hydraulic Proportional Control
for “Dual-Path” Vehicles (Type HC)
The HC control operates in a similar manner to the HP
control, however the HC control is optimized for use
in “dual-path” drive vehicles. This control consists of
a valve block with two (2) hydraulic ports mounted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
51000158
spool in the end cap. Fig. 10-29 - Series 51 Motor with HC
A bleed valve is provided to eliminate any air which Control
might become trapped in the pilot piston oil passages.

Feedback springs are installed in the end cap. Servo

pressure is supplied internally by a ball type shuttle
valve in the control housing. PCOR is not available
with this control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback springs,
and the lower pressure to the opposite side of the pilot
piston. The pin transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

An increase in the difference between the pilot pres- 51000111

sures will result in a decrease in motor displacement, Fig. 10-30 - HC Control Components
while a decrease will result in an increase in displace-
ment. The feedback springs in the end cap have L2 M6 M4 M3
differing spring rates and operate in parallel (060,
A
080, and 110) or series (160 or 250) to provide a linear M1
relationship between motor displacement and pilot
pressure differential. max.
disp.

U4 (opt.) T3

T2

T7,
T8 M9
T1
M5

M2
B

L1

X2 X1
51000160
Fig. 10-31 - HC Control Schematic

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) valve mounted on the multi-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin transmits force from the
pilot piston to the control spool in the end cap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
51000026
cap. These springs function similar to the HS control.
Fig. 10-32 - Series 51 Motor with EP Control
Servo pressure may be supplied from an external
(EQ Similar)
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

An external pilot pressure source is connected to the

inlet of the PCP valve, which produces differential
pilot pressures proportional to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is similar to that of the HP
Control, with the motor displacement being propor-
tional to the current through the PCP valve.

An increase in current (above the threshold current)

will result in a decrease in motor displacement, while
a decrease will result in an increase in displacement.
51000027
Fig. 10-33- EQ Control Components (EP
Similar)

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 M8
51000028
Fig. 10-34 - EP and EQ Control Schematic

16 10 - 12

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides internally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) function with optional brake pressure
defeat.

51000029
Fig. 10-35 - Multi-function Block (Without
Control)

Servo Pressure Supply

For internal supply, the multi-function block incorpo-

rates a shuttle spool with internal check ball valve that
routes oil from the main circuit ports of the motor to the
control valve in the end cap. “High side” pressure is
provided to the servo control valve in the end cap.

For external supply, the connection between the

shuttle spool and the servo control valve is blocked in
51000030
the end cap. The external pressure supply to the Fig. 10-36 - Multi-function Block with Servo
servo control valve connects to a port (“M5”) on the Pressure Supply Shuttle Spool
end cap.

Pressure Compensator Over-Ride (PCOR)

The Pressure Compensator Over-Ride (PCOR) sys-

tem includes a spool valve located in the PCOR block
which is attached to the multi-function block. This
system increases the motor displacement at system
pressures above the PCOR valve setting. (Pressure
Compensator Over-Ride is not available with the N2
and HZ controls, or the PC regulator.)

For bi-directional PCOR operation, the shuttle valve

in the multi-function block routes system high pres-
sure to the PCOR spool valve. For single direction
51000031
PCOR operation, the PCOR spool valve is connected Fig. 10-37 - Multi-function Block with PCOR
to one (1) side of the closed loop through passages in Block and Spool Valve (K1•K2 Control
the multi-function block
Shown)
When system pressure exceeds the PCOR setting,
the spool valve moves to connect the displacement
reducing end of the servo piston to the motor case,
and the displacement increasing end of the servo
piston to system pressure. This increases the motor
displacement, which reduces the motor output speed.
When the PCOR valve closes, control of the servo
piston returns to the control spool in the motor end
cap.

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
An optional “brake pressure defeat” spool may be
installed in the multi-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displacement to increase during
deceleration (which could cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defeat spool to block the
high pressure supply to the PCOR valve from the
“deceleration” side of the closed loop. Either bi-
51000032 directional or single direction PCOR operation can be
Fig. 10-38 - Multi-function Block with PCOR specified when PCOR defeat is installed.
Defeat Spool Components

Shuttle Valve Shuttle Valve PCOR Brake Pressure Defeat Operation

A1 T4 A1
Rotation High pressure Control pressure
Defeat
Spool
port on port

CW A XB
T5
CCW B XA
U7 U7

U6 U6
B1 T6
B1

PCOR PCOR
Valve Valve

XA XB

Standard with Defeat

Pressure Compensator Override
51000033
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic

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Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)
Pressure Compensator Regulator (Type
PC)
In this regulator, the Pressure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is maintained
in the minimum motor displacement position. When
system pressure exceeds the POR setting, hydraulic
pressure acts on the servo piston to increase the
motor displacement.

With the Pressure Compensator regulator, an in- 51000034

crease in system pressure (above the setting pres- Fig. 10-40 - Series 51 Motor with PC
sure) will result in an increase in motor displacement Regulator
and output torque, and a decrease in motor shaft
speed.

51000035
Fig. 10-41 - PC Regulator Components

L2 M6 M4 M3

A
M1

max.
disp.
T5
U7

U4 (opt.)

U6 T7

T1
M9
M5

M2
B

L1
51000036
Fig. 10-42 - PC Regulator Schematic

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Bent Axis Variable Displacement Motors Series 51

Technical Specifications and Data - Variable Displacement Motors
Design Hydraulic Fluid
Piston motor with variable displacement, bent axis Refer to Sauer-Sundstrand publication BLN-9887 or
construction. 697581.
Type of Mounting Temperature 1)

SAE four (4) bolt flange – SAE Flange Configuration. min = -40°C (-40°F), intermittent, cold start
Two (2) bolt flange – Cartridge Motor Configuration. nominal = 104°C (220°F), continuous
max = 115°C (240°F), intermittent
Pipe Connections
1)
at the hottest point, normally the case drain line.
Main pressure ports: SAE flange
Hydraulic fluid viscosity must be as shown below.
Remaining ports: SAE O-ring thread
Fluid Viscosity Limits
Direction of Rotation
min = 5 mm2/s (42 SUS) intermittent
Clockwise and counter-clockwise.
min = 6.4 mm2/s (47 SUS) min. continuous
Installation Position min = 13 mm2/s (70 SUS) optimum
max = 110 mm2/s (510 SUS) max. continuous
Installation position discretionary. The housing must max = 1600 mm2/s (7400 SUS) intermittent, cold start
always be filled with hydraulic fluid.
Filtration
System Pressure Range, Input
Acceptable contamination level: ISO Code 18/13 or
Max: 480 bar (6960 psi) better. Refer to Sauer-Sundstrand publication BLN-9887
Min: 10 bar (145 psi) or 697581.
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)

Frame Size
Dimension 060 080 110 160 250
3
Displacement maximum cm 60.0 80.7 109.9 160.9 250.0
in3 3.66 4.92 6.71 9.82 15.26
minimum cm3 12.0 16.1 22.0 32.2 50.0
in3 0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min-1 (rpm) 3600 3100 2800 2500 2200
at min disp min-1 (rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min-1 (rpm) 4400 4000 3600 3200 2700
at min disp min-1 (rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbf•in / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbf•in / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg • m2 0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf • ft2 0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190

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Bent Axis Variable Displacement Motors Series 51

Safety Precautions

When Series 51 units are used in vehicular Use caution when dealing with hydraulic
hydrostatic drive systems, the loss of hy- fluid under pressure. Escaping hydraulic
drostatic drive line power in any mode of fluid under pressure can have sufficient
operation may cause a loss of hydrostatic force to penetrate your skin causing seri-
braking capacity. A braking system, redun- ous injury. This fluid may also be hot enough
dant to the hydrostatic transmission must, to burn. Serious infection or reactions can
therefore, be provided which is adequate to develop if proper medical treatment is not
stop and hold the system should the condi- administered immediately.
tion develop.
Some cleaning solvents are flammable. To
Certain service procedures may require the avoid possible fire, do not use cleaning
vehicle/machine to be disabled (wheels solvents in an area where a source of igni-
raised off the ground, work function discon- tion may be present.
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.

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Bent Axis Variable Displacement Motors Series 51

Notes

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Bent Axis Variable Displacement Motors Series 51

Gauge Installation
Various pressure gauge readings can be a great Snubbers are recommended to protect pressure
asset in troubleshooting problems with the Series 51 gauges. Frequent gauge calibration is necessary to
motor or support system. insure accuracy.

Fig. 30-1 - Gauge Ports, Motor with N2 Control

Port "L1" Port Y2:
Servo press., external
(N2 Control Only) Gauge port M6:
Charge pressure
"X" Gauge port M3; 9/16 — 18 UNF-2B
Servo pressure
min. displacement Gauge port M2:
Port "B" system
pressure
A B
Gauge port M1:
Port "A" system M1
pressure Port Y1:
M2
Servo press., external
(N2 Control Only)
Port "L2"
Gauge port M4:
Servo pressure
max. displacement
Side Port End Cap Axial Port End Cap
Right Side View View in Direction "X"
51000037

Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Controls
Port X3:
servo press., external
Gauge port M5:
servo press., internal Control • E1/E2 • F1/F2
XA
Control • E1/E2•F1/F2 Control • H1/H2 • K1/K2
Gauge port M8 Gauge port M7
Control • H1/H2 control pressure
Control pressure port X1 View"T"
Control • K1/K2
Control pressure port X1
XA
XB XB

"T" 51000038

Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls

Port X3:
servo press., ext.
Gauge port M5: Gauge port M7:
servo press., int. Control pressure
XA
Gauge port M7:
Control pressure
View"U" View"U"
(HS) (HZ)

XA XB
Control pressure Control pressure
XB
port X1 port X1
"U" 51000039

30 - 1 23

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Bent Axis Variable Displacement Motors Series 51

Gauge Installation (Continued)
Fig. 30-4 - Gauge Ports, Motor with HP Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"V"

XA XB

XB X1 X2 Ports X1, X2:

Control pressure
9/16 — 18 UNF-2B
"V" 51000040

Fig. 30-5 - Gauge Ports, Motor with EP•EQ Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"W"

XA XB

XB
MS-Connector (MS3102C) Packard
7/8 — 20 UNEF Connector
Manual override
Port X1:
External PCP
"W" supply pressure 51000041

Gauge Information
System 600 bar or 10,000 psi Gauge Motor 60 bar or 1000 psi Gauge
M1 Pressure M6 Charge
Port “A” 9/16 — 18 O-Ring Fitting Pressure 9/16 — 18 O-Ring Fitting
System 600 bar or 10,000 psi Gauge M7 Control 60 bar or 1000 psi Gauge
M2 Pressure M8 Test Port 9/16 — 18 O-Ring Fitting
Port “B” 9/16 — 18 O-Ring Fitting L1 Case 60 bar or 1000 psi Gauge
Servo 600 bar or 10,000 psi Gauge L2 Pressure 060, 080, 110:
M3 Pressure 1-1/16 — 12 O-Ring Fitting
(Min. Angle) 9/16 — 18 O-Ring Fitting 160, 250:
Servo 600 bar or 10,000 psi Gauge 1-5/16 — 12 O-Ring Fitting
M4 Pressure X1 Control 60 bar or 1000 psi Gauge
(Max. Angle) 9/16 — 18 O-Ring Fitting X2 Pressure 9/16 — 18 O-Ring Fitting
Servo 600 bar or 10,000 psi Gauge X3
M5 Supply 9/16 — 18 O-Ring Fitting or XA Defeat 60 bar or 1000 psi Gauge
(M9) Pressure Tee into Control Pressure Line XB Pressure Tee into Defeat Pressure
Line(s)
24 30 - 2

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Bent Axis Variable Displacement Motors Series 51

Start-Up Procedure and Maintenance
Start-Up Precautions Fill the reservoir with recommended hydraulic fluid,
which should be passed through a 10 micron (nomi-
Cleanliness
nal, no bypass) filter prior to entering the reservoir.
Ensure that all system components, including fittings, The use of contaminated fluid will cause damage to
pipes, and hoses, are completely clean. If cloths are the components, which may result in unexpected
used for cleaning components, they must be made of vehicle/machine movement.
lint-free materials.
The inlet line leading from the reservoir to the pump
Follow the guidelines presented in Sauer-Sundstrand must be filled prior to start up. Check inlet line for
publication BLN-9887 or 697581 for required fluid properly tightened fittings and make sure it is free of
cleanliness levels at machine start-up. restrictions and air leaks.
Reservoir and Fluid Level Be certain to fill the pump and motor housing with
clean hydraulic fluid prior to start up. Fill the
The reservoir should be designed to accommodate
housing by pouring filtered oil into the upper case
maximum volume changes during all system operat-
drain port.
ing modes, and to promote de-aeration of the fluid as
it passes through the tank. The reservoir outlet (charge Install a 0 to 60 bar or 0 to 1000 psi pressure gauge
pump inlet) and the reservoir inlet (fluid return) must in the charge pressure gauge port to monitor the
always be below the normal fluid level. A sight glass charge pressure during start-up.
is the preferred method for checking fluid level.
The external control input signal should be discon-
The reservoir inlet (fluid return) should be positioned nected at the pump control during initial start-up. This
so that flow to the reservoir is directed into the interior will allow the pump to remain in its neutral position.
of the reservoir for maximum dwell and efficient de-
“Jog” or slowly rotate prime mover until charge pres-
aeration. A baffle (or baffles) between the reservoir
sure starts to rise. Start the prime mover and run at
inlet and outlet ports will promote de-aeration and
the lowest possible RPM until charge pressure is
reduce surging of the fluid.
established. Excess air may be bled from the high
No funnel-shaped eddying at the reservoir outlet pressure lines through the high pressure gauge ports.
(charge pump inlet) or formation of foam at the
Once charge pressure is established, increase speed
reservoir inlet (fluid return) is permitted.
to normal operating RPM. Note the charge pressure.
Start-Up Procedure If charge pressure is incorrect, shut down and deter-
mine cause for improper pressure.
The following start-up procedure should always be
followed when starting-up a new Series 51 installa- Shut down prime mover and connect external control
tion or when restarting an installation in which either input signal. Start prime mover, checking to be
the pump or motor has been removed from the certain pump remains in neutral. With prime mover at
system. normal operating speed, slowly check for forward and
reverse machine operation.
WARNING
Charge pressure should be maintained during for-
The following procedure may require the ve- ward or reverse operation. Continue to cycle slowly
hicle/machine to be disabled (wheels raised off between forward and reverse for at least five (5)
the ground, work function disconnected, etc.) minutes.
while performing the procedure in order to
prevent injury to the technician and bystand- Shut down prime mover, remove gauges, and plug
ers. Take necessary safety precautions before ports. Check reservoir level and add fluid if neces-
operating the vehicle/machine. sary.
Prior to installing the motor, inspect the unit for The transmission is now ready for operation.
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses,
valves, fittings, heat exchanger, etc.) are clean prior
to filling with fluid.

30 - 3 25

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Bent Axis Variable Displacement Motors Series 51

Start-Up Procedure and Maintenance (Continued)
Maintenance Changing the Fluid and Filter
Cleanliness
To insure optimum service life on Series 51 products,
The reservoir breather air filter (if equipped) must be regular maintenance of the fluid and filter must be
kept clean. Clean the area around the filler cap before performed.
opening the reservoir. The hydraulic fluid should be
The fluid and filter must be changed per the vehicle/
filtered before it enters the reservoir.
machine manufacturer’s recommendations. In the
Follow the guidelines presented in Sauer-Sundstrand absence of such recommendations, the following
publication BLN-9887 or 697581 for required fluid intervals may be used:
cleanliness levels during machine operation.
• System with a sealed type reservoir - 2000 hrs.
Recommended Fluids • System with a breathing type reservoir - 500 hrs.

Hydraulic fluids used with Sauer-Sundstrand prod- It may be necessary to change the fluid more fre-
ucts should be carefully selected with assistance quently if the fluid becomes contaminated with for-
from a reputable supplier, following the guidelines eign matter (dirt, water, grease, etc.) or if the fluid has
presented in Sauer-Sundstrand publication BLN-9887 been operating at temperature levels greater than the
or 697581. maximum recommended. Never reuse fluid.

Checking for Leaks The filter should be changed when changing the fluid,
or whenever the filter indicator shows that it is neces-
Check the system components for leakage at regular sary to change the filter.
intervals. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.

Check hydraulic hoses for damage or aging. When

installing replacements, be certain that the hoses are
clean and connected properly.

Checking the Fluid Level

Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy or milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).

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Bent Axis Variable Displacement Motors Series 51

Component Inspection and Adjustment

WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustments to prevent
injury to the technician and bystanders.

Charge Pressure Relief Valve Adjustment

An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.

To measure motor charge pressure, install a 0 to 60

bar or 0 to 500 psi pressure gauge in the motor charge 51000042

pressure gauge port. Install a gauge to measure case Fig. 30-6 - Adjusting Charge Pressure
pressure. Operate the system with the prime mover Relief Valve
at normal operating speed and the pump at half
stroke (forward or reverse) when measuring motor
charge pressure.

In most applications, the motor charge relief valve is

set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief valve (measured with the pump in
its “neutral” or zero-angle position). This setting as-
sumes a reservoir temperature of 50° C (122° F), and
is referenced to case pressure.
51000043
Series 51 motors are equipped with an external screw
Fig. 30-7 - Tighten Charge Pressure Relief
adjustable charge pressure relief valve. To adjust the
charge pressure, loosen the lock nut (with a 1-1/16" Valve Lock Nut
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the plug increases
the setting, and counter-clockwise rotation decreases
the setting (at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ft•lbsf).

Once the desired charge pressure setting is achieved,

remove the gauges and reinstall the port plugs.

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Minimum Displacement Limiter Adjustment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
510000434
ditions. The sealing lock nut must be retorqued
Fig. 30-8 - Loosen Minimum Displacement after every adjustment to prevent an unex-
Limiter Lock Nut pected change in operating conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.

To adjust the minimum displacement, first remove

51000045
Fig. 30-9 - Rotate Minimum Displacement and discard the cap covering the adjusting screw.
Adjusting Screw Using a 17 mm hex wrench for 060 and 080 frame
size motors or a 19 mm hex wrench for 110 through
250 frame size motors, loosen the lock nut retaining
Approximate Change in the minimum displacement limiter adjusting screw.
Minimum Displacement Using a 5 mm internal hex wrench for 060 and 080
Frame Per Revolution frame size motors or a 6 mm internal hex wrench for
Size of Adjusting Screw 110 through 250 frame size motors, rotate the adjust-
060 1.5 cc/Rev (.09 in3/Rev) ing screw to limit the minimum displacement of the
080 2.1 cc/Rev (.13 in3/Rev) motor.
110 3.1 cc/Rev (.19 in3/Rev) Rotating the adjusting screw clockwise will increase
180 4.0 cc/Rev (.24 in3/Rev) the minimum displacement of the motor, while rotat-
250 6.2 cc/Rev (.38 in3/Rev) ing the adjusting screw counter-clockwise will de-
crease the minimum displacement.
Min. Displacement Screw Size
Frame Range and Length For each full revolution, of the adjusting screw, the
Size cc/Rev (in /Rev)
3
mm (in) displacement will change according to the accompa-
nying chart.
060 12 to 29 (.73 to 1.77) M10x65 (2.56)
30 to 40 (1.83 to 2.44) M10x80 (3.15) Different minimum displacements may require differ-
080 16 to 35 (.98 to 2.14) M10x65 (2.56) ent length adjusting screws. The various lengths are
36 to 54 (2.20 to 3.20) M10x80 (3.15) shown in the accompanying chart.
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76) After establishing the desired minimum displacement
47 to 74 (2.87 to 4.52) M12x80 (3.15) setting, tighten the lock nut on the adjusting screw to
160 32 to 72 (1.95 to 4.39) M12x75 (2.95) 51 Nm (38 ft•lbsf) for 060 and 080 frame size motors
73 to 107 (4.45 to 6.53) M12x90 (3.54) or 86 Nm (63 ft•lbsf) for 110 through 250 frame size
250 50 to 90 (3.05 to 5.49) M12x75 (2.95) motors. Install a new tamper-resistant cap on the
91 to 130 (5.55 to 7.93) M12x90 (3.54) adjusting screw.
131 to 167 (7.99 to 10.19) M12x100 (3.94)

28 30 - 6

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the valve
segment. A displacement stop screw is installed on
the setting piston (under the minimum angle servo
cover) to limit the stroke of the piston.

Spacers may be installed on the displacement stop

screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner spacer.

WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at 51000046
maximum displacement and monitoring the Fig. 30-10 - Remove Minimum Angle Servo
motor output shaft speed. An increase in Cover Screws
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed. Approximate Change in
Frame Maximum Displacement
To adjust the maximum displacement, first remove Size with Change in Spacer Thickness
the screws retaining the minimum angle servo cover cc/mm (in3/.1 in)
to the end cap with an 8 mm internal hex wrench (060,
060 0.98 (.15)
080, 110, and 160 units), or a 10 mm internal hex
wrench (250 units). Remove the minimum angle 080 1.14 (.18)
servo cover and O-rings. Remove the displacement 110 1.48 (.23)
limiter screw with an 8 mm internal hex wrench. 160 1.93 (.30)
Installing a thicker spacer on the end of the setting 250 2.63 (.41)
piston will reduce the maximum displacement of the
motor. Installing a thinner spacer will increase the
maximum displacement. The displacement will
change according to the accompanying chart.

Torque the displacement limiter screw to 54 Nm (40

ft•lbsf).

Install the minimum angle servo cover and its O-rings.

Install the cover screws and torque to 78 Nm (58
ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ft•lbsf) for 250 motors.
51000070
Fig. 30-11 - Torque Maximum Displacement
Limiter Screw

30 - 7 29

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Displacement Control Adjustments
NOTE: A change in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor and monitoring the motor output
shaft speed while adjusting the control. An
increase in displacement will result in a de-
crease in shaft speed, while a decrease in
displacement will result in an increase in shaft
speed.

Hydraulic 2-Position Control (Type N2)

No adjustments are provided for the N2 control.

A minimum of 25 bar (360 psi) servo pressure is

required to change the motor displacement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to change the motor dis-
placement with the motor shaft locked.
50000009
Fig. 30-12 - Hydraulic 2-Position Control,
Type N2)

Electrohydraulic 2-Position Control (Types E1•E2

and F1•F2) and Electric 2-Position Control (Type
S1)

These controls do not require adjustment.

CAUTION

Do not tamper with the adjusting screw in the

end cap (opposite the control).
50000012
Fig. 30-13 - Electrohydraulic 2-Position Pilot pressure for the E1•E2 or F1•F2 electric sole-
Control, Types E1•E2 and F1•F2 noid valve is internally supplied. When the solenoid is
energized, motor charge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 should drop to case pressure.

The S1 control utilizes a direct acting solenoid to

operate the control valve spool in the end cap.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
50000162 displacement with the motor shaft turning, and a
Fig. 30-14 - Electric 2-Position Control, minimum of 70 bar (1015 psi) is required with the
Type S1 motor shaft locked.

30 30 - 8

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Hydraulic Proportional Control (Types HZ, HS,
H1•H2, and K1•K2)
The control start pressure for these controls may be
adjusted with the adjusting screw on the end cap
(opposite the control block). Control start is that pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install a gauge to
monitor the pilot pressure (connect to port M7 or tee 51000015

into the pilot line connected to port X1), and the Fig. 30-15 - Hydraulic Proportional Control,
minimum angle servo pressure (port M3). If adjusting Type HZ
an H1 or H2 control, the override solenoid must be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.
Increase the pilot signal to the required control start
pressure. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to 51000018
decrease. Fig. 30-16 - Hydraulic Proportional Control,
To adjust the control start pressure, loosen the lock Type HS
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start pressure.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.
For the H1•H2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 should drop to case
pressure.
51000020
For the K1•K2 controls, the pilot signal pressure Fig. 30-17 - Hydraulic Proportional Control
supplied to port X1 should also be present at test port with Electric Override, Type H1•H2 (K1•K2
M7 when the solenoid is not energized. When the Similar)
solenoid is energized, test port M7 should drop to
case pressure.
Shut down the prime mover. Remove the gauges and
install the gauge port plugs. Return the pump and
motor controls to their normal operation.
Servo pressure supply oil is usually provided inter-
nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor 51000047
displacement with the motor shaft turning, and a Fig. 30-18 - Adjusting Control Threshold,
minimum of 70 bar (1015 psi) is required with the Types HS, HZ, H1•H2, and K1•K2
motor shaft locked.

30 - 9 31

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
(Type HP)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
differential pilot pressure at which the motor displace-
ment starts to decrease.

To check the control start setting, install gauges to

51000023 monitor the pilot pressures (tee into the pilot lines
Fig. 30-19 - Two Line Hydraulic connected to ports X1 and X2), and the minimum
Proportional Control, Type HP angle servo pressure (port M3).

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.
51000047 The differential control start pressure should be the
Fig. 30-20 - Adjusting Control Threshold same no matter which pilot pressure is higher. Differ-
(Type HP) ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw clockwise increases the control
start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf)
after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.

32 30 - 10

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
for “Dual Path” Vehicles (Type HC)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the
control housing. Control start is that differential pilot
pressure at which the motor displacement starts to
decrease.

To check the control start setting, install gauges to

monitor the pilot pressures (tee into the pilot lines 51000158

connected to ports X1 and X2), and the minimum Fig. 30-21 - Two Line Hydraulic
angle servo pressure (port M3). Proportional Control, Type HC

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.

The differential control start pressure should be the 51000159

same no matter which pilot pressure is higher. Differ- Fig. 30-22 - Adjusting Control Threshold
ences in control operation when the pilot pressure (Type HC)
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw counter-clockwise (CCW) increases
the control start pressure. Torque the lock nut to 9 Nm
(6.6 ft•lbsf) after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is provided internally from

the main system ports of the motor.

30 - 11 33

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
The control start current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Pressure Control Pilot)
valve at which the motor displacement starts to de-
crease.
51000026 To check the threshold setting, install instruments to
Fig. 30-23 - Electrohydraulic Proportional monitor the PCP current, and the minimum angle
Control, Type EP (EQ Similar) servo pressure (port M3).

NOTE: The current supplied to the PCP may be

determined by prime mover speed, other
shaft speeds, control pressures, or other elec-
trical signals, depending upon the design of
the vehicle / machine control circuit.

Increase the PCP current to the required control start

current. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
51000047
Fig. 30-24 - Adjusting Control Threshold To adjust the control start current, loosen the lock nut
(Type EP•EP) using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start current.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.

PCP supply pressure oil is provided externally. PCP

supply pressure must be a minimum of 20 bar (290
psi) and no more than 70 bar (1015 psi).

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.

34 30 - 12

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Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the multi-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC regulator starts to increase
the motor displacement.
In order to measure the regulator start pressure
setting of the PCOR or the PC regulator, the motor
output shaft must be loaded to increase the system 51000031

working pressure. This can accomplished by apply- Fig. 30-25 - PCOR Block on Multi-Function
ing the vehicle’s brakes or by loading the work func- Block (K1•K2 Control Shown)
tion.
WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustment to prevent
injury to the technician and bystanders.
Install gauges to monitor system pressure (connect
to ports M1 and M2), the minimum angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
51000034
Start the prime mover and operate at normal speed. Fig. 30-26 - Pressure Compensator
Provide a signal to the pump control to provide a
Regulator (Type PC)
constant flow of hydraulic fluid to the motor. Provide
a signal to the motor control to maintain the motor at
its minimum displacement.
Increase the load on the motor to increase the system
pressure to the required regulator start pressure. The
maximum angle servo pressure (M4) will increase
and the minimum displacement servo pressure (M3)
will decrease as the PCOR or PC regulator operates.
The servo pressures will equalize, and the maximum
angle servo pressure continue to increase, as the
motor displacement starts to increase.
51000048
During the transition from minimum to maximum Fig. 30-27 - System Pressure Gauge Ports
displacement, an additional 10 bar (145 psi) increase (Side Port End Cap)
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will result in increasing system
pressure until the maximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is reached.

30 - 13 35

5/20112 735
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Component Adjustment (Continued)
Allow the pump to return to its neutral position.
Repeat the procedure for the other side of the closed
circuit if so configured. The PCOR or PC regulator
must operate at the same start pressure as noted
previously. Any noticeable difference in operation
from side to side may indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the multi-function block.
NOTE: Some motors may be configured for the
PCOR or PC regulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor nameplate.
In order for the PCOR or PC regulator to function
properly on motors equipped with a brake pressure
defeat spool, the defeat spool must be positioned
correctly. The control pressure for the defeat spool
should be applied to the appropriate port (XA or XB)
as shown in the following table to shift the defeat
spool and permit PCOR or PC regulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
51000049 Pressure Compensator Override Defeat Operation
Fig. 30-28 - Loosen PCOR/PC Lock Nut Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC regulator valve is screw adjustable.
To adjust, loosen the locknut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired pressure setting is estab-
lished. Clockwise rotation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per turn.
51000050
Fig. 30-29 - Rotate PCOR/PC Adjusting CAUTION
Screw A stop pin is installed in the adjusting screw to
prevent “overtravel” of the PCOR/PC valve
spool. The stop pin must protrude (distance
"X" “X”) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from turning, torque
the lock nut to 52 Nm (38 ft•lbsf). Recheck the PCOR
or PC regulator setting.
51000051
Shut down the prime mover. Remove the gauges and
Fig. 30-30 - PCOR/PC Adjusting Screw Stop
install the gauge port plugs. Return the pump and
Pin motor controls to their normal operation.

36 30 - 14

736 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Troubleshooting
Fault-Logic Diagrams • Closed Circuit

Check Oil Level Check System Check Pump Check Prime Mover
OK OK OK Speed
in Reservoir Relief Valve Inlet Pressure
Pressure Low Low
Low OK
Settings

Fill to Proper Defective Inspect Inlet Filter Adjust

Level and Replace if
Adjust or Necessary
Replace

Replace Check System Check Charge and

Transmission OK Internal Leakage OK Control Pressures
(Pump and Motor)
High Incorrect

Repair as Required Repair as Required

SYSTEM RESPONSE IS SLUGGISH

Check Oil Air in System OK Check Pump Inspect Shaft Inspect Shaft
OK OK OK
Level in Inlet Pressure Couplings Alignment
Reservoir
Loose Fitting Low Defective Defective
Low

Fill to Proper Purge Air and Inspect Inlet Filter Repair or Align Shafts
Level Tighten and Replace if Replace
Fittings Necessary

EXCESSIVE NOISE AND/OR VIBRATION

Check Oil Level Inspect Heat Check Charge Check Pump Inlet
OK OK OK Pressure
in Reservoir Exchanger Pressure
Low Defective Incorrect Low OK

Fill to Proper Clean, Repair Repair as Inspect Inlet Filter

Level or Replace Required and Replace if
Necessary

Replace Check System Check for Internal Check System Relief

Transmission OK Pressure OK System Leakage OK Pressure Settings
(Pump and Motor)
High High Low

Reduce Load on Repair as Required Adjust or Replace

Transmission

SYSTEM OPERATING HOT

30 - 15 37

5/20112 737
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Troubleshooting (Continued)
Fault-Logic Diagrams • Closed Circuit (Continued)

Check Charge Check Pump Interchange System Replace

Pressure OK Control System OK Relief Valves and/or OK Transmission
Charge Check (Pump and
Decays in One Defective Valves Motor)
Direction (Forward
Problem Changes
or Reverse) Only
Direction

Inspect and Repair Repair or Replace Repair or Replace

Loop Flushing Appropriate Valve
Valve

MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY

Check Inlet Check Outlet Motor at Incorrect Repair or Replace

Pressure at OK Pressure at OK (Minimum) Displacement OK Motor
Motor Motor

Low High / Low Incorrect

Correct System Correct System Check Control Supply

Pressure and/or Repair
LOW MOTOR OUTPUT TORQUE Displacement Control

Check Oil Check Charge Check Pump

Level in OK Pressure OK Output Flow OK Check Motor Displacement
Reservoir
Low Incorrect Improper Incorrect OK

Fill to Proper Repair Charge Repair Pump Check and Repair

Level System Control and/or Control System and
Pump Displacement Controls
(Pump and Motor)

Repair or Replace
Motor
IMPROPER MOTOR OUTPUT SPEED

38 30 - 16

738 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Notes

30 - 17 39

5/20112 739
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Notes

40 30 - 18

740 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor
The following information is for general parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service parts.
Base Unit
L35

W10 OPTION
WNNT L40
W50
L50
B71
W25 B80
B71A B80
L70 L80

L75

L40
L50

B70
B70A

B70A

Y10
B70
Y20
W25
Y30

Y20

W50
Y10 Y10
W10 B70A
OPTION Y20
WNNS B70
Y30

Name Plate
saue
Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ

51V160 RF1N
E1A2 ANE1 NNN Model Code
050AA210322
Model No. Ident Nr
Model Number
516-40104 786673
Serial Number N 91 25 67890
Serial No. Fabr Nr
MADE IN GERMANY

Place of Manufacture
Name Plate (German Production)
40 - 1 41

5/20112 741
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
End Cap
(....) = Applies to the indicated
G30 frame size(s).
G24

G30A
J70
G26
J60 G38

J50 G36

M18/M98 F10N, F10A–G

M16/M96 F20A–G
K90
K50
J40
K10
OR
K16 K70 OR
(250) K90N
G20
G20A K80
Q40 K90A
K14
K16 G50
(060—160)
G12 G50A G12
G12A G30A K18N
G30
(250) (250)
G80
(060, 080) G12A OR
G80A K16
G30 K18
(060, 080) (060—160) K16
(250)
G30A (250)
G30
(250) G30A K14
G20A
M11/T3A1-A9
T3B0-B6 G20
G12 T3C2-C7
G12A S20 OR
G12A
G12 S10
M11/T1A1-A9
T1B0-B6 (060, 080,
T1C2-C7 G30A 110)
G18 (250) OR S10
G90 (160, 250)
G12A G30
Y40 G12 (250)
N1U5 J30
T8A1-A9
Y50 T8B0-B6 J10A-D
T8C2-C7
J20/S70
G30A
G30 T7A1-A9
G42
G36 T7B0-B6
T7C2-C7
M11/T2A1-A9 G44
T2B0-B6
T2C2-C7 G38
F33
G38

G38
G42 F32

42 40 - 2

742 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Multi-Function Valve
N28 Q50
N28A N84
N84A

N52 OR
N32 N34
N34A
N72 N46/T5
N66 N52/T4
N72A
N66A
N34
N34A N84
N30
N34
N34A OR
N52/T6
N34A N84A
N34
N34
N34A

N1A1-A6 N28
OR N28A
N90A
N66A
N90 OR N66
N26A
N26
N34
N34A
N58
N24
N82
N11

N29

Z10 & Z20

N82 N22 & N20

U7 N24
U6 N11 & N21
N14

N16
N18
N27A
N27 N29

N23
N27A
N23A
N27

Q60

40 - 3 43

5/20112 743
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Controls

M28

M30
M24
M38

M36

M10 M30
M18
M28
M32A M32 M26 M14
M32
M24
M26
M30 M28
M1HS
M1HP
M16 M18
M16
M20 M22
M1EP•EQ
M14 M18 M16 M16
M12 M14
M12
EP•EQ M10 HS M18
M10

M36

HP

M16 M1S1
M10

M20 M14
M22
M1E1•E2•E5 M22A S1
M1F1•F2
M1H1•H2
M1K1•K2 M18A

M14
M18

M2E5

E1•E2•E5 / F1•F2 / H1•H2 / K1•K2

44 40 - 4

744 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Controls (Continued)
(....) = Applies to the indicated
frame size(s).
S50
S30
S20
S40
S60
S11T
(060, 080,
110)
OR
S11T
S10 (160, 250)
(060, 080, S10
110) (160, 250)
S10T S10T
M10 (060, 080, (160, 250)
M12 110)

S70

M44 M32
M34
M34A
M14
M40 M1HC
M1N2 M16
M38 M47
M16A M14 M46
N2
M18
M50A
M18A
M50
M10 M34A M48A
M18 M12 M11 M34
M18A M48
(060, 080, 110) M26

M18A M34A
M22 M10
M18 M16A J10 M34
M1HZ M16 M25
HZ
M24

M22

M20

M14

M12

M28 M18

M16
HC

40 - 5 45

5/20112 745
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
PC Regulator

T7

F33
F32
M84
M28
M84A
M28A
M52
M34
M34A
M72 T5
M66 T4
M66A M72A
M34
M34A
M30
M34
M34A
T6 M84
M34A M84A
M34
M34 M34A

M10 M28
M28A
M90A
M90 M28A
M26 M28
M26A

M34A
M34
M58

Z10 & Z20

M24 M82 M22 & M20

U7
U6
M1PC & M21
M14

M16
M18
M27A
M27 M29

M23
M27A
M23A
M27
Q60

46 40 - 6

746 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
B000 COMMON PARTS GROUP (SAE FLNG) J00A-K CONTROL START SETTING
B80 O-RING 1 J10A-K SPRING-HEL COMP- CONT START 1
L35 FLANGE- SAE 1 J20 SEAT-SPRING 1
L40 SEAL- SHAFT 1 J30 SEAT-SPRING 1
L50 O-RING 1 J40 SCREW-ADJUSTING 1
L70 SCREW- SOC HD 8 J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
C000 COMMON PARTS GROUP (CARTRIDGE) J70 NUT-LOCK 1
L40 SEAL- SHAFT 1
L50 O-RING 1 J00N CONT START N/A (FOR 2 POS CONT)
L75 COVER- SEAL 1
L80 RING- RETAINING 1 M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F••• MAXIMUM DISPLACEMENT F32 BUSHING- VALVE ASSY 1
F10 SPACER- MAX DISPL LMTR 1 M1EP PCP VALVE, PACKARD CONN 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1 M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
G00A END CAP-AXIAL (160-250) M12 SCREW- SOC HD 4
G00B END CAP-AXIAL, CODE 61 (160-250) M14 COVER 1
G00R END CAP-SIDE, LOOP FL M16 GASKET 1
G00S END CAP-SIDE, LOOP FL, CODE 61 M18 SCREW- SOC HD 4
G12 PLUG-STR THD HEX 7 M24 PISTON- SHUTTLE, DELTA P 1
G14 PLUG-EXP 1 M26 SPRING- HEL COMPRESSION 1
G16 PLUG-MANDREL 2 M28 PIN 1
G18 SCREW-SET, FLAT PT 2 M30 O-RING 1
G20 PLUG- SPECIAL 2 M32 PLUG-SOC HD 2
G20N PLUG- STR THD HEX 2 M34 PLUG-MANDREL 6
G24 SCREW-SOC HD 4 M36 O-RING 1
G26 COVER-SERVO PISTON 1 M38 O-RING 1
G30 PLUG-STR THD HEX 3 M40 CONTROL SCREEN FILTER 1
G36 O-RING 2 M42 PLUG-SOC HD 1
G38 O-RING 4 M44 PLUG-PLASTIC 1
G42 O-RING 2 N90 PLUG-STR THD HEX 1
G44 O-RING 1
G50 PLUG-ST THD HEX 2 M0E1/E2 CONTROL- ELHYD 2 POS
G70 COVER-PORT 2 M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
G90 CONTROL SCREEN FILTER 1 F32 BUSHING- VALVE ASSY 1
K10 ADJ PLUG ASSY-CHG RLF 1 M1E1 VALVE ASSY- SOLENOID,12V 1
K14 SPRING-HELICAL COMP 2 M1E2 VALVE ASSY- SOLENOID,24V 1
K16 GUIDE-SPRING (060 — 160) 2 M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
K16 GUIDE-SPRING (250) 2 M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
K18 SHUTTLE VALVE SPOOL 1 M12 PLUG-EXP 7
K18N LOOP FLUSH SPOOL- DEFEAT 1 M14 SCREW-SOC HD 4
K50 O-RING 1 M16 O-RING 2
K70 SPRING-HELICAL COMPRESSION 1 M18 PLUG-STR THD HEX 1
K80 POPPET-CHG RELIEF 1 M20 O-RING 1
K90 NUT-HEX LOCK 1 M22 PLUG-STR THD HEX 1
K90N PLUG- ST THD HEX 1 N90 PLUG-STR THD HEX 1

40 - 7 47

5/20112 747
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING- VALVE ASSY 1 F32 BUSHING-VALVE ASSY 1
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1 M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4 M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4 M12 O-RING 1
M12 COVER 1 M14 PLUG-STR THD HEX 1
M14 GASKET 1 M16 PLUG-PLASTIC 1
M16 NUT-SEAL LOCK 1 N90 PLUG-STR THD HEX 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1 M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M22 SPRING-HELICAL COMPRESSION 1 F32 BUSHING- VALVE ASSY 1
M24 PISTON- DELTA P 1 M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M25 SEAT- SPRING 1 M10 VALVE ASSY- DBL CHECK 1
M26 PIN 1 M12 SCREW- SOC- DRILLED 1
M28 SCREW-SOC HD 4 M14 CONTROL SCREEN FILTER 2
M32 CONTROL SCREEN FILTER 2 M16 PLUG-STR THD HEX 2
M34 PLUG-SOC HD 4 M18 PLUG-STR THD HEX 3
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1 M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M44 VALVE, SHUTTLE- DELTA P 1 M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
M46 SEAT- BALL CHECK 1 F32 BUSHING-VALVE ASSY 1
M47 BALL- SHUTTLE 1 M1H1 VALVE ASSY-SOLENOID,12V 1
M48 PLUG-STR THD HEX 1 M1H2 VALVE ASSY-SOLENOID,12V 1
M50 PLUG-STR THD HEX 1 M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M0HP CONTROL- HYD PRPNL 2LN, W/BLD M14 SCREW-SOC HD 4
F32 BUSHING- VALVE ASSY 1 M16 O-RING 2
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1 M18 PLUG-STR THD HEX 1
M10 COVER 1 M20 O-RING 1
M12 GASKET 1 M22 PLUG-PLASTIC 1
M14 PISTON-SHUTTLE, DELTA P 1 N90 PLUG-STR THD,SOC HD 1
M16 SPRING-HELICAL COMPRESSION 1
M18 PIN 1 M0N2 CON-HYD, 2 POS, DIRECT
M24 O-RING 1 M1N2 COVER 1
M26 VALVE SHUTTLE,DELTA P 1 M10 PLUG 1
M28 PLUG-SEALING 1 M11 SCREW- SET,FLT PT 3
M30 O-RING 2 M12 O-RING 1
M32 PLUG-SEALING 1 M14 SCREW-SOC 4
M34 PLUG-EXP 6 M16 GASKET 1
M36 SCREW-SOC HD 4 M18 PLUG 1
N90 PLUG-STR THD HEX 1

48 40 - 8

748 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0PC REGULATOR- PRESS COMP N0A1-6 SVO PRS SPLY, PCOR, DFT
F32 PLUG- VALVE BUSHING BORE 1 N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
F33 O-RING 1 N11 HOUSING-VALVE 1
M1PC HOUSING- VALVE 1 N14 NUT-HEX LOCK 1
M10 HOUSING- MULTI FUNCTION BLOCK 1 N16 O-RING 1
M14 NUT-HEX LOCK 1 N18 SPRING-HELICAL COMPRESSION 1
M16 O-RING 1 N20 SEAT-SPRING, PCOR 1
M18 SPRING-HELICAL COMPRESSION 1 N21 BUSHING-VALVE 1
M20 SEAT-SPRING, PC 1 N22 SPOOL-PCOR VALVE 1
M21 BUSHING-VALVE 1 N23 PLUG-STR THD HEX 1
M22 SPOOL-PC VALVE 1 N24 O-RING 5
M23 PLUG-STR THD HEX 1 N26 PLUG-SOC HD (W/PCOR) 1
M26 PLUG-SOC HD 1 N26 PLUG-STR THD HEX (WO/PCOR) 1
M27 PLUG-STR THD HEX 10 N27 PLUG-STR THD HEX 17
M28 PLUG-STR THD HEX 4 N28 PLUG-PLASTIC (W/DFT) 2
M29 SCREW-SOC 4 N28 PLUG-STR THD HEX (WO/DFT) 2
M30 SPOOL, BI-DIRECTIONAL CHECK 1 N29 SCREW-SOC 4
M34 PLUG-STR THD HEX 10 N30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5 N32 PISTON 1
M38 PLUG-EXP 11 N34 PLUG-STR THD HEX 10
M50 PLUG-EXP 8 N36 SCREW-SET,FLT PT 5
M52 CONTROL SCREEN FILTER 2 N38 PLUG-EXP (060 - 110 ONLY) 11
M54 PLUG-EXP 1 N50 PLUG-EXP (060 - 110 ONLY) 6
M58 SCREW-SOC HD 4 N52 CONTROL SCREEN FILTER 2
M62 PLUG-EXP 1 N54 PLUG-EXP 1
M66 PLUG-STR THD HEX 2 N58 SCREW-SOC HD 4
M72 PLUG-STR THD,SOC HD 1 N62 PLUG-EXP 1
M82 O-RING 1 N66 PLUG-STR THD HEX (060-110) 2
M84 PLUG-STR THD HEX 2 N66 PLUG-STR THD HEX (160-250) 1
M86 SCREW-FL PT 1 N72 PLUG-STR THD,SOC HD 1
M90 PLUG-STR THD HEX 1 N74 SCREW-SET, FL PT 3
M96 GASKET 1 N82 O-RING 1
M98 PLUG 1 N84 PLUG, SPECIAL 2
N24 O-RING 5 N84 PLUG-STR THD HEX 2
N86 SCREW-SET 1
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT U5 PLUG- SOC (EXT SUPPLY) 1
F32 BUSHING- VALVE ASSY 1 U6 ORIFICE, PCOR DAMPING 1
M1S1 SOLENOID,12V 1 U7 ORIFICE, PCOR DAMPING 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4 N0NN SERVO PRESS SPLY- NONE
M16 O-RING 1
M18 O-RING 1 P0AA SYS PRESS PROTECT- NONE
M20 PIN 1
M22 O-RING 1
N90 PLUG-STR THD HEX 1

40 - 9 49

5/20112 749
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2 Y••• MINIMUM DISPLACEMENT
S10 GUIDE-SPRING (160-250) 1 Y10 SCREW- SET, FLT PT 1
S10D-G CONT RAMP SPRING (060-110) 1 Y20 NUT- HEX, SEAL LOCK 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2 Y30 TAMPER RESISTANT CAP 1
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1 Z000 PRS COMP SET- NONE

S00N CONTROL RAMP-NONE Z0•• PCOR / PRESS COMP SETTING

Z10 ADJUSTER- THREADED 1
S00T CONTROL RAMP- HC Z20 PIN-STRAIGHT 1
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1

S00U-Z CONTROL RAMP- EP/EQ

S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1

T0A0 CON ORIFICE (A0)- NONE

T0A1 CON ORIFICE (A1)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1

T0A2 CON ORIFICE (A2)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1

WNNN SPCL HDW-NONE

A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1

50 40 - 10

750 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor

Charge Pressure
Relief Valve
Loop Flushing
Valve

Shaft
Seal

Control
Orifices

Multi-function
Block

Control
Minimum Displacement
Limiter

51000052
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repairs

Minor Repairs may be performed, following the proce- Protect all exposed sealing surfaces and open cavi-
dures in this section, without voiding the unit war- ties from damage and foreign material.
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51 It is recommended that all gaskets and O-rings be
family. replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
General rings with clean petroleum jelly prior to assembly.
Cleanliness is a primary means of insuring satisfac-
tory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
and related items must be kept free of foreign mate-
rials and chemicals.

50 - 1 51

5/20112 751
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Shaft Seal (SAE Flange Configuration)
Lip type shaft seals are used on the Series 51 motors.

Replacement of the shaft seal usually requires re-

moval of the motor from the machine.

Remove the screws holding the flange to the housing,

using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm internal hex wrench (110 units), a 10 mm
internal hex wrench (160 units), or a 12 mm internal
hex wrench (250 units).

Remove the flange from the housing using a suitable

puller. Care must be taken so as to not damage the
housing bore or shaft.
51000178 51000179 CAUTION
Fig. 50-2 - Remove Fig. 50-3 - Remove
Screws Holding Flange (SAE) Do not allow the output shaft to move out of the
Flange to Housing housing while removing the flange. After the
(SAE) flange is removed, do not attempt to remove
the shaft from the housing. If the output shaft
moves out of the housing, the synchronizing
shaft and rollers could fall out of position,
requiring major disassembly of the unit.

Remove the old seal from the flange. Once removed,

the seal is not reusable.

Inspect the flange and the new seal for any damage
or nicks.

Using an arbor press, press the new seal into the

flange. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

51000053 51000054 lightly coated with a sealant (such as Loctite
Fig. 50-4 - Remove Fig. 50-5 - New Seal High Performance Sealant #59231) prior to
Old Seal from Flange Installed in Flange installation. This will aid in preventing leaks
(SAE) (SAE) caused by damage to the seal bore in the
flange.

Inspect the sealing area on the shaft for rust, wear, or

contamination.

52 50 - 2

752 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install a new O-ring on the flange. Prior to assembly,
lubricate the flange O-ring and the I.D. of the seal with
petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the flange and seal over the shaft and into
the housing bore. Install four (4) of the flange screws,
51000055 51000056
and tighten them evenly to pull the flange into posi- Fig. 50-6 - Install Fig. 50-7 - Torque
tion. Take care to not damage the O-ring or seal lip
Flange onto Housing Flange Screws (SAE)
during installation.
(SAE)
Install the flange screws and torque evenly to 32 Nm
(24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•lbsf)
for 110 motors, 110 Nm (81 ft•lbsf) for 160 motors,
and 174 Nm (128 ft•lbsf) for 250 motors.

Shaft Seal (Cartridge Configuration)

Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft
seal requires removal of the motor from the wheel
drive or track drive gearbox.

Remove the seal carrier retaining ring from the hous-

ing.

Carefully pull the seal cover out of the housing. Care

must be taken so as not to damage the housing bore
or shaft.

Remove the O-ring from the housing.

Remove the old seal from the carrier. Once removed,

the seal is not reusable. 51000057 51000058
Fig. 50-8 - Remove Fig. 50-9 - Remove
Inspect the carrier and the new seal for any damage
Carrier Retaining Seal Carrier
or nicks.
Ring (Cartridge) (Cartridge)
Using an arbor press, press the new seal into the
carrier. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the seal
carrier.
51000059 51000060
Inspect the sealing area on the shaft for rust, wear, or
Fig. 50-10 - Seal Fig. 50-11 - Seal
contamination.
Carrier Removed Installed in Carrier
(Cartridge) (Cartridge)
50 - 3 53

5/20112 753
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install the carrier O-ring into the groove in the hous-
ing. Prior to assembly, lubricate the carrier O-ring and
the I.D. of the seal with petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not damage the O-ring
51000061 51000057
Fig. 50-12 - Install Fig. 50-13 - Install or seal lip during installation.
Seal Carrier Carrier Retaining Install the seal carrier retaining ring.
(Cartridge) Ring (Cartridge)
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex plugs from
both sides of end cap.
Remove springs and spring seat washers. Note the
orientation of the washers.
NOTE The 250 frame size motors use thicker spring
seat washers.
51000062 51000063 Remove flushing valve spool.
Fig. 50-14 - Remove Fig. 50-15 - Remove
Shuttle Valve Plugs Valve Spool

Inspect parts for damage or foreign material.

51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components

Install flushing valve spool in end cap, then install the

spring seat washers (thick washers on 250 frame size
motors) on each end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex plugs. Torque the
plugs to 41 Nm (30 ft•lbsf).

51000064 51000065
Fig. 50-17 - Install Fig. 50-18 - Install
Valve Spool and Plugs and Springs
Washers
54 50 - 4

754 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Charge Pressure Relief Valve
Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and end cap to allow
maintaining the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut (with a 1-1/16"
hex wrench), and unscrewing the plug with a large
screwdriver.

Remove the spring and relief valve poppet. 51000067 51000068

Fig. 50-19 - Remove Fig. 50-20 - Remove
Inspect the poppet and mating seat in the end cap for Charge Relief Valve Charge Relief Valve
damage or foreign material. Plug
Install the poppet and spring. Install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 ft•lbsf).

Check and adjust, if necessary, the charge pressure.

51000069
Fig. 50-21 - Charge Relief Valve
Components

Minimum Angle Servo Cover

Thoroughly clean external surfaces prior to removal
of cover.

Remove the four (4) screws retaining the cover to the

end cap with an 8 mm internal hex wrench (060, 080,
110, and 160 units) or a 10 mm internal hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end cap.
51000046 51000006
Install new O-rings on the end cap and retain with Fig. 50-22 - Remove Fig. 50-23 - Install
petroleum jelly. Install the cover onto the end cap and Servo Cover Screws Servo Cover
install the screws. Torque the screws to 78 Nm (58
ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•lbsf)
for 160 or 250 units.

The plug in the cover may be removed with a 7/16"

hex wrench. Torque this plug to 9 Nm (7 ft•lbsf).

50 - 5 55

5/20112 755
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic 2-Position Control (Type N2)
Thoroughly clean external surfaces prior to removal
of cover plate.

Remove the four (4) screws retaining the cover plate

to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units). Remove the cover plate.

51000071 51000072 Remove the solid plug from the valve sleeve bore in
Fig. 50-24 - Remove Fig. 50-25 - Remove the end cap. (An 8 mm threaded hole is provided in
Cover Plate Screws Cover Plate the plug for a puller screw.) Remove the O-ring from
the plug.

Remove the O-rings from the end cap.

Install new O-rings on the end cap and retain with

petroleum jelly.

Install a new O-ring on the solid plug and install the

solid plug into the end cap.

51000168
Fig. 50-26 - Remove Valve Sleeve Bore
Plug Install the cover plate onto the end cap and install the
screws. Torque the screws to 78 Nm (58 ft•lbsf) for
060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160
or 250 units.

Set screws are installed in control orifice holes in the

end cap to plug the valve sleeve bore passages. To
gain access to the screw plugs, remove the outer
plugs from the end cap with a 7/16" or 11/16" hex
wrench. Remove the screw plugs with a 3 mm internal
hex wrench. When installing, torque the screw plugs
51000010
to 4 Nm (35 in•lbsf). Torque the 5/16" outer plugs to
Fig. 50-27 - N2 Control Components 9 Nm (7 ft•lbsf), and the 9/16" outer plugs to 37 Nm (27
ft•lbsf). Refer to the “Control Orifices” topic for addi-
tional information.

The special plug and seal washer on the end cap

opposite the control may be removed with a 13 mm
hex wrench. When installing, torque this plug to 20
Nm (15 ft•lbsf).

51000073 51000074
Fig. 50-28 - Torque Fig. 50-29 - Torque
Cover Plate Screws Plug in End Cap

56 50 - 6

756 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic 2-Position Controls
(Types E1•E2 and F1•F2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
51000075 51000076
Fig. 50-30 - Remove Fig. 50-31 - Remove
E1•E2 or F1•F2 Solenoid Valve
Control Solenoid
Remove the screws retaining the valve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).

51000013
Fig. 50-32 - E1•E2 and F1•F2 Control
Components

Install new O-rings onto the valve housing. Install the

valve housing onto the multi-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ft•lbsf).

51000077
Fig. 50-33 - Install E1•E2 or F1•F2 Control
Valve Housing

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf). When installing the solenoid onto the valve,
torque the nut to 15 Nm (11 ft•lbsf.).

51000078 51000079
Fig. 50-34 - Install Fig. 50-35 - Install
Solenoid Valve Solenoid

50 - 7 57

5/20112 757
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Electric 2-Position Controls (Type S1)
Thoroughly clean external surfaces prior to removing
the control.

Remove the screws retaining the solenoid and sole-

noid adapter plate to the multi-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the multi-function
block.
51000164 51000165
Fig. 50-36 - Remove Fig. 50-37 - Remove Remove the solenoid pin from the multi-function
S1 Control Screws Adapter Plate and block.
Solenoid
Install new O-rings onto the adapter plate and the
solenoid.

51000163
Fig. 50-38 - S1 Control Components

Install the solenoid pin into the hole in the multi-

function block.

51000086
Fig. 50-39 - Install S1 Control Solenoid Pin

Install the adapter plate with O-rings onto the multi-

function block.

Install the solenoid with O-ring onto the adapter plate.

Install the screws and torque to 6.4 Nm (4.7 ft•lbsf).

51000165 51000166
Fig. 50-40 - Install Fig. 50-41 - Torque
Adapter Plate and Control Solenoid
Solenoid Screws

58 50 - 8

758 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HZ)
Thoroughly clean external surfaces prior to removal
of control.

Remove the four (4) screws retaining the valve hous-

ing to the end cap with an 8 mm internal hex wrench
(060, 080, and 110 units) or a 10 mm internal hex
wrench (160 and 250 units). Remove the valve hous-
ing. Remove the O-rings between the valve housing
and end cap, and the O-ring on the valve spool 51000080 51000081

sleeve. Fig. 50-42 - Remove Fig. 50-43 - Remove

HZ Control Housing HZ Control Housing
The plugs on the control housing may be removed Screws
with a 7/16" or 11/16" hex wrench. When reinstalling,
torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16"
plugs to 37 Nm (27 ft•lbsf)

The valve housing is equipped with filter screens in

51000016
Fig. 50-44 - HZ Control Components

the passages between the housing and the end cap.

Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.

Units with external servo pressure supply have a plug 51000082 51000083
installed in the end cap passage leading to the valve Fig. 50-45 - HZ Fig. 50-46 - End Cap
spool sleeve. This plug may be removed with a 2.5 Control Housing O-Rings Installed
mm internal hex wrench. When installing this plug, Screens
torque to 2 Nm (18 in•lbsf).

Install a new O-ring onto the valve spool sleeve in the

end cap. Install new O-rings onto the end cap.

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250
units. 51000081 51000084
Fig. 50-47 - Install HZ Fig. 50-48 - Torque
Control Housing HZ Control Valve
Housing Screws
50 - 9 59

5/20112 759
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HS)
Thoroughly clean external surfaces prior to removal
of control.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

51000087
Fig. 50-49 - Remove HS Control Housing
Screws

The plug on the control housing may be removed with

an 11/16" hex wrench. When reinstalling, torque the
plug to 37 Nm (27 ft•lbsf).

Install a new O-ring onto the valve housing.

51000019
Fig. 50-50 - HS Control Components

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000088
Fig. 50-51 - Torque HS Control Housing
Screws

60 50 - 10

760 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control with
Maximum Angle Over-ride (Types H1•H2 or
K1•K2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench.

51000089 51000090
Fig. 50-52 - Remove Fig. 50-53 - Remove
H1•H2 or K1•K2 Solenoid Valve
Control Solenoid
The solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).
51000091
Fig. 50-54 - Remove Control Housing
Screws

Install new O-rings onto the valve housing.

Install the valve housing onto the multi-function block,

and install the screws. Torque the screws to 6.4 Nm
(4.7 ft•lbsf).

51000021
Fig. 50-55 - H1•H2 and K1•K2 Control
Components

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf).

When installing the solenoid onto the valve, torque

the nut to 15 Nm (11 ft•lbsf.).

51000092 51000093
Fig. 50-56 - Install Fig. 50-57 - Install
Solenoid Valve Solenoid

50 - 11 61

5/20112 761
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control (Type HP)
Thoroughly clean external surfaces prior to removal
of control.

Hold the control housing in position, and remove the

screws retaining the cover and control housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the housing cover and gasket. Remove the
51000094 51000095 valve housing with shuttle valve assembly and pilot
Fig. 50-58 - Remove Fig. 50-59 - Remove piston from the multi-function block.
HP Control Housing Control Housing
Screws Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

Remove the inner shuttle spool plug from the valve

housing. (A 5 mm threaded hole is provided in the
inner plug for a puller screw.) Remove the shuttle
spool from the valve housing. Remove the outer
shuttle spool plug. Remove the O-rings from the
51000096 51000086 plugs.
Fig. 50-60 - Remove Fig. 50-61 - Remove
Shuttle Spool Plug Pilot Piston Pin

Install new O-rings on the shuttle spool plugs.

Install new O-rings on the valve housing and retain

with petroleum jelly.

51000024
Fig. 50-62 - HP Control Components

62 50 - 12

762 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Install the outer (thin) shuttle piston plug with the large
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the large chamfer toward the shuttle valve
bore.

51000097 51000098
Fig. 50-63 - Pilot Fig. 50-64 - Install
Piston Pin Installed Shuttle Spool and
Plugs
Position the valve housing (with O-ring) on the multi-
function block.

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

51000099 51000100
Fig. 50-65 - Install Fig. 50-66 - Install
Control Housing Pilot Piston

Install the small spring in the outer end of the pilot

piston.

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

51000101 51000102
Fig. 50-67 - Install Fig. 50-68 - Install
Spring Cover, Gasket, and
Screws

50 - 13 63

5/20112 763
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control for “Dual Path” Vehicles (Type HC)
Bleed Valve

Loosen the seal lock nut on the bleed valve with a 10

mm hex wrench, and remove the valve with a 4 mm
internal hex wrench.

Install the bleed valve and torque to 3 Nm (27 in•lbsf).

51000103 51000175
Fig. 50-69 - Remove Fig. 50-70 - Install
HC Control Bleed HC Control Bleed
Valve Valve
Install the seal lock nut and torque to 19 Nm (14
ft•lbsf).

Servo Pressure Shuttle Valve

Remove the servo pressure shuttle plug with an

11⁄16" hex wrench. Remove the shuttle ball seat with
a 5 mm internal hex wrench and remove the ball.

51000176 51000104
Fig. 50-71 - Install Fig. 50-72 - Remove
HC Control Bleed Servo Pressure Ball
Valve Seal Nut Shuttle Valve
Install the servo pressure shuttle ball.

Install the shuttle ball seat and torque to 11 Nm (8

ft•lbsf). Install the shuttle passage plug and torque to
37 Nm (27 ft•lbsf).

51000123 51000174
Fig. 50-73 - Install Fig. 50-74 - Torque
Servo Pressure Servo Pressure
Shuttle Ball Valve Shuttle Ball Seat
Control Pressure Shuttle Valve

Remove the shuttle spool plugs with a 1/4" internal

hex wrench. Remove the control pressure shuttle
spool.

Install the control pressure shuttle spool.

Install the shuttle spool plugs and torque to 20 Nm (15

ft•lbsf).
51000105 51000122
Fig. 50-75 - Install Fig. 50-76 - Torque
Control Pressure Shuttle Spool Plugs
Shuttle Spool
64 50 - 14

764 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Pilot Piston and Control Housing

Thoroughly clean external surfaces prior to disas-

sembly of control.

Remove the four (4) screws retaining the cover to the

control housing with a 4 mm internal hex wrench.

Remove the housing cover and gasket (with the

adjusting screw and seal lock nut).
51000177 51000106
Fig. 50-77 - Remove Fig. 50-78 - Remove
HC Control Housing HC Control Housing
Cover Screws Cover
Remove the control start adjustor spring seat and
spring from the pilot piston.

Remove the pilot piston from the control housing.

Remove the pilot piston pin seat and pin from the
control housing (or pilot piston).

Remove the control start spring from the control

housing.
51000107 51000108
Fig. 50-79 - Remove Fig. 50-80 - Remove
Adjustment Spring Pilot Piston Pin and
and Pilot Piston Control Start Spring
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the control housing to
the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units).

Remove the control housing from the end cap. Re-

move the O-rings between the control housing and
the end cap, and the O-ring on the valve spool sleeve.
51000109 51000110
Fig. 50-81 - Remove Fig. 50-82 - Remove
HC Control Housing HC Control Housing
Screws

50 - 15 65

5/20112 765
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
The plugs on the control housing may be removed
with a 7/16" hex wrench or a 1/4" internal hex wrench.
When reinstalling, torque the 5/16" plugs to 9 Nm (7
ft•lbsf), and the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000111
Fig. 50-83 - HC Control Components

The control housing is equipped with filter screens in

the passages between the housing and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.
51000112 51000113
Fig. 50-84 - HC Fig. 50-85 - End Cap Install a new O-ring onto the valve spool sleeve in the
Control Housing O-Rings Installed for end cap. Install new O-rings onto the end cap.
Screens HC Control

Install the valve housing onto the end cap, and install
the screws (with flat washers on 060, 080, and 110
units).

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

and 110 units, or to 110 Nm (81 ft•lbsf) for 160 and
250 units.

51000110 51000114
Fig. 50-86 - Install Fig. 50-87 - Torque
HC Control Housing HC Control Housing
Screws
66 50 - 16

766 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install the control start spring into the control housing.

Install the pilot piston pin. The end of the pin must
engage the recess in the end of the control valve
spool.

51000115 51000116
Fig. 50-88 - Install Fig. 50-89 - Install
HC Control Start Pilot Piston Pin
Spring
Install the pilot piston pin seat.

Install the pilot piston into the housing and over the
spring and spring seat. The end of the piston with the
deeper bore and the cross drilled hole should engage
the start spring and pin seat.

51000117 51000118
Fig. 50-90 - Install Fig. 50-91 - Install
Pilot Piston Pin Seat HC Control Pilot
Piston
Install the adjustor spring in the outer end of the pilot
piston.

Install the adjustor spring seat.

51000119 51000120
Fig. 50-92 - Install Fig. 50-93 - Install
HC Control Start HC Control Start
Adjuster Spring Adjuster Spring Seat
Install the control cover and gasket (with adjusting
screw and seal lock nut).

Torque the control cover screws to 6.4 Nm (4.7

ft•lbsf).

51000106 51000121
Fig. 50-94 - Install Fig. 50-95 - Torque
HC Control Cover Control Cover
and Gasket Screws
50 - 17 67

5/20112 767
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces prior to removal
of control.

The Pressure Control Pilot (PCP) valve may be

removed from the control valve housing, as de-
scribed under the following heading.

51000124 51000125 Remove the screws retaining the control housing

Fig. 50-96 - Remove Fig. 50-97 - Remove cover and control valve housing to the multi-function
PCP Valve EP•EQ Control block with a 4 mm internal hex wrench. Remove the
Housing Screws housing cover and gasket.

Remove the valve housing with the pilot piston from

the multi-function block.

Remove the O-rings from the valve housing. Remove

the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

51000126 51000086
Fig. 50-98 - Remove Fig. 50-99 - Remove
EP•EQ Control Pilot Piston Pin
Housing
Install new O-rings on the valve housing and retain
with petroleum jelly.

The plugs on the control housing may be removed

with a 1/4" internal hex wrench. When reinstalling,
torque the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000027
Fig. 50-100 - EQ Control Components (EP
Similar)

68 50 - 18

768 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Position the valve housing (with O-rings) on the multi-

function block.

51000097 51000127
Fig. 50-101 - Pilot Fig. 50-102 - Install
Piston Pin Installed Control Housing

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

Install the small spring in the outer end of the pilot

piston.

51000128 51000129
Fig. 50-103 - Install Fig. 50-104 - Install
Pilot Piston Spring

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

Reinstall the PCP valve, if removed.

51000130 51000131
Fig. 50-105 - Torque Fig. 50-106 - Install
Cover, Gasket, and PCP Valve
Screws

50 - 19 69

5/20112 769
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Pressure Control Pilot (PCP) Valve for
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces of control.

Using a 4 mm internal hex wrench, remove the four

(4) screws and remove the PCP valve.

Check surfaces for nicks or damage. Clean internal

51000132 51000133 screens.
Fig. 50-107 - Remove Fig. 50-108 - PCP
PCP Valve Screws Valve Components

Install new O-rings on the PCP housing and retain

with petroleum jelly. Position the PCP on the control
valve housing and install the screws.

Torque the screws to 5.4 Nm (48 in•lbsf).

51000124 51000131
Fig. 50-109 - Install Fig. 50-110 - Torque
PCP onto Control PCP Valve Screws

70 50 - 20

770 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Multi-function Block
Removal and Installation
Remove the external control assembly as described
in the instructions for the specific control.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the multi-function block
to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
51000087 51000134
(160 and 250 units).
Fig. 50-111 - Remove Fig. 50-112 - Remove
Remove the multi-function block from the end cap. External Control (HS Multi-function Block
Remove the O-rings between the multi-function block Shown) Screws
and the end cap, and the O-ring on the valve spool
sleeve.
The multi-function block is equipped with filter screens
in the passages between the block and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the multi- 51000135 51000136

function block or end cap. Fig. 50-113 - Remove Fig. 50-114 - Multi-
Multi-function Block function Block
Units with external servo pressure supply have a plug
Screens
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 in•lbsf).
Install a new O-ring onto the valve spool sleeve in the
end cap.
Install new O-rings onto the end cap.
Install the multi-function block onto the end cap, and
install the screws. 51000083 51000135

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, Fig. 50-115 - End Fig. 50-116 - Install
or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 Cap O-Rings Multi-function Block
units. Installed
Reinstall the external control assembly as described
in the instructions for the specific control.

51000137 51000088
Fig. 50-117 - Torque Fig. 50-118 - Install
Multi-function Block External Control (HS
Screws Shown)
50 - 21 71

5/20112 771
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Servo Pressure Supply Shuttle Spool

Remove the servo pressure supply shuttle spool plug

from the multi-function valve with a 9/16" hex wrench.

NOTE: If a pressure compensator valve block is

installed, the opposite end of the shuttle
spool bore in the multi-function valve is
plugged with an internal hex head plug lo-
cated under the valve block. If a pressure
51000138 51000139
Fig. 50-119 - Remove Fig. 50-120 - Remove compensator valve block is not installed, the
opposite end of the shuttle spool bore is
Servo Pressure Servo Pressure
plugged with a hex head plug.
Supply Spool Plug Supply Shuttle Spool
Remove the servo pressure supply shuttle spool from
the multi-function valve block.

Inspect the shuttle spool for burrs or scoring. The

spool must slide free in its bore. The shuttle ball in the
spool must be free to move.

51000030
Fig. 50-121 - Multi-function Block with
Servo Pressure Supply Shuttle Spool

Install the shuttle spool into the multi-function block.

Install the hex head plug into the multi-function valve

and torque to 37 Nm (27 ft•lbsf).

NOTE: If an internal hex head plug was removed

from the opposite end of the shuttle spool
bore, torque it to 20 Nm (15 ft•lbsf).

51000139 51000140
Fig. 50-122 - Install Fig. 50-123 - Torque
Servo Pressure Servo Pressure
Supply Shuttle Spool Supply Spool Plug

72 50 - 22

772 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Blocking Plate for Multi-function Block Without
PCOR

The blocking plate may be removed by removing the

four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the plate.

Install new O-rings on the blocking plate and retain

with petroleum jelly. Install the plate on the multi-
function block and install the screws. Torque the
51000170 51000171
screws to 11 Nm (8 ft•lbsf). Fig. 50-124 - Remove Fig. 50-125 - Torque
Blocking Plate (Less Blocking Plate
PCOR) Screws (Less PCOR)
Pressure Compensator Valve for Pressure
Compensator Over-Ride (PCOR) and Pressure
Compensator Regulator (Type PC)

Loosen the adjusting screw lock nut with a 1-1/16"

hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.

Remove the pressure compensator valve spring and

the spool assembly from the block.
51000142 51000143
Fig. 50-126 - Remove Fig. 50-127 - Remove
PCOR•PC Adjustor PCOR•PC Spring
and Spool Valve
Remove the valve block plug with a 1" hex wrench.

Remove the four (4) screws retaining the valve block

to the multi-function block with a 5 mm internal hex
wrench. Remove the valve block and O-rings.

51000144 51000145
Fig. 50-128 - Remove Fig. 50-129 - Remove
PCOR•PC Plug PCOR•PC Valve
Block
Install new O-rings on the pressure compensator
valve block and retain with petroleum jelly. Install a
new O-ring on the adjusting screw.

The plugs on the valve block may be removed with a

7⁄16" hex wrench. When reinstalling, torque the 5⁄16"
plugs to 9 Nm (7 ft•lbsf).

51000146
Fig. 50-130 - Pressure Compensator Valve
Block Components

50 - 23 73

5/20112 773
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Install the valve block on the multi-function block and
install the screws. Torque the screws to 11 Nm (8
ft•lbsf).

Install the valve block plug and torque to 54 Nm (40

ft•lbsf).

51000147 51000148
Fig. 50-131 - Install Fig. 50-132 - Install
PCOR•PC Valve PCOR•PC Valve Plug
Block
Install the pressure compensator spool assembly
and the valve spring.

Install the adjusting screw and lock nut. Perform the

PCOR or PC regulator pressure adjustment as de-
scribed under “Component Adjustment."

51000143 51000142
Fig. 50-133 - Install Fig. 50-134 - Install
PCOR•PC Spring PCOR•PC Adjusting
and Spool Valve Screw
PCOR and PC Regulator Orifices

To gain access to the PCOR or PC regulator orifices,

remove the three (3) plugs located between the
defeat spool stop plugs on the multi-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if installed). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
51000149
Fig. 50-135 - PCOR and PC Regulator Refer to the appropriate Service Parts Manual for
information on orifice locations and sizes.
Orifices
Install the orifice plug(s) and plain plug(s), and torque
to 4 Nm (35 in•lbsf). Install the outer plugs and torque
to 6 Nm (4 ft•lbsf). Reinstall the PCOR defeat spool (if
removed).

Additional orifices are installed in the passages under

the pressure compensator valve block.

51000172
Fig. 50-136 - PCOR and PC Regulator
Orifices

74 50 - 24

774 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
PCOR Brake Pressure Defeat Spool

Remove the PCOR defeat spool bore plugs or fittings

with a hex wrench.

Remove the PCOR defeat spool stop plugs with a

7⁄16" hex wrench. Remove the defeat spool.

NOTE: The defeat spool may be removed from

either end of its bore in the multi-function block.
51000150 51000151
Fig. 50-137 - Remove Fig. 50-138 - Remove
PCOR Defeat Spool PCOR Defeat Spool
Plug or Fitting Stop Plug
Inspect the defeat spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop plugs for damage.

51000032
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components

Install the PCOR defeat spool into its bore in the multi-
function block.

Install the spool stop plugs into the multi-function

block. Torque the stop plugs to 6 Nm (4 ft•lbsf).

Install the defeat spool bore plugs or fittings and

torque to 27 Nm (20 ft•lbsf).

51000152 51000153
Fig. 50-140 - Install Fig. 50-141 - Install
PCOR Defeat Spool PCOR Defeat Spool
Stop Plug

50 - 25 75

5/20112 775
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Pressure Compensator Regulator (Type
PC)
The PC regulator utilizes the multi-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the “Multi-function Block” section of this
manual.
51000035
Fig. 50-142 - PC Regulator Components

A valve sleeve bore plug is installed in the motor end

cap in place of the valve spool sleeve. Remove the
plug from the valve sleeve bore in the end cap. (An 8
mm threaded hole is provided in the plug for a puller
screw.) Remove the O-ring from the plug.
A single servo drain orifice is installed in the valve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
51000169 51000173
Fig. 50-143 - Remove Fig. 50-144 - Servo Install a new O-ring on the valve sleeve bore plug.
Valve Sleeve Bore Drain Orifice (T7) Install the bore plug into the end cap.
Plug
The special plug and seal washer on the end cap
opposite the multi-function block may be removed
with a 13 mm hex wrench. When installing, torque this
plug to 20 Nm (15 ft•lbsf).

76 50 - 26

776 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Bent Axis Variable Displacement Motors Series 51

Minor Repair and Replacement - Variable Motor (Continued)
Control Orifices
Orifices are installed in the motor end cap to regulate
oil flow to the servo control valve and the servo piston.

To gain access to these orifice plugs, remove the

three (3) plugs located on the motor end cap nearest
the multi-function block or control, using a 7⁄16" or
9⁄16" hex wrench. Remove the orifice plugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
51000154 51000155
Install the orifice plugs, and torque to 4 Nm (35 Fig. 50-145 - Servo Fig. 50-146 - Servo
in•lbsf). Torque the 5⁄16" outer plugs to 9 Nm (7 Pressure Supply Orifice for Maximum
ft•lbsf), and the 9⁄16" outer plug to 37 Nm (27 ft•lbsf). Orifice (T1) Displacement (T2)
Orifices are also installed in the servo control valve
sleeve to control oil flow from the servo piston to the
motor case.

51000156 51000157
Fig. 50-147 - Servo Fig. 50-148 - Servo
Orifice for Minimum Drain Orifices (T7
Displacement (T3) and T8)
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated
in the accompanying table.

Item Torque
Pressure Gauge Ports 37 Nm
(9/16—18 O-Ring Hex) (27 ft•lbsf)
Construction Plugs 20 Nm
(9/16—18 O-Ring Int. Hex) (15 ft•lbsf)
Construction Plugs 9 Nm
(5/16—24 O-Ring) (7 ft•lbsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 in•lbsf)

50 - 27 77

5/20112 777
778
78
DO NOT REMOVE UNTIL CONTROL VALVE AND
SPRINGS ARE REMOVED!
Remove as an assembly to preserve adjustment.
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
J70 For Proportional Controls
J60 [Except HC]
J40 (060 — 110 Frame Sizes)
For Proportional Controls
Items T1, T2, and T3: [Except HC]
3 mm internal hex wrench; (160 — 250 Frame Sizes)
J50
Torque to 5 Nm (44 lbsf•in)
4 mm internal S20
hex wrench T2
S10

S20
J30
J10
S10 S70
J30
J10
T1 S70
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

T3
Remove Item T1 BEFORE removing Item F32! T7
Install Item T1 AFTER installing Item F32! F32
J30
Install O-ring J10 F33
a
Genuine

on adjustor screw J20 T8

Service Parts

Minor Repair Instructions

13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) For 2-Position Controls 2.5 mm int. hex wrench
4-Way Valve and Feedback Springs

10 mm hex wrench [Except N2] Torque to 2 Nm (18 lbsf•in)

Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
after adjustment for puller screws
FOR 2-POSITION CONTROLS,
Sheet 1 of 2

Install O-rings
DO NOT DISTURB ADJUSTMENT! on valve sleeve
Series 51 MV

5/2012
5/20112
DO NOT REMOVE UNTIL CONTROL VALVE AND
SPRINGS ARE REMOVED!
Remove as an assembly to preserve adjustment (060 — 110).
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
S50
S30
For 060 — 110 Frame Sizes
S60
Items T1, T2, and T3: For 160 — 250 Frame Sizes
S40 3 mm internal hex wrench;
Torque to 5 Nm (44 lbsf•in)
4 mm internal
hex wrench T2 S20

S11T
S10
S20 S10T
S70
S11T
T1 S10
T3 S10T
S70
Remove Item T1 BEFORE removing Item F32!
T7
Install Item T1 AFTER installing Item F32!
F32
Install O-ring
a
Genuine

on adjustor screw F33

Service Parts

Minor Repair Instructions

T8
13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) 2.5 mm int. hex wrench
Torque to 2 Nm (18 lbsf•in)
10 mm hex wrench
Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
Sheet 2

after adjustment. for puller screws

Install O-rings
4-Way Valve and Feedback Springs - HC Control

on valve sleeve
Series 51 MV

79

779
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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TWX: 9105201150 Phone: (04321) 871-0 • FAX: (04321) 871 122
SM-VMV51E • 11/97 • 300 043A
BLN-10043 • Revision A • November 1997

780 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

-AINTENANCE AND 2EPAIR -ANUAL

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$ATA SUBJECT TO CHANGE WITHOUT NOTICE 7E DECLINE ALL RESPONSABILITY FOR THE USE OF NON ORIGINAL COMPONENTS OR ACCES
SORIES WHICH HAVE NOT BEEN TESTED AND SUBMITTED FOR APPROVAL
$ATI SOGGETTI A MODIlCHE SENZA IMPEGNO DI PREAVVISO 3I DECLINA OGNI RESPONSABILITÜ á PER LUTILIZZO DI COMPONENTI NON
ORIGINALI O ACCESSORI NON COLLAUDATI ED APPROVATI
!NDERUNGEN OHNE VORHERIGE !NKUNDINGUNG VORBEHALTEN %S WIRD JEDE 6ERANTWORTUNG FUR DIE 6ERWENDUNG VON .ICHTORIG
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,OS DATOS PUEDEN SER MODIlCADOS SIN AVISO PREVIO 3E DECLINA TODA RESPONSABILIDAD EN EL CASO DE USO DE COMPONENTES
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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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5/20112 783
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

).42/$5#)/. ).42/$5:)/.% 6/2!533%4:5.' 02/,/'/ ).42/$5#4)/.

4HE EFlCIENCY AND CONTINUED OPERATION OF MECHANICAL )-0/24!.4% )N TUTTE LE OPERAZIONI á CONSIGLIABILE USARE
'" UNITS DEPEND ON CONSTANT CORRECT MAINTENANCE AND ATTREZZATURE IDONEE QUALI CAVALLETTI O BANCHI DI SOSTEGNO MARTELLI
ALSO ON EFlCIENT REPAIR WORK SHOULD THERE BE A BREAK IN PLASTICA O RAME LEVE APPROPRIATE ESTRATTORI E CHIAVI SPECIlCHE
DOWN OR MALFUNCTION 4HE INSTRUCTION CONTAINED IN THIS MANUAL AL lNE DI FACILITARE IL LAVORO SALVAGUARDATO NEL CONTEMPO LE
HAVE BEEN BASED ON COMPLETE OVERHAUL OF THE UNIT SUPERlCI LAVORATE E LA SICUREZZA DEGLI OPERATORI 0RIMA DI
(OWEVER IT IS UP TO THE MECHANIC TO DECIDE WHETHER OR NOT IT IS PROCEDERE AL DISASSEMBLAGGIO DELLE PARTI E SCARICARE LOLIO á
NECESSARY TO ASSEMBLE ONLY INDIVIDUAL COMPONENTS WHEN PARTIAL OPPORTUNO ESEGUIRE UNACCURATA PULIZIA DEL PONTE ASPORTANDO
REPAIR WORK IS NEEDED INCROSTAZIONI ED ACCUMULI DI GRASSO
4HE MANUAL PROVIDES A QUICK AND SURE GUIDE WHICH WITH THE USE
OF PHOTOGRAPHS AND DIAGRAMS ILLUSTRATING THE VARIOUS PHASES OF 02%-%33! 4UTTI GLI ORGANI MECCANICI SMONTATI DEVONO ESSERE
THE OPERATIONS ALLOWS ACCURATE WORK TO BE PERFORMED ACCURATAMENTE PULITI CON PRODOTTI APPROPRIATI QUINDI RIPRISTINATI O
!LL THE INFORMATION NEEDED FOR CORRECT DISASSEMBLY CHECKS AND SOSTITUITI NEL CASO PRESENTINO DANNI USURA INCRINATURA GRIPAGGI
ASSEMBLY OF EACH INDIVIDUAL COMPONENT IS SET OUT BELOW )N ORDER ECC )N PARTICOLARE VERIlCARE LINTEGRITÜ DI TUTTE QUELLE PARTI IN
TO REMOVE THE DIFFERENTIAL UNIT FROM THE VEHICLE THE MANUALS MOVIMENTOCUSCINETTI INGRANAGGI COPPIA CONICA ALBERI E DI
PROVIDED BY THE VEHICLE MANUFACTURER SHOULD BE CONSULTED )N TENUTAANELLI /2 PARAOLIO SOGETTE A MAGGIORI SOLLECITAZIONI ED
DESCRIBING THE FOLLOWING OPERATIONS IT IS PRESUMED THAT THE UNIT HAS USURA % CONSIGLIABILE COMUNQUE LA SOSTITUZIONE DEGLI ORGANI
ALREADY BEEN REMOVED FROM THE VEHICLE DI TENUTA OGNI QUALVOLTA SI PROCEDE ALLA REVISIONE O RIPARAZIONE
DEI COMPONENTI !L MOMENTO DEL MONTAGGIO GLI ANELLI DI TENUTA
)-0/24!.4 )N ORDER TO FACILITATE WORK AND PROTECT BOTH WORKING DEVONO ESSERE LUBRIlCATI SUI BORI DI TENUTA .EL CASO DELLA COPPIA
SURFACES AND OPERATORS IT IS ADVISABLE TO USE PROPER EQUIPMENT CONICA LA SOSTITUZIONE DI UNO DEI SUOI INGRANAGGI COMPORTA
SUCH AS TRESTLES OR SUPPORTING BENCHES PLASTIC OR COPPER ANCHE LA SOSTITUZIONE DELLALTRO )N FASE DI MONTAGGIO SONO DA
HAMMERS APPROPRIATE LEVERS EXTRACTOR AND SPECIlC SPANNERS OR RISPETTARE SCRUPOLOSAMENTE I GIOCHI I PRECARICHI E LE COPPIE
WRENCHES PRESCRITTE
"EFORE GOING ON TO DISASSEMBLED THE PARTS AND DRAIN THE OIL IT
IS BEST TO THOROUGHLY CLEAN THE UNIT REMOVING ANY ENCRUSTED OR 6!,)$)4! )L MANUALE FORNISCE LE VALIDITÜ DEI GRUPPI SOTTOFORMA DI
ACCUMULATED GREASE MATRICOLA!L lNE DI UNA CORRETTA INTERPRETAZIONE LE VALIDITÜ SONO
INDICATE COME
).42/$5#4/29 2%-!2+3 !LL THE DISASSEMBLED MECHANICAL
UNITS SHOULD BE THOROUGHLY CLEANED WITH APPROPRIATE PRODUCTS AND &INO ALLA MATRICOLA
RESTORED OR REPLACED IF DAMAGE WEAR CRACKING OR SEIZING HAVE
OCCURRED $ALLA MATRICOLA
)N PARTICULAR THOROUGHLY CHECK THE CONDITION OF ALL MOVING PARTS
BEARINGS GEARS CROWN WHEEL AND PINION SHAFTS AND SEALING 3E NON SONO INDICATE LE VALIDITÜ LE OPERAZIONI DI SMONTAGGIO ED
PARTS / RINGS OIL SHIELDS WHICH ARE SUBJECT TO MAJOR STRESS AND ASSEMBLAGGIO SONO COMUNI A TUTTE LE VERSIONI
WEAR )N ANY CASE IT IS ADVISABLE TO REPLACE THE SEALS EVERY
TIME A COMPONENT IS OVERHAULED OR REPAIRED $URING ASSEMBLY -!.54%.:)/.% % 2)0!2!:)/.) !L lNE DI FACILITARE INTERVENTI
THE SEALING RINGS MUST BE LUBRICATED ON THE SEALING EDGE )N THE SUI GRUPPI PONTE DIFFERENZIALI E CAMBI DI VELOCITÜ LA
CASE OF THE CROWN WHEEL AND PINION REPLACEMENT OF THE OTHER 30)#%2 #,!2+ (524( HA RITENUTO OPPORTUNO COMPILARE
ONE $URING ASSEMBLY THE PRESCRIBED PRE LOADING BACKLASH AND QUESTE ISTRUZIONI DI MANUTENZIONE E RIPARAZIONE ) DISEGNI
TORQUE OF PARTS MUST BE MAINTAINED DELLE ATTREZZATURE SPECIlCHE EVENTUALMENTE NECESSARIE PER L
ESECUZIONE DI INTERVENTI DI MANUTENZIONE E RIPARAZIONE POSSONO
#,!33)&)#!4)/. 4HIS MANUAL CLASSIlES UNITS ACCORDING TO PART ESSERE ACQUISTATI DIRETTAMENTE PRESSO IL COSTRUTTORE I RICAMBI
NUMBERS &OR A CORRECT INTERPRETATION CLASSIlCATION IS INDICATED POSSONO ESSERE ORDINATI TRAMITE IL COSTRUTTORE DELLA MACCHINA O
AS FOLLOWS DIRETTAMENTE PRESSO LA 30)#%2 #,!2+ (524(

UP TO THE PART NUMBER

$IE LEISTUNG UND ,EBENSDAUER DER MECHANISN 4EILE
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7HEN NO CLASSIlCATION IS GIVEN DISASSEMBLY AND ASSEMBLY SOFORTIGEN %INGRIFF IM 3TORUNGSFALL AB 5M DIESES (ANDBUCH
OPERATIONS ARE THE SAME FOR ALL VERSIONS ZU ERSTELLEN SIND WIR VON EINER ALLGEMEINER 5BERPRUFUNG DER
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BE FOUND AT THE END OF THIS MANUAL SPARE PARTS MAY BE ORDERED ERMOGLICHT ES ANHANDE DER !BBILDUNGEN UND DER :EICHNUNGEN
EITHER FROM THE VEHICLE MANUFACTURER OR DIRECTLY FROM THE 3ERVICE DIE DIE VERSCHIDENEN 6ORGANGE DARSTELLEN GEZIELT EINZUGREIFEN
#ENTERS OR !UTHORISED $ISTRBUTORS OF 30)#%2 #,!2+ (524( .ACHSTEHEND SIND ALLE )NFORMATIONEN UND (INWEISE AUFGEFUHRT DIE
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SI á CONSIDERATA LIPOTESI DI UNA REVISIONE GENERALE DEL GRUPPO MA VERARBEITETEN &LACHEN ZU SCHUTZEN UND DIE 3ICHERHEIT DER !RBEITER
á IL MECCANICO A VALUTARE LA NECESSITÜ DI MONTARE SOLO I SINGOLI ZU GEWAHELEISTEN EMPFEHLEN WIR GEEIGNETE 7ERKZEUGE WIE
COMPONENTI NEL CASO DI RIPARAZIONE )L MANUALE á UNA GUIDA RAPIDA "OCKE 4ISCH 'UMMI ODER +UPFERHAMMER GEEIGNETE !USZIEHER
E SICURA CHE CONSENTE INTERVENTI PRECISI TRAMITE LE FOTOGRAlE ED UND 3CHLUSSEL ZU VERWENDEN "EVOR MIT DER :ERLEGUNG DER
I DISEGNI PROSPETTICI CHE ILLUSTRANO LE VARIE FASI DELLE OPERAZIONI 4EILE BEGONNEN UND DAS /L ABGELASSEN WIRD MUSS DIE !CHSE
$I SEGUITO SONO RIPORTATE TUTTE QUELLE INFORMAZIONI ED AVVERTENZE SORGFALTIG GEREINGT UND 6ERKRUSTUNGEN UND &ETTABLAGEN ABGETRANGE
NECESSARIE AL CORRETTO DISASSEMBLAGGIO ALLE RELATIVE VERIlCHE ED WERDEN
ALLASSEMBLAGGIO DEI SINGOLI COMPONENTI 0ER LA RIMOZIONE DEL
PONTE DIFFERENZIALE DAL VEICOLO á NECESSARIO CONSULTARE I MANUALI 6/2!533%4:5.' !LLE ABMONTIERTEN MECHANISCHEN 4EILE
FORNITI DAL COSTRUTTORE DAL VEICOLO .EL DESCRIVERE LE OPERAZIONI MUSSEN SORGFALTIG MIT GEEIGNETEN 2EINIGUNGSMITTELN GEREINIT
SEGUENTI SI PRESUPPONE CHE IL PONTE SIA GIÜ STATO RIMOSSO DAL ODER WENN BESCHADIGT VERSCHLEISST GERISSEN FESTGEFRESSEN
VEICOLO USW AUSGEWECHSELT WERDEN )NSBESONDERE MUSS DER

784 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

).42/$5#)/. ).42/$5:)/.% 6/2!533%4:5.' 02/,/'/ ).42/$5#4)/.

EINWANDFREIE :USTAND ALLER BEWEGLICHEN 4EILE ,AGER :AHNRADER HASTA LA MATRICOLA

KEGELRADPAARE 7ELLEN UND DIE $ICHTUNGEN/ 2INGE
/LABDICHTUNGEN DIE AM MEISTEN BEANSPRUCHT WERDEN UND $ESDE LA MATRICULA EN ADELANTE
VERSCHLEISSEN +ONTROLLIERT WERDEN 7IR EMPFEHLEN AUF JEDEN
&ALL DIE !BDICHTUNGSELEMENTE IMMER AUSZUWECHSELN WENN EINE 3I NO HA SIDO INDICADA VALIDEZ LAS OPERACION DE DESMONTAJE Y
5BERHOLUNG ODER EINE 2EPARATUR DER 4EILE VORGENOMMEN WIRD MONTAJE SON COMUNES A TODAS LAS VERSIONES
"EI DER -ONTAGE MUSSEN DIE 2ANDER $ICHTRINGE GESCHMIERT
WERDEN 7ENN BEIM +EGELRADPAAR EIN :AHNRAD AUSGEWECHSELT (%22!-)%.4!3 %30%#)&)#!3 9 2%#!-")/3 ,OS PLANOS
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s 4HE OLEOCOMPATIBLE ALTERNATIVE TO $OES NOT REQUIRE THE ACTIVATION OF LUBRICATED SURFACES
s 0RODOTTO ALTERNATIVO AL CHE ESSENDO OLEOCOMPATIBILE NON RICHIEDE LATTIVAZIONE DI SUPERlCI LUBRIlCATE
s !LTERNATIVES 0RODUKT ZU ,OCTITE $A ES šLKOMPATIBEL IST MÓSSEN DIE GESCHMIERTEN &LÛCHEN NICHT AKTIVIERT
,OCTITE
WERDEN
s 0RODUCTO ALTERNATIVO AL QUE SIENDO OLEOCOMPATIBLE NO REQUIERE LA ACTIVACI˜N DE SUPERlCIES LUBRICADAS
s 0RODUIT EN ALTERNANCE AVEC LE LEQUEL £TANT OL£OCOMPATIBLE NE REQUIERT AUCUNE ACTIVATION DES SURFACES
LUBRIl£ES

!NAEROBIC PRODUCT FOR VERY HIGH STRENGTH LOCKING OF SCREWS AND NUTS "EFORE USING IT COMPLETELY REMOVE ANY
LUBRICANT BY USING THE SPECIlC ACTIVATOR 4O REMOVE PARTS IT MAY BE NECESSARY TO HEAT THEM AT —# APPROX
0RODOTTO ANAEROBICO ADATTO PER LA FRENATURA AD ALTISSIMA RESISTENZA DI VITI E DADI $EVE ESSERE USATO DOPO AVER
ASPORTATO OGNI TRACCIA DI LUBRIlCANTE CON LATTIVATORE SPECIlCO
,A RIMOZIONE DELLE PARTI PUÒ RICHIEDERE UN RISCALDAMENTO A CIRCA —#
,OCTITE !NAEROBES 0RODUKT FÓR HOHE 7IDERSTANDSKRÛFTE FÓR 3CHRAUBEN UND -UTTERN GEEIGNET :UERST DIE &LÛCHE SORGFÛLTIG
AKTIVIEREN 5M DIE &ÛCHEN ZU SÛUBERN DIESE AUF CA —# ERWÛRMEN
0RODUCTO ANAER˜BICO APTO PARA EL FRENADO DE ALTA RESISTENCIA DE TORNILLOS Y TUERCAS TIENE QUE SER USADO DE
SPU£S DE HABER QUITADO TODO RESIDUO DE LUBRICANTE CON EL ACTIVADOR ESPEC¤lCO
,A REMOCI˜N DE LAS PARTES PUEDE REQUERIR UN CALENTAMIENTO A UNOS —#
0RODUIT ANAR£OBIC APTE AU FREINAGE Ü TRáS HAUTE R£SISTANCE DES VIS ET DES £CROUS )L DOIT äTRE UTILIS£ APRáS AVOIR
ENLEV£ TOUTE TRACE DE LUBRIlANT Ü LAIDE DUN ACTIVEUR SP£CIAL

!NAEROBIC PRODUCT SUITABLE FOR HIGH STRENGTH LOCKING AND SEALING OF LARGE THREADED PARTS BOLTS AND STUD BOLTS
FOR PIPE SEALING AND FOR PROTECTING PARTS AGAINST TAMPERING SUITABLE FOR SEALING COUPLING SURFACES WITH A MAX
DIAMETRICAL CLEARANCE OF MM
0RODOTTO ANAEROBICO ADATTO PER LA FRENATURA E SIGILLATURA AD ALTA RESISTENZA DI PARTI lLETTATE BULLONI E PRIGIONIERI
DI GRANDI DIMENSIONI PROTEZIONE ANTIMANOMISSIONE E SIGILLATURA DI TUBAZIONI PUÒ SIGILLARE ACCOPPIAMENTI CON
GIOCO DIAMETRALE MASSIMO DI MM
,OCTITE !NAEROBES 0RODUKT ZUM "REMSEN UND 3IEGELN VON GRO”EN 'EWINDEN -UTTERN UND 3TIFTSCHRAUBEN SEHR
WIDERSTANDSFÛHIG VERSCHLEIERUNGSBESTÛNDIG UND ZUM 3IEGELN VON 2OHRLEITUNGEN GEEIGNET KANN +UPPLUN
GEN MIT EINER MAXIMALEN ,AGERLUFT VON MM SIEGELN
0RODUCTO ANAEROBICO APTO PARA EL FRENADO Y SELLADURA A ALTA RESISTENCIA DE TORNILLOS TUERCAS Y PRISIONEROS DE
GRANDES DIMENSIONES PROTECION ANTI MANOMISION Y SELLADURA DE TUBACIONES PUEDE SELLAR ENCOLCADOS CON
JUEGO DIAMETRAL
0RODUIT ANA£ROBIE ADAPT£AU FREINAGE ET AU SCELLAGE Ü HAUTE R£SISTANCE DES PARTIES lLET£ES BOULONS ET PRI
SONNIERS DE GRANDES DIMENSIONS PROTECTION ANTI ALT£RATION ET SCELLAGE DE TUYAUTERIES IL PEUT SCELLER DES AC
COUPLEMENTS AYANT UN JEU DIAM£TRAL MAXIMAL DE MM

5/20112 789
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

3#2%7 ,/#+).' 3%!,).' !.$ ,5"2)#!4).' -!4%2)!,3 -!4%2)!,) 0%2 ",/##!'')/ 6)4) 4%.54!
% ,5"2)&)#!:)/.% -!4%2)!, :52 ",/#+)%25.' 6/. 3#(2!5"%. 5.$ &ã2 $)#(45.'%. 5.$
3#(-)%2-)44%, -!4%2)!,%3 0!2! %, ",/15%/ %34!.15%)$!$ 9 ,5"2)#!#)/.
-!4»2)!58 0/52 ,% ",/#!'% 6)3 »4!.#(»)4» %4 ,5"2)&)#!4)/.

$%./-).!4)/.
$%./-).!:)/.%
"%:%)#(.5.' !00,)#!4)/. !00,)#!:)/.% !.7%.$5.' !0,)#!#)/. !00,)#!4)/.
$%./-).!#)/.
$%./-).!4)/.
s !NAEROBIC PRODUCT FOR THE HERMETIC SEALING OF mANGED UNITS AND SCREW HOLES COMMUNICATING WITH mUIDS #AN
SEAL CLEARANCES BETWEEN mANGES UP TO MM
s 0RODOTTO ANAEROBICO ADATTO ALLA TENUTA ERMETICA DI mUIDI TRA ASSIEMI mANGIATI E DI VITI A FORO COMUNICANTE CON
I mUIDI 0UÒ SIGILLARE GIOCHI TRA LE mANGE lNO A MM
s !NAEROBES 0RODUKT ZUR !BDICHTUNG VON &LÓSSIGKEITEN AN &LANSCHEN UND 3CHRAUBEN MIT ,šCHER DIE MIT
,OCTITE &LÓSSIGKEITEN IN +ONTAKT STEHEN +ANN EIN 3PIEL ZWISCHEN &LANSCHEN BIS MM ABDICHTEN
s 0RODUCTO ANAER˜BICO APTO PARA LE ESTANQUEIDAD DE mUIDOS ENTRE GRUPOS BRIDADOS Y DE TORNILLOS DE ORIlCIO
COMUNICANTE CON LOS mUIDOS 0UEDE SELLAR JUEGOS ENTRE LAS BRIDAS HASTA MM
s 0RODUIT ANAR£OBIC APTE Ü LA TENUE £TANCHE DES mUIDES ENTRE LES PIáCES Ü BRIDES ET DES VIS Ü TROU EN CONTACT
AVEC LES mUIDES )L PEUT SCELLER UN JEU PARMI LES mASQUES JUSQUÜ MM
s 1UICK ANAEROBIC SEALANT FOR SEALING THREADED PORTIONS OF CONICAL OR CYLINDRICAL UNIONS UP TO - "EFORE
USING IT REMOVE ANY LUBRICANT WITH THE SPECIlC ACTIVATOR !FTER POLYMERISATION DISASSEMBLY MAY RESULT
RATHER DIFlCULT SO HEATING MAY BE NECESSARY FOR LARGER DIAMETERS
s 0RODOTTO ANAEROBICO SIGILLANTE RAPIDO PER LA TENUTA DI lLETTATURE DI RACCORDI CONICI O CILINDRICI lNO A -
$EVE ESSERE USATO DOPO AVER ASPORTATO OGNI TRACCIA DI LUBRIlCANTE CON LATTIVATORE SPECIlCO
$OPO LA POLIMERIZZAZIONE PRESENTA UNA MODERATA DIFlCOLTÜ DI SMONTAGGIO PER CUI PUÒ RICHIEDERE PER
I DIAMETRI MAGGIORI UN RISCALDAMENTO
s !NAEROBES 0RODUKT ZUM SCHNELLEN 3IEGELN UND !BDICHTEN VON +EGEL ODER :YLINDERKUPPLUNGEN BIS -
,OCTITE $ARF ERST AUFGETRAGEN WERDEN NACHDEM MIT EINEM SPEZIlSCHEN 7IRKSTOFF JEDE 3PUR VON 3CHMIERMITTEL AB
GETRAGEN WORDEN IST.ACH DER 0OLYMERISATION KšNNTE DAS !BMONTIEREN ETWAS SCHWIERIG SEIN WESHALB
GRš”ERE $URCHMESSER ZUERST ERHITZT WERDEN MÓSSEN
s 0RODUCTO ANAEROBICO SELLANTE RAPIDO PARA EL ESTANQUEIDO DE TORNILLOS DE EMPALME CONICO O CILINDRICO HASTA
- $EBE DE SER UTILISADO DESPUES DE HABER QUITADO CADA MANCHA DE LUBRIlCANTE CON ACTIVADOR
ESPECIlCO$ESPUES DE LA POLIMERACION PRESENTA UNA MODERADA DIlCULTÜ DE DESMONTAJE POR LO TANTO
PUEDE NECESITAR PARA LOS DIAMETROS MAJORES UN CALIENTAMIENTO
s 0RODUIT ANA£ROBIE COLLAGE RAPIDE ASSURANT L£TANCH£IT£ DES lLETAGES DES RACCORDS CONIQUES OU
CYLINDRIQUES JUSQUÜ - )L DOIT äTRE UTILIS£ APRáS QUON AIT ENLEV£ TOUTE TRACE DE LUBRIlANT Ü
LAIDE DUN ACTIVEUR SP£CIAL 5NE CERTAINE DIFlCULT£ DE D£MONTAGE SE PR£SENTE APRáS LA POLYM£
RISATION ON PEUT DONC AVOIR LA N£CESSIT£ DE DEVOIR CHAUFFER PR£ALABLEMENT POUR DE PLUS AMPLES DIAMáTRES
s !NAEROBIC ADHESIVE FOR FAST AND HIGH STRENGTH GLUING OF CYLINDRICAL METAL JOINTS HUB ON SHAFT #AN GLUE
TOGETHER PARTS WITH CLEARANCE RANGING BETWEEN AND MM
s !DESIVO ANAEROBICO PER LINCOLLAGGIO RAPIDO AD ALTA RESISTENZA DI GIUNTI CILINDRICI IN METALLO MOZZO SU ALBERO
0UÒ INCOLLARE PARTICOLARI CON GIOCO TRA E MM
s !NAEROBER +LEBSTOFF FÓR GRO”E 7IDERSTANDSKRÛFTE FÓR :YLINDERKUPPLUNGEN AUS -ETALL GEEIGNET
,OCTITE 7ELLENNABEN +ANN %INZELTEIL MIT EINEM 2ADIALSPIEL ZWISCHEN MM UND MM ZUSAMMENKLEBEN
s !DHESIVO ANAER˜BICO PARA EL ENCOLADO RÖPIDO DE ALTA RESISTENCIA DE JUNTAS CIL¤NDRICAS DE METAL
CUBO EN EL EJE 0UEDE ENCOLAR PIEZAS CON JUEGO ENTRE MM Y MM
s !DH£SIF ANA£ROBIC SERVANT Ü UN COLLAGE RAPIDE ET HAUTEMENT R£SISTANT DES JOINTS CYLINDRIQUES EN M£TAL
MOYEU SUR LARBRE )L PEUT SERVIR Ü COLLER DES PIáCES AVEC UN JEU ALLANT DE Ü MM

s !NAEROBIC ADHESIVE FOR FAST AND MEDIUM STRENGTH GLUING OF CYLINDRICAL METAL JOINTS HUB ON SHAFT #AN GLUE
TOGETHER PARTS WITH RADIAL CLEARANCE BELOW MM
s !DESIVO ANAEROBICO PER LINCOLLAGGIO RAPIDO A MEDIA RESISTENZA DI GIUNTI CILINDRICI IN METALLO MOZZO SU ALBERO
0UÒ INCOLLARE PARTICOLARI CON GIOCO RADIALE INFERIORE A MM
s !NAEROBER +LEBSTOFF FÓR MITTLERE 7IDERSTANDSKRÛFTE FÓR :YLINDERKUPPLUNGEN AUS -ETALL GEEIGNET
,OCTITE 7ELLENNABEN +ANN %INZELTEIL MIT EINEM 2ADIALSPIEL VON WENIGER ALS MM ZUSAMMENKLEBEN
s !DHESIVO ANAER˜BICO PARA ENCOLADO RÖPIDO DE MEDIA RESISTENCIA JUNTAS CIL¤NDRICAS DE METAL
CUBO EN EL EJE 0UEDE ENCOLAR PIEZAS CON JUEGO RADIAL INFERIOR A MM
s !DH£SIF ANA£ROBIC SERVANT Ü UN COLLAGE RAPIDE MOYENNEMENT R£SISTANT DES JOINTS CYLINDRIQUES EN M£TAL
MOYEU SUR LARBRE )L PEUT SERVIR Ü COLLER DES PIáCES AVEC UN JEU RADIAL INF£RIEUR Ü MM
!2%8/.3 s 3OLVENT BASED SEALING COMPOUND FOR ELASTIC SEALS DRYING THROUGH EVAPORATION 5SED FOR SEALING THE OUTER
2EPOSITIONABLE JOINTING DIAMETER OF SEALING RINGS FOR ROTATING SHAFTS WITH OUTER METAL REINFORCEMENT
COMPOUND FOR SEALS s -ASTICE SIGILLANTE PER GUARNIZIONI ELASTICHE A BASE DI SOLVENTE ESSICANTE PER EVAPORAZIONE 6IENE UTILIZZATO
-ASTICE PER GUARNIZIONI PER LA TENUTA SUL DIAMENTRO ESTERNO DI ANELLI DI TENUTA PER ALBERI ROTANTI CON ARMATURA METALLICA ESTERNA
RIPOSIZIONABILE s +LEBSTOFF FÓR 'UMMIDICHTUNG AUF ,šSEMITTELBASIS TROCKNET DURCH 6ERDAMPFUNG
+LEBSTOFF FÓR VERSTELLBARE 7IRD AM ÛU”EREN $URCHMESSER VON $ICHTUNGSRINGE BEI ROTIERENDEN 7ELLEN MIT -ETALLMANTEL VERWENDET
$ICHTUNGEN s 0ASTA PARA JUNTAS DE SELLADO PARA JUNTAS ELÖSTICAS A BASE DE DISOLVENTE DESHIDRATANTE POR EVAPORACI˜N
0ASTA PARA JUNTAS 3E UTILIZA PARA LA ESTANQUEIDAD EN EL DIÖMETRO EXTERNO DE SEGMENTOS DE COMPRESI˜N PARA EJES GIRATORIOS
REPOSICIONABLE CON ARMADURA METÖLICA EXTERIOR
-ASTIC POUR GARNITURES Ü s -ASTIC ADH£SIF Ü BASE DE SOLVANTS POUR GARNITURES £LASTIQUES S£CHANT PAR £VAPORATION )L SERT GARDER £TANCHE
REMETTRE EN PLACE LE DIAM£TRE EXT£RIEUR DES BAGUES D£TANCH£IT£ DES ARBRES ROTATIFS AYANT UNE ARMATURE M£TALLIQUE EXTERNE

790 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

3#2%7 ,/#+).' 3%!,).' !.$ ,5"2)#!4).' -!4%2)!,3 -!4%2)!,) 0%2 ",/##!'')/ 6)4) 4%.54!
% ,5"2)&)#!:)/.% -!4%2)!, :52 ",/#+)%25.' 6/. 3#(2!5"%. 5.$ &ã2 $)#(45.'%. 5.$
3#(-)%2-)44%, -!4%2)!,%3 0!2! %, ",/15%/ %34!.15%)$!$ 9 ,5"2)#!#)/.
-!4»2)!58 0/52 ,% ",/#!'% 6)3 »4!.#(»)4» %4 ,5"2)&)#!4)/.

$%./-).!4)/.
$%./-).!:)/.%
"%:%)#(.5.' !00,)#!4)/. !00,)#!:)/.% !.7%.$5.' !0,)#!#)/. !00,)#!4)/.
$%./-).!#)/.
$%./-).!4)/.
s 3EMI mUID ADHESIVE MATERIAL USED FOR SEALING AND lLLING AND TO PROTECT COMPONENTS FROM ENVIRONMENTAL AND
PHYSICAL ELEMENTS 0OLYMERISES WITH NON CORROSIVE DAMPNESS
3ILICONE s -ATERIALE ADESIVO SEMImUIDO USATO PER SIGILLATURA RIEMPIMENTI E PER LA PROTEZIONE DI COMPONENTI DAGLI ELEMENTI
3ILICONE AMBIENTALI E lSICI 0OLIMERIZZA CON UMIDITÜ NON CORROSIVA
3ILIKON s (ALBmÓSSIGER +LEBSTOFF ZUM "EFESTIGEN &ÓLLEN UND ZUM 3CHUTZ VON "ESTANDTEILEN VOR ÛU”EREN
3ILICONA %INWIRKUNGEN 0OLYMERISIERT DURCH NICHT KORROSIVE &EUCHTIGKEIT
3ILICONE s -ATERIAL ADHESIVO SEMImUIDO USADO PARA EL SELLADO LLENADO Y PARA LA PROTECCI˜N DE COMPONENTES DE
ELEMENTOS AMBIENTALES Y F¤SICOS 0OLIMERIZA CON HUMEDAD NO CORROSIVA
s 0RODUIT ADH£SIF SEMI mUIDE UTILIS£ POUR LE SCELLAGE REMPLISSAGE ET PROTECTION DES £L£MENTS AMBIANTS
ET PHYSIQUES 0OLYM£RISE Ü UNE HUMIDIT£ NON CORROSIVE
s (IGHLY ADHESIVE SYNTHETIC GREASE WITH SILICONE COMPOUNDS ADDED!PPLIED TO ADJUSTMENT SCREWS WITH HOLE
COMMUNICATING WITH OIL TYPE mUIDS5SED WHEN FREQUENT ADJUSTING IS REQUIRED
s 'RASSO SINTETICO CON ELEVATO GRADO DI ADESIVITÜ ADDITIVATO CON COMPOSTI SILICONICI!PPLICATO SU VITI DI
REGISTRAZIONE A FORO COMUNICANTE CON mUIDI DI TIPO OLEOSO5SATO QUANDO SI RICHIEDONO FREQUENTI INTERVENTI
DI REGISTRAZIONE
4%#./ ,5"% s 3YNTHETISCHES &ETT MIT HOHER (AFTFESTIGKEIT MIT SILIKONHALTIGEN 3TOFFEN LEGIERT7IRD AUF 3TELLSCHRAUBEN MIT
3ILICONE BASED GREASE ,OCH DIE MIT šLHALTIGEN &LÓSSIGKEITEN IN +ONTAKT STEHEN ANGEBRACHT7IRD VERWENDET WENN DIE 3CHRAUB
'RASSO AL SILICONE šFTERS EINGESTELLT WERDEN MU”
3ILIKONFETT s 'RASA SINT£TICA CON ELEVADO GRADO DE ADHESI˜N ADITIVADA CON COMPONENTES SILIC˜NICOS!PLICADA EN
'RASA A LA SILICONA TORNILLOS DE AJUSTE DE ORIlCIO COMUNICANTE CON mUIDOS DE TIPO OLEOSO3E USA CUANDO SE REQUIEREN FRECUENTES
'RAISSE AU SILICONE INTERVENCIONES DE AJUSTE
s 'RAISSE SYNTH£TIQUE AYANT UN DEGR£ DADH£SIVIT£ £LEV£ ADJUV£DE COMPOS£S AU SILICONE
!PPLIQU£ SUR LES VIS DE R£GLAGE Ü TROU COMMUNIQUANT AVEC DES mUIDES DU TYPE HUILEUX5TILIS£ QUAND
IL Y A BESOIN DE R£GLAGES FR£QUENTS

s ,UBRICATING COMPOUND CONTAINING MOLYBDENUM DISULPHIDE USED TO LUBRICATE ARTICULATION PINS AND TO PREVENT
STICKING AND OXIDATION OF PARTS THAT ARE NOT LUBRICATED ON A REGULAR BASIS
s #OMPOSTO LUBRIlCANTE CONTENENTE BISOLFURO DI MOLIBDENO USATO PER LA LUBRIlCAZIONE DI PERNI SNODO E PER
PREVENIRE INCOLLAMENTI ED OSSIDAZIONI DI PARTICOLARI NON LUBRIlCATI IN MODO CONTINUO
-OLIKOTE s 3CHMIERSTOFF MIT -OLYBIDÛNDISULlD WIRD ZUM 3CHMIEREN VON 'ELENKSTIFTEN UND GEGEN !NKLEBEN UND
$/7 #/2.).' /XYDATION VON NICHT DAUERGESCHMIERTEN %INZELTEILEN VERWENDET
s #OMPUESTO LUBRICANTE QUE CONTIENE BISULFURO DE MOLIBDENO USADO PARA LA LUBRICACI˜N DE R˜TULAS Y PARA
PREVENIR ENCOLADURAS Y OXIDACIONES DE PIEZAS NO LUBRICADAS DE MANERA CONTINUA
s #OMPOS£ LUBRIlANT CONTENANT DU BISULFURE DE MOLYBD£NE UTILIS£ POUR LUBRIlER LES AXES DARTICULATION ET
PR£VENIR COLLAGES ET OXYDATIONS DES PI£CES QUI NE SONT PAS CONTINUELLEMENT LUBRIl£ES
s !PPLIED TO BEARINGS SLIDING PARTS AND USED TO LUBRICATE SEALS OR PARTS DURING ASSEMBLY
,ITHIUM BASED 'REASE s !PPLICATO A CUSCINETTI PARTI SCORREVOLI E PER LUBRIlCARE GUARNIZIONI O PEZZI IN FASE DI MONTAGGIO
'RASSO AL ,ITIO s 7IRD AUF ,AGER 'LEITTEILEN AUFGETRAGEN UND ZUM 3CHMIEREN VON $ICHTUNGEN ODER VON 4EILEN BEI DER
,ITHIUM &ETT -ONTAGE VERWENDET
'RASA AL ,ITIO s !PLICADA A COJINETES PARTES DESLIZABLES O PARA LUBRICAR JUNTAS O PIEZAS EN FASE DE MONTAJE
'RAISSE AU ,ITHIUM s !PPLIQU£ SUR LES PALIERS PARTIES COULISSANTES ET POUR LUBRIlER LES GARNITURES OU PI£CES PENDANT LA PHASE DE
MONTAGE

5/20112 791
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

./4%3 /. 3!&%49 02%#!54)/.3 ./4% 2)'5!2$!.4) ,! 3)#52%::! "%-%2+5.'%. :52

3)#(%2(%)4 ./2-!3 #/.#%2.)%.4%3 ! ,! 3%'52)$!$ ./4%3 %. -!4)%2% $% 3%#52)4%

$URING ALL OPERATIONS DESCRIBED IN THIS MANUAL THE AXLE ,šSEMITTEL MÓSSEN ALS 3ONDERMÓLL UND AUF JEDEN &ALL LAUT DEN šRTLICH
'" SHOULD BE FASTENED ONTO A TRESTLE WHILE THE OTHER PARTS GELTENDEN 6ORSCHRIFTEN ENTSORGT WERDEN
MENTIONED SHOULD REST ON SUPPORTING BENCHES :UR 2EINIGUNG AUSSCHLIE”LICH SCHWACHE ,šSEMITTEL WIE 0ETROLEUM
7HEN REMOVING ONE OF THE ARMS AN ANTI TILTING SAFETY TRESTLE SHOULD BE 4ERPENTIN ODER WASSERHALTIGE ,šSEMITTEL VERWENDEN !UF KEINEN
PLACED UNDER THE OTHER ARM &ALL 4RICHLORÛTHYLEN TUOLOL ODER XYLOLHLATIGE ,šSEMITTEL USW VERWENDEN
7HEN WORKING ON AN ARM THAT IS lTTED ON THE MACHINE MAKE SURE THAT 5M DIE !RBEITSVORGÛNGE VERSTÛNDLICH ABZUBILDEN WERDEN IN EINIGEN
THE SUPPORTING TRESTLES ARE CORRECTLY POSITIONED AND THAT THE MACHINE IS &OTOS DIE !GGREGATE OHNE %INZELTEILE GEZEIGT DIE SONST BEI DER !RBEIT NICHT
LOCKED LENGTHWAYS ABMONTIERT WERDEN MÓSSEN.UR DIE BESCHRIEBENEN 4EILE ABMONTIEREN
$O NOT ADMIT ANY OTHER PERSON INSIDE THE WORK AREA MARK OFF THE AREA 5NTER 2%#(43 UND ,).+3 VERSTEHT MAN IN DIESEM (ANDBUCH DIE
HANG WARNING SIGNS AND REMOVE THE IGNITION KEY FROM THE MACHINE 3EITE EINER 0ERSON DIE ZUR !CHSE SCHAUT UND ZWAR DEM !NTRIEB
5SE ONLY CLEAN QUALITY TOOLS DISCARD ALL WORN DAMAGED LOW QUALITY OR ENTGEGENGESETZT
IMPROVISED WRENCHES AND TOOLS %NSURE THAT ALL DYNAMOMETRIC WRENCHES .ACH BEENDETEN !RBEITEN UND UM 2OSTBILDUNGEN ZU VERMEIDEN
HAVE BEEN CHECKED AND CALIBRATED DIE 4EILE AN DENEN DER ,ACK GGF BESCHÛDIGT WORDEN IST ANSTREICHEN
!LWAYS WEAR GLOVES AND NON SLIP RUBBER SHOES WHEN PERFORMING REPAIR
WORK ,AS OPERACIONES DESCRITAS SE RElEREN AL EJE BLOQUEADO
3HOULD YOU STAIN A SURFACE WITH OIL REMOVE MARKS STRAIGHT AWAY %30 EN UN CABALLETE Y A ALGUNAS PARTES APOYADAS EN EL BANCO DE
$ISPOSE OF ALL LUBRICANTS SEALS RAGS AND SOLVENTS ONCE WORK HAS BEEN TRABAJO
COMPLETED 4REAT THEM AS SPECIAL WASTE AND DISPOSE OF THEM ACCORDING #UANDO SE SACA UN BRAZO DEL EJE COLOCAR DEBAJO DEL OTRO UN
TO THE RELATIVE LAW PROVISIONS OBTAINING IN THE COUNTRY WHERE THE AXLES ARE CABALLETE DE SEGURIDAD ANTIVUELCO
BEING OVERHAULED 3I SE TRABAJA CON UN EJE MONTADO EN LA MÖQUINA ASEGURARSE DE HABER
-AKE SURE THAT ONLY WEAK SOLVENTS ARE USED FOR CLEANING PURPOSES COLOCADO CABALLETES SOPORTE Y DE HABER INMOVILIZADO
AVOID USING TURPENTINE DILUTANTS AND TOLUOL XYLOL BASED OR SIMILAR SOLVENTS LONGITUDINALMENTE LA MÖQUINA
USE LIGHT SOLVENTS SUCH AS +EROSENEMINERAL SPIRITS OR WATER BASED .O PERMITIR QUE PERSONAS EXTRA®AS ENTREN EN LA ZONA DE TRABAJO
ENVIRONMENT FRIENDLY SOLVENTS DELIMITAR ESTA ZONA COLGAR CARTELES DE AVISO DE HOMBRES
&OR THE SAKE OF CLARITY THE PARTS THAT DO NOT NORMALLY NEED TO BE TRABAJANDO Y SACAR LAS LLAVES DE ARRANQUE DE LA MÖQUINA
REMOVED HAVE NOT BEEN REPRODUCED IN SOME OF THE DIAGRAMS 5SAR S˜LO Y EXCLUSIVAMENTE HERRAMIENTAS LIMPIAS Y DE BUENA CUALIDAD
4HE TERMS 2)'(4 AND ,%&4 IN THIS MANUAL REFER TO THE POSITION OF THE DESCARTAR LLAVES O HERRAMIENTAS GASTADAS O DA®ADAS DE CALIDAD MEDIOCRE
OPERATOR FACING THE AXLE FROM THE SIDE OPPOSITE THE DRIVE O IMPROVISADAS !SEGURARSE DE QUE LAS LLAVES
!FTER REPAIR WORK HAS BEEN COMPLETED ACCURATELY TOUCH UP ANY COATED DINAMOM£TRICAS HAN SIDO CONTROLADAS Y CALIBRADAS
PART THAT MAY HAVE BEEN DAMAGED $URANTE LAS OPERACIONES DE REPARACI˜N LLEVAR SIEMPRE GUANTES Y
CALZADO ANTIDESLIZAMIENTO
,E OPERAZIONI DESCRITTE SONO RIFERITE ALLASSALE BLOCCATO ,IMPIAR INMEDIATAMENTE LAS ZONAS QUE PUDIERAN ESTAR SUCIAS DE
)4! SU CAVALLETTO ED ALCUNI PARTICOLARI APPOGGIATI SU UN BANCO DI ACEITE
,OS LUBRICANTES LAS JUNTAS LOS TRAPOS PARA LA LIMPIEZA Y LOS
LAVORO
1UANDO SI ASPORTA UN BRACCIO DELLASSALE SISTEMARE SOTTO LALTRO BRACCIO DISOLVENTES USADOS HAY QUE ELIMINARLOS COMO DESECHOS ESPECIA
UN CAVALLETTO DI SICUREZZA ANTIRIBALTAMENTO LES Y DE TODAS FORMAS DE ACUERDO CON LAS NORMATIVAS VIGENTES EN EL PA¤S
3E SI OPERA SU UNASSALE MONTATO SULLA MACCHINA ASSICURARSI DI EN EL QUE SE REVISAN LOS EJES
AVER SISTEMATO DEI CAVALLETTI DI SOSTENTAMENTO E DI AVER IMMOBILIZZATO 0ARA LIMPIAR UTILIZAR S˜LO DISOLVENTES D£BILES EXCLUYENDO EN ABSOLUTO
LONGITUDINALMENTE LA MACCHINA TRICLOROETILENO DILUYENTES Y DISOLVENTES A BASE DE TOLUOL
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5/20112 795
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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796 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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2EMOVE PINION COMPLETE WITH / RING ./4% 4HE / RING MUST BE REPLACED EACH TIME THE UNIT IS
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5NSCREW AND EXTRACT THE BRAKING DISK CLEARANCE ADJUSTMENT
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798 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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)NSTALL THE AXLE SHAFT ,IGHTLY LUBRICATE THE lRST STEEL BRAKING DISK THEN INSTALL
IT ON THE ARM

800 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

)4! ,UBRIlCARE LA lLETTATURA DELLA CORONA ED AVVI

TARLA A FONDO NEL BRACCIO )4! ,UBRIlCARE IL PIGNONE E MONTARLO NELLA SEDE DEL
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)NSERIRE SEMIASSE ,UBRIlCARE LEGGERMENTE IL PRIMO DISCO DI FRENA

)4! )4! TURA IN ACCIAIO E MONTARLO NEL BRACCIO

$IE 7ELLE ERSET ZEN $IE ERSTE "REMSSCHEIBE AUS 3TAHL ETWAS
$ $ SCHMIEREN UND IN DEN !RM MONTIEREN

E F
-ONTAR EL SEMEJE ,UBRIlCAR LIGERMENTE EL PRIMER DISCO DE FRENA
%30 %30 DURA EN ACERO Y MONTARLO EN EL EJE

-ONTER LE DEMI ESSIEU ,UBRIlER LáG£REMENT LE PREMIER DISQUE DE FREIN

& & AGE EN ACIER PUIS MONTER CELUI CI DANS LE
BRAS

5/20112 801
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

!33%-",).' 4(% "2!+).' 5.)4 !33%-",!'')/ '2500/ &2%.)

:53!--%."!5 $%3 "2%-3!''2%'!43 -/.4!*% $% ,/3
'250/3 $% &2%.!$/ !33%-",!'% $5 '2/50% &2%).3

'" A '" B
#ECKING WEAR BRAKING DISKS
.EWMM ,UBRICATE THE lRST FRICTION DISK AND INSTALL IT ON THE AXLE
#HANGE LESS THAN MM SHAFT
#OMPLETE THE ASSEMBLY ALTERNATING STEEL DISKS AND FRICTION
DISKS

'" C '" D
2EMOVE THE BREATHER FROM THE CYLINDER

'" E '" F
'REASE WITH 4%#./,5"%

802 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

6ERIlCA USURA DISCHI FRENO ,UBRIlCARE IL PRIMO DISCO DI ATTRITO E MONTARLO

)4! .UOVO MM )4! SUL SEMIASSE
#OMPLETARE IL MONTAGGIO ALTERNANDO DISCHI DI
#AMBIO INFERIORE A MM
ACCIAIO E DISCHI DI ATTRITO

6ERSCHLEISS KONTROLLIEREN "REMSSCHEIBEN

$ .EUE MM $ $IE ERSTE 2EIBSCHEIBE SCHMIEREN UND AUF DIE
(ALBACHSE MONTIEREN
%RSETZEN ALS MM $ANN DIE 3TAHLSCHEIBEN ABWECHSELND MIT DEN
2EIBSCHEIBEN MONTIEREN

A B
#ONTROL DESGASTE DISCOS FRENOS ,UBRIlCAR EL PRIMER DISCO DE STRITO Y MONTARLO
%30 .UEVO MM %30 SOBRE EL SEMI EJE
2EEMPLAZAR INFERIOR MM #OMPLETAR EL MONTAJE ALTERNANDO DISCOS DE ACERO
Y DISCOS DE ATRITO

& #ONTROLE SUBSTITUTION DU DISQUE FREIN & ,UBRIlER LE PREMIER DISQUE DE FRICTION PUIS
.OUVEAU MM MONTER CE DERNIER SUR LE DEMI ESSIEU
2EMPLACER INF£RIEUR MM !CHEVER LE MONTAGE EN ALTERNANT LES DISQUES EN
ACIER ET LES DISQUES DE FRICTION

2IMUOVERE LO SlATO DAL COPERCHIO CILINDRO

)4!

%NTLUEFTER ABNEMEN

$

D
%30 2EMOVER EL PURGADOR

& 2EMOVER LE RENImARD

)4! )NGRASSARE CON GRASSO 4%#./,5"%

%INFETTEN MIT 4%#./,5"%

$

E
%30 %NGRASAR CON 4%#./,5"%

'RASSEIR AVEC 4%#./,5"%

&

5/20112 803
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

!33%-",).' 4(% "2!+).' 5.)4 !33%-",!'')/ '2500/ &2%.)

:53!--%."!5 $%3 "2%-3!''2%'!43 -/.4!*% $% ,/3
'250/3 $% &2%.!$/ !33%-",!'% $5 '2/50% &2%).3

'" A '" B
&IT / RINGS AND ONTO THE PISTON
,UBRICATE THE PISTON AND THE / RINGS AND INSTALL THE UNIT INTO
THE CYLINDER
./4% 0ISTON RELIEF i#w MUST FACE DOWNWARDS

4%#./,5"%

4%#./,5"%

'" C '" D
'REASE THE DIAMETER WITH 4%#./,5"% 5SING A PLASTIC HAMMER RAM THE PISTON INTO THE CYLINDER

./4% ,IGHTLY HAMMER ALL AROUND THE EDGE IN AN ALTERNATE
SEQUENCE

'" E '" F
)NSERT THE INTERMEDIATE DISK ,OCK THE INTERMEDIATE DISK TIGHTENING THE SCREWS
WITH A DYNAMOMETRIC WRENCH SET TO A TORQUE OF Õ .M

804 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

-ONTARE SUL PISTONE GLI ANELLI /2 E

,UBRIlCARE IL PISTONE E GLI ANELLI /2 E MONTARE IL
)4! GRUPPO NEL CILINDRO
./4! -ONTARE IL PISTONE NELLA POSIZIONE
MARCHIATA

!UF DEN +OLBEN DIE / 2INGE UND

$ MONTIEREN
$EN +OLBEN UND DIE / 2INGE SCHMIEREN UND DAS
!GGREGAT IN DEN :YLINDER MONTIEREN
"%-%2+5.' $IE !BLAœO³ FFNUNG h#v DES
+OLBENS MUœ NACH UNTEN
GERICHTET SEIN

A -ONTAR SOBRE EL PISTON LOS ANILLOS /2 Y

%30 ,UBRIlCAR EL PISTON Y LOS ANILLOS /2 Y MONTAR EL
GRUPO EN LOS CILINDROS
./4! %L ESCARGO h#v DEL PISTON DEBE DE SER
DIRIJIDO HACIA EL BAJO

-ONTER SUR LE PISTON LES ANNEAUX /2).'

& ET
,UBRIlER LE PISTON ET LES ANNEAUX /2).' PUIS
MONTER LE GROUPE DANS LE CYLINDRE
2%-!215% ,áCOULEMENT h#v DU PISTON DOIT á
TRE TOURNá VERS LE BAS

)NGRASSARE I DIAMETRI CON 4%#./,5"% 5TILIZZANDO UN MAZZUOLO IN MATERIALE PLASTICO

)4! )4! INSERIRE A FONDO IL PISTONE NEL CILINDRO
./4! "ATTERE LEGGERI COLPI DISTRIBUITI IN MODO
ALTERNATO SU TUTTA LA CIRCONFERENZA

%INFETTEN DAS 5EBERMASS MIT 4%#./,5"%

$ $ -IT EINEM 'UMMIHAMMER DEN +OLBEN IN DEN
:YLINDER BIS ZUM !NSCHLAG EINSCHLAGEN
"%-%2+5.' $EN +OLBEN ABWECHSELND RUND UM
DIE GESAMTE +REISLINIE LEICHT SCHLAGEN

C D
%30 %NGRASAR EL DIAMETRO CON 4%#./,5"% %30 5TILIZANDO UN MARTILLO DE MATERIA PLASTICA INTRO
DUCIR A FONDO EL PISTON EN EL CILINDRO
./4! 0EGAR LIGEROS GOLPES DISTRIBUIDOS DE
MANERA ALTERNADA SOBRE TODA LA CIRCONFERENCIA

'RASSEIR LE DIAM£TRE AVEC 4%#./,5"%

& & ! LAIDE DUN MAILLET EN MATI£RE PLASTIQUE
INTRODUIRE LE
PISTON Ü FOND DANS LE CYLINDRE
2%-!215% $ONNER DE L£GERS COUPS R£
GULIERS TOUT AUTOUR DE LA CIRCONF£RENCE

)NSERIRE IL DISCO INTERMEDIO DEL PISTONE

)4! )4! "LOCCARE IL DISCO INTERMEDIO DEL PISTONE CON
LE VITI SERRATE CON CHIAVE DINAMOMETRICA AD UN
COPPIA DI Õ .M

-ITTLERE 3CHEIBE MONTIEREN $EN -ITTLERE 3CHEIBE MIT DEN 3CHRAUBEN
$ $ MIT EINEM $YNAMOMETER UND EINEM !NZUGSMO
MENT VON Õ .M BLOCKIEREN

E F
-ONTAR EL DISCO INTERMEDIO "LOQUEAR EL DISCO INTERMEDIO CON LOS TORNIL
%30 %30 LOS APRETADOS CON LLAVE DINAMOMETRICA A UN
PAR DE Õ .M

-ONTER LE DISQUE )NTERM£DIAIRE "LOQUER LE DISQUE )NTERM£DIAIRE AVEC LES VIS
& & SERRER Ü LAIDE DE LA CL£DYNAMOM£TRIQUE Ü UN
COUPLE DE Õ .M

5/20112 805
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

!33%-",).' 4(% "2!+).' 5.)4 !33%-",!'')/ '2500/ &2%.)

:53!--%."!5 $%3 "2%-3!''2%'!43 -/.4!*% $% ,/3
'250/3 $% &2%.!$/ !33%-",!'% $5 '2/50% &2%).3

'" A '" B
!SSEMBY THE BREATHER

'" C '" D
#HECK INTEGRITY AND POSITION OF THE CYLINDERS / RING #HECK INTEGRITY AND POSITION OF THE ARMS / RING

OUT SIDE DIFFERENTIAL

SIDE

OUT SIDE
DIFFERENTIAL SIDE

'" F
0OSITION THE "ELLEVILLE WASHERS AND ENGAGE THE CYLINDER

./4% #HECK THE SENSE OF DIRECTION OF WASHERS AND RELA
TIVE CENTRING

806 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

)4! -ONTARE LO SlATO

$ %NTLUEFTER MONTIEREN

B
%30 -ONTAR EL PURGADOR

& -ONTER LE RENImARD

6ERIlCARE LINTEGRITÜ ED IL POSIZIONAMENTO 6ERIlCARE LINTEGRITÜ ED IL POSIZIONAMENTO

)4! DELLANELLO /2 )4! DELLANELLO /2

$ :USTAND UND DIE 0OSITION DES / 2INGES

KONTROLLIEREN
$ :USTAND UND DIE 0OSITION DES / 2INGES
KONTROLLIEREN

C D
%30 !VERIGUAR LA INTEGRIDAD Y LA COLOCACIÒN DEL ANILLO
/2 %30 !VERIGUAR LA INTEGRIDAD Y LA COLOCACIÒN DEL ANILLO
/2

& 6£RIlER LE BON £TAT ET LE POSITIONNEMENT DE

LANNEAU /2).' & 6£RIlER LE BON £TAT ET LE POSITIONNEMENT DE
LANNEAU /2).'

0OSIZIONARE LE MOLLE A TAZZA E MANDARE IN

BATTUTA IL CILINDRO
)4! ./4! #ONTROLLARE IL SENSO DI ORIENTAMENTO DELLE
MOLLE A TAZZA E LA LORO CENTRATURA

4ELLERFEDERN POSITIONIEREN UND DEN :YLINDER

$ BIS ZUM !NSCHLAG EINSETZEN
"%-%2+5.' /RIENTIERUNG DER 4ELLERFEDERN
UND IHRE :ENTRIERUNG KONTROLLIEREN

F
#OLOCAR LOS MUELLES A TAZA Y MANDAR A TOPE
%30 EL CILINDRO
./4! #ONTROLAR EL SENTIDO DE ORIENTAMIENTO DE
LOS MUELLES A TAZA Y SU CENTRAJE

0OSITIONNER LES RESSORTS BELLEVILLE ET INS£RER Ü

FOND LE CYLINDRE
& 2%-!215% #ONTRÒLER LORIENTATION DES RESSORTS
BELLEVILLE ET LEUR CENTRAGE

5/20112 807
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

!33%-",).' 4(% "2!+).' 5.)4 !33%-",!'')/ '2500/ &2%.)

:53!--%."!5 $%3 "2%-3!''2%'!43 -/.4!*% $% ,/3
'250/3 $% &2%.!$/ !33%-",!'% $5 '2/50% &2%).3

4%#./,5"%

'" A '" B
0RELOAD THE SPRING AND TIGHTEN SCREWS IN TWO STAGES
,UBRICATE THE / RING AND POSITION THE CYLINDER ON THE STUDS USING THE CRISS CROSS METHOD
AND FASTENING

'" C '" D
,OCK THE CYLINDER TIGHTENING THE SCREWS WITH A DYNAMO )NSTALL THE COMPLETE ARM
METRIC WRENCH SET TO A TORQUE OF Õ .M

'" E '" F
4EMPORARILY LOCK THE ARM WITH NUTS PREVIOUSLY COATED WITH #HECK THE mATNESS OF THE ARMS USING TOOL 4 THEN LOCK
,OCTITE TIGHTEN LIGHTLY TO MAKE THE UNIT TOUCH THE MAIN THE ARMS INTO THEIR lNAL POSITION USING SCREWS ADEQUATELY
BODY COATED WITH ,OCTITE

808 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

,UBRIlCARE LANELLO /2 E POSIZIONARE IL CILINDRO 0RECARICARE LA MOLLA 3ERRARE LE VITI IN DUE
)4! SUI PRIGIONIERI E MANDARLO IN BATTUTA )4! TEMPI E CON IL METODO DEL

6ORBELASTUNG DIE &EDER UND 3CHRAUBEN IM

$ $EN / 2ING SCHMIEREN UND DEN :YLINDER
AUF DIE 3TIFTSCHRAUBEN POSITIONIEREN IHN BIS ZUM $ +REUZ SCHRITTWEISE FESTZIEHEN
!NSCHLAG GANZ EINZUSETZEN

A A 0RECARGAR LA MUELLE APRETAR LOS TORNILLOS EN

%30 ,UBRIlCAR EL ANILLO /2 Y COLOCAR EL CILINDRO
SOBRE LOS PRIGIONEROS Y LLEVARLO A TOPE %30 DOSS TIEMPOS CON EL METODO
DE TORSION CRUZADA

,UBRIlER LANNEAU /2).' ET POSITIONNER LE CYLIN 0RECHARGE LE RESSORT ET SERRER LES VIS EN DEUX
& DRE SUR LES PRISONNIERS ET LENVOYER EN BUT£E & TEMPS AVEC LA MáTHODE DU
SERRAGE CROIS£

)4! "LOCCARE IL CILINDRO CON LE VITI SERRATE CON

CHIAVE DINAMOMETRICA AD UN COPPIA DI Õ )4! )NSTALLARE IL BRACCIO COMPLETO
.M

$ $EN :YLINDER MIT DEN 3CHRAUBEN MIT

EINEM $YNAMOMETER UND EINEM !NZUGSMOMENT $ $EN GESAMTEN !RM INSTALLIEREN
VON Õ .M BLOCKIEREN

C D
%30 "LOQUEAR EL CILINDRO CON LOS TORNILLOS
APRETADOS CON LLAVE DINAMOMETRICA A UN PAR DE %30 #OLOCAR EL EJE COMPLETO
Õ .M

& "LOQUER LE CYLINDRE AVEC LES VIS SERRER Ü

LAIDE DE LA CLá DYNAMOM£TRIQUE Ü UN COUPLE DE & )NSTALLER LE BRAS COMPLET
Õ .M

&ISSARE PROVVISORIAMENTE IL BRACCIO CON I DADI #ONTROLLARE LA PLANARITÜ DEI BRACCI CON LATTREZZO
)4! SPALMATI CON ,OCTITE E SERRATI LEGGERMENTE PER )4! 4 E lSSARLI DElNITIVAMENTE CON LE VITI
FRIZIONARE IL GRUPPO SUL CORPO CENTRALE SPALMATE CON ,OCTITE

6ORUEBERGEHEND DEN !RM MIT DEN MIT ,OCTITE

$ GESCHMIERTEN -UTTERN BEFESTIGEN UND -UT $ $IE %BENHEIT DER !RME MIT DEM 7ERKZEUG 4 KON
TROLLIEREN UND ENDGU³ LTIG MIT DEN MIT ,OCTITE
TERN ZUSCHRAUBEN BIS DAS !GGREGAT AN DEM GESCHMIERTEN 3CHRAUBEN BEFESTIGEN
:ENTRALKOERPER ANGLIET

E F
&IJAR PROVISORIAMENTE EL EJE CON LAS TUERCAS
%30 PASADOS CON ,OCTITE Y APRETADOS LIGERMENTE %30 #ONTROLAR LA PLANARIDAD DE LOS EJES CON LA HER
RAMIENTA
PARA FRICIONAR EL GRUPO SOBRE EL CUERPO CENTRAL 4 Y lJARLOS DElNITIVAMENTE CON LOS TORNILLOS
PASAR CON ,OCTITE

&IJAR PROVISORIAMENTE EL EJE CON LAS TUERCAS PASA

& DOS CON ,OCTITE Y APRETADOS LIGERMENTE PARA & #ONTRÒLER LA PLAN£IT£ DES BRAS Ü LAIDE DE LOUTIL
4 PUIS lXER CEUX CI DE¸ lNITIVEMENT AVEC LES
FRICIONAR EL GRUPO SOBRE EL CUERPO CENTRAL VIS ENDUITES DE ,OCTITE

5/20112 809
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

!33%-",).' 4(% "2!+).' 5.)4 !33%-",!'')/ '2500/ &2%.)

:53!--%."!5 $%3 "2%-3!''2%'!43 -/.4!*% $% ,/3
'250/3 $% &2%.!$/ !33%-",!'% $5 '2/50% &2%).3

0
,/#4)4%

'" A bar '" B

4ORQUE WRENCH SETTING Õ .M #ONNECT AN EXTERNAL PUMP TO THE UNION PIECE h0v OF THE
./4% 4IGHTEN USING THE CRISS CROSS METHOD NEGATIVE BRAKE AND INTRODUCE PRESSURE TO BAR

14

+
--
13

'" C '" D
2OTATE THE ADJUSTMENT PINION ANTICLOCKWISE Õ TO ELIMI 2OTATE PINION CLOCKWISE TO OBTAIN THE ACCURATE CLEARANCE
NATE ALL EXISTING CLEARANCE BETWEEN THE BRAKING DISKS ./4% %VERY TURN OF THE PINION PRODUCES A CLEARANCE OF
2OTATE UP TO A TORQUE OF .M MM
'AP MM TURNS
'AP MM TURNS

'" E '" F
2ELEASE PRESSURE lT THE CATCH AND LOCK WITH SCREW COATED
WITH ,OCTITE
4IGHTEN SCREW TO A TORQUE OF .M

810 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

#OPPIA DI SERRAGGIO Õ .M #OLLEGARE AL RACCORDO h0v DEL FRENO NEGATIVO UNA
)4! ./4! 3ERRARE CON IL METODO INCROCIATO )4! POMPA ESTERNA ED IMMETTERE UNA PRESSIONE DI
BAR

!N DAS !NSCHLUœSTUECK h0v DER &EDERSPEICHERB

$ !NZUGSMOMENT Õ .M
"%-%2+5.' )M +REUZ FEST DREHEN $ REMSE EINE AUESSERE 0UMPE SCHLIEœEN UND $RUCK
BEI BAR
EINLASSEN

A B #ONECTAR AL EMPALME h0v DEL FRENO NEGATIVO UNA

%30 0AR DE SERRAJE Õ .M
./4! !PRETAR DE MANERA CRUZADA %30 POMPA EXTERNA Y INTRODUCIR PRESION DE BAR

#OUPLE DE SERRAGE Õ .M "RANCHER AU RACCORD h0v DU FREIN N£GATIF UNE
& 2%-!215% 3ERRER AVEC LA M£HODE CROISE & POMPE EXTERNE ET ENVOYER UNE PRESSION DE
BAR

2UOTARE IN SENSO ANTIORARIO Õ IL PIGNONE DI REG 2UOTARE IL PIGNONE IN SENSO ORARIO PER OTTE
)4! ISTRO PER ELIMINARE TOTALMENTE IL GIOCO TRA I
DISCHI DI FRENATURA
)4! NERE IL GIOCO ESATTO
./4! /GNI GIRO DI PIGNONE CREA UN GIOCO DI
2UOTARE lNO AD OTTENERE UNA COPPIA DI .M MM
'IOCO MM GIRI
'IOCO MM GIRI

'EGEN DEN 5HRZEIGERSINN Õ DAS +EGELRAD

$ DREHEN BIS KEIN 3PIEL ZWISCHEN DEN "REMSS $ $AS 2AD IN DEN 5HRZEIGERSINN DREHEN UM
CHEIBEN DAS GENAUE 3PIEL ZU ERREICHEN
MEHRUEBRIG BLEIBT !NZUGSMOMENT .M "%-%2+5.' *EDE 5MDREHUNG DES +OLBENS
ERZEUGT EIN 3PIEL VON MM
3PIEL MM 5MDREHUNGEN
3PIEL MM 5MDREHUNGEN

C D
'IRAR EN SENTIDO ANTI HORARIO Õ EL PINON DE
%30 REGISTRO PARA ELIMINAR TOTALMENTE EL JUEGO ENTRE %30 'IRAR EL PINON EN SENTIDO HORARIO PARA
DISCOS DE FRENADURA OBTENER EL JUEGO EXACTO
'IRAR HASTA OBTENER UN PAR DE .M ./4! ! CADA GIRO DE PIGNON NACE UN JUEGO DE
MM
*UEGO MM GIROS
*UEGO MM GIROS

& 4OURNER LE PIGNON DE RáGLAGE DANS LE SENS

CONTRAIRE AUX AIGUILLES DUNE MONTRE LE REGLEUR & 4OURNER LE PIGNON DANS LE SENS DES AIGUILLES
POUR FAIRE DISPARAÒTRE ENTIáREMENT LE JEU DUNE MONTRE POUR OBTENIR LE JEU EXACT
EXISTANT ENTRE LES DISQUES DE FREINAGE ./4% #HAQUE TOUR DE PIGNON CR£E UN JEU DE
4OURNER JUSQUÜ OBTENIR UN COUPLE DE .M MM
*EU MM TOUR
*EU MM TOUR

2ILASCIARE LA PRESSIONE MONTARE LARRESTO E BLOC

)4! CARE CON LA VITE SPALMATA CON ,OCTITE
3ERRARE LA VITE AD UNA COPPIA DI .M

$EN $RUCK ABLASSEN DEN 3PERRSTIFT MONTIEREN

$ UND DIE 3CHRAUBE DIE MIT ,OCTITE GESCHMIERT
WORDEN IST BLOCKIEREN $IE 3CHRAUBEN MIT EINEM
!NZUGSMOMENT VON .M FESTZIEHEN

E
$EJAR LA PRESION MONTAR EL PARO Y BLOQUEAR CON EL
%30 TORNILLO PASADA CON ,OCTITE
!PRETAR EL TORNILLO A UN PAR DE .M

2ELâCHER LA PRESSION MONTER LA BAGUE DE RETENUE

& ET BLOQUER AVEC LA VIS ENDUITE DE ,OCTITE
3ERRER LA VIS AU COUPLE DE .M

5/20112 811
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

-%#(!.)#!, !.$ -!.5!, 2%,%!3% /& 4(% !8,% 3",/##!'')/ -%##!.)#/ -!.5!,%
$%,,!33!,% !#(3% -%#(!.)3#( -!.5%,, %.43)#(%2. $%3",/15%/ -!.5!, $% ,/3 !8!,
$%",/#!'% -%#!.)15% -!.5%, $% ,%33)%5

1 18

12

10 11

'" A '" B
-!.5!, %-%2'%.#9 2%,%!3% 4IGHTEN SCREWS SO AS TO FASTEN THEM ONTO THE PRESSURE
,OOSEN NUTS OF SCREWS PROVIDED FOR THE MECHANICAL PLATE
AND MANUAL RELEASE OF THE BRAKING UNITS THEN MOVE THE NUTS
BACKWARDS BY APPROX MM

'" C '" D
!$*534-%.4 !&4%2 -!.5!, 2%,%!3%
5SING A WRENCH TIGHTEN THE SCREWS IN AN ALTERNATE 2EMOVE SCREWS COMPLETE WITH NUTS AND SEALS
SEQUENCE BY TURN AT A TIME SO AS TO COMPRESS THE 2EPLACE SEALS APPLY SILICONE BASED 4ECNO ,UBE GREASE
"ELLEVILLE WASHERS TO THE SCREWS AND INSTALL ALL PARTS INTO THE ARM
AND DISENGAGE THE BRAKING DISKS
)-0/24!.4 4IGHTEN MAX BY ONE TURN

812 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

3",/##!'')/ -!.5!,% $%-%2'%.:! !VVITARE LE VITI lNO A MANDARLE IN BATTUTA

)4! !LLENTARE I DADI DELLE VITI PER LO SBLOCCO
MECCANICO MANUALE DEI GRUPPI DI FRENATURA E FAR
)4! SULLO SPINGIDISCO
ARRETRARE I DADI DI CIRCA MM

!.5%,,% ./4 %.43)#(%25.' 3CHRAUBEN BIS ZUM !NSCHLAG AN DIE $RUCK
$ $IE -UTTERN DER 3CHRAUBEN ZUR MECHAN $ PLATTE ZUDREHEN
SCHEN MANUELLEN %NTSICHERUNG DER "REMSAG
GREGATE LOCKERN UND DIE -UTTERN UM MM
ZURUECK DREHEN

A B
%30 %3",/15%/ -!.5!, $% %-%2'%.#)! %30 !TORNILLAR LOS TORNILLOS HASTA LLEGAR AL TOPE
!mOJAR LAS TUERCAS DE LOS TORNILLOS PARA SOBRE EL EMPUJA DISCO
EL DESBLOQUEO MECANICO MANUAL DE LOS GRUPOS
DE FRENADURA Y HACER PASAR LAS TUERCAS DE MM
APPROX

$%",/#!'% -!.5%, $%-%2'%.#% 6ISSER LES VIS PUIS LES ENVOYER EN BUT£E SUR
& $ESSERRER LES £CROUS DES VIS POUR LE & LE PLATEAU DE PRESSION
D£ BLOCAGE M£CANIQUE MANUEL DES GROUPES DE
FRENAGE EN FAISANT RECULER LES £CROUS DENVIRON
MM

5TILIZZANDO UNA CHIAVE AVVITARE LE VITI IN 2%'/,!:)/.% $/0/ ,/ 3",/##!'')/ -!.
)4! MODO ALTERNATO DI DI GIRO ALLA VOLTA PER COM
PRIMERE LE MOLLE A TAZZA E LIBERARE I DISCHI
)4! 5!,%
2IMUOVERE LE VITI COMPLETE DEI DADI E DELLE
DI FRENATURA GUARNIZIONI
)-0/24!.4% !VVITARE PER MAX UN GIRO 3OSTITUIRE LE GUARNIZIONI LUBRIlCARE LE VITI CON
GRASSO AL SILICONE 4ECNO ,UBE E MONTARE IL
TUTTO NEL BRACCIO

%).34%,,5.' .!#( $%2 -!.5%,,%. %.43)

$ -IT EINEM 3CHLUESSEL DIE 3CHRAUBEN
ABWECHSELND JEWEILS UM 5MDREHUNG ZUDRE
$ #(%25.'
HEN UM DIE 4ELLERFEDERN EINZUDRUECKEN UND $IE 3CHRAUBEN MIT DEN -UTTERN UND DEN
DIE "REMSSCHEIBEN FREIZUSETZEN $ICHTUNGEN ABNEHMEN
7)#(4)' -AXIMAL UM EINE 5MDREHUNG $IE $ICHTUNGEN AUSWECHSELN DIE 3CHRAUBEN MIT
ZUSCHRAUBEN 3ILIKON FETT 4ECNO ,UBE SCHMIEREN UND DAS
GANZE 4EIL IN DEN !RM MONTIEREN

C D
5TILIZANDO UNA LLAVE ATORNILLAR LOS TORNILLOS
%30 DE MANERA ALTERNADA DE DE GIRO A LA VEZ %30 2%'5,!#)/. $%305%3 $%, $%3",/15%/
-!.5!,
PARA COMPRIMIR LOS MUELLES A TAZA Y LIBRAR LOS 2EMOVER LOS TORNILLOS COMPLETAS DE GUARNICIONES
DISCOS DE FRENADURA 3OBSTITUIR LAS GUARNICIONES LUBRIlCAR LOS TOR
)-0/24!.4% !TORNILLAR POR MAX UN GIRO NILLOS CON GRASA AL SILICONE 4ECNO ,UBE Y
MONTAR TODO EN EL EJE

! LAIDE DUNE CLÜ VISSER LES VIS ALTERNATIVE

& MENT DE TOUR Ü LA FOIS POUR CONTRAINDRE LE & 2%',!'% &!)3!.4 35)4% !5 $%",/#!'%
-!.5%,
RESSORT BELLEVILLE ET D£GAGER LES DISQUES DE %NLEVER LES VIS COMPL£TES D£CROUS ET DE GARNI
FREINAGE TURES
)-0/24!.4 6ISSER POUR MAX UN TOUR 3UBSTITUER LES GARNITURES LUBRIlER LES VIS AVEC DE
LA GRAISSE AU SILICONE 4ECNO ,UB E MONTER
LE TOUT DANS LE BRAS

5/20112 813
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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Automatic Positive Locking Traction Differential

OWNER'S MANUAL
With warnings and precautions on back cover

Tractech has been a leading manufacturer of premium quality traction-adding differentials for over 50 years. Each step
in our manufacturing process, from design to final assembly and inspection reflects the highest industry standards

This manual is intended to help provide safe and trouble free operation of NoSPIN/Detroit Locker differentials for the life
of the product. We strongly recommend that all who come in contact with the products read this manual thoroughly.

GENERAL INFORMATION AND RECOMMENDATIONS

To Contact Tractech Inc. Telephone: (586) 759-3850 U.S.A.

FAX: (586) 759-1645 U.S.A.
Web Site: www.tractech.com
Office Hours: 7:30 - 4:30 (FT) Mon. - Fri.
General Assistance: Customer Service Dept.
Technical Assistance: Engineering Dept.
Warranty Assistance: Customer Service Dept.
Printed Matter: Marketing Department

Glossary To assist the reader in understanding the language in this manual a Glossary is included.

Limited Warranty The complete Tractech Limited Warranty appears on page 22 Owners of NoSPIN/Detroit Locker
differentials are encouraged to read this warranty carefully before putting the vehicle into service.

Technical Bulletins Tractech has published several Technical Bulletins which are helpful supplements to the information presented
throughout this manual Copies are available by writing to the Marketing Dept.

Application Approval It is essential that NoSPIN/Detroit Locker differentials be used only in applications approved by Tractech
Engineering. Read page 3 carefully and follow the stated guidelines.

Model Lists Refer only to approved Tractech model lists when ordering or specifying the products. Copies are available by
writing to the Marketing Dept - Web page www.tractech.com.

The performance of a vehicle equipped with a NoSPIN/Detroit Locker differential is somewhat different from
Vehicle Performance that of a vehicle equipped with a conventional differential. Read page 4 carefully to assure proper under standing
of the characteristics of the product.

Before installing NoSPIN/Detroit Locker differentials, read pages 7-11 Note: Tractech recommends that a
Installation competent driveline mechanic perform the installation in that tools of the trade are required.
Note: The vehicle/axle manufacturer's instructions for installing a conventional differential must be consulted
when disassembling and reassembling axle components and when making all final adjustments.

Maintenance Refer to pages 13-16 for important information regarding proper maintenance of your NoSPIN/Detroit Locker
differential. Carefully follow the recommended lubrication, service and inspection procedures.

Trouble Shooting Information on pages 17-18 will help owners and operators of NoSPIN equipped vehicles diagnose and correct
problems related to vehicle performance.

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TABLE OF CONTENTS

PREFACE, GENERAL INFORMATION AND RECOMMENDATIONS 1

APPLICATION 3
VEHICLE PERFORMANCE 4
EXPLODED VIEWS OF REPRESENTATIVE ASSEMBLIES 5
OPERATION 6
INSTALLATION 7-11
TESTS FOR PROPER INSTALLATION AND OPERATION 12
MAINTENANCE 13-16
TROUBLE SHOOTING 17-18
NEW IMPROVED DETROIT LOCKER™ SPECIAL INSTRUCTIONS 19
NEW DETROIT C-LOCKER FOR C-CLIP AXLES - SPECIAL INSTRUCTIONS 20
GLOSSARY 21
LIMITED WARRANTY AND EXCLUSIONS 22
WARNING, PRECAUTIONS 23
INSTRUCTIONS TO AXLE MANUFACTURER AND CHASSIS ASSEMBLY PLANT 24

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APPLICATION APPROVAL
Over the past 50 years, the NoSPIN differential has been successfully utilized by a variety of on/off road vehicle/axle
manufacturers. Traditional applications are Medium/Heavy Truck, Construction, Mining, Forestry, Agricultural, Military and
Specialty Vehicles.

O ensure successful application of our product, Tractech Engineering requires approval for each new vehicle/axle application.
The following guidelines are examples of successful NoSPIN differential application:

Applications:

• 6x4 (tandem-drive axle) Trucks Primary location - forward rear. Both rear axles for maximum mobility if used 75% off-
road.
• 4x4 Off-Road Vehicles Farm tractors (articulated & rigid) front axle. Also rear axle for maximum traction.
(Consult Tractech Engineering.)
• Farm Tractors (straight frame with front-wheel-drive) -front axle only
(cannot be used in rear axle with individual wheel brakes).
• Loader - One axle only, either front or rear.
• Trencher - One or both axles.
• Front drive axles of Light Trucks. While successful in specialty vehicles, this application must be reviewed and
approved by Tractech Engineering.

It is important when considering the use of a traction device to review key vehicle parameters i.e., loading, geometry, power
requirements, duty cycles (miles/hours) etc.

The following marginal applications must be reviewed with Tractech Engineering Application Approval Form No.
7003 is required. Successful field testing must be performed by the customer prior to production approval by
Tractech.

Examples are:

Transit Buses- NoSPIN should not be used when operated in cities where sharp turns are required continually changing
lanes, as in leaving bus stops to avoid parked vehicles.
Transit buses utilized in non city operations are an acceptable application. School bussses have also proven to be
another successful application for NoSPIN.

• Yard Tractors (Spotters)

• Light-duty Pickup Trucks - Equipped with fifth wheels to pull "gooseneck" trailers in pickup and delivery operations
unless equipped with automatic transmission.

• Small Fork Lift Trucks -with short wheelbase and high turn angle capability utilized inside buildings on smooth
surfaces.
Highway Tractors - with less than 120" wheelbase (see page 4 for details).

CAUTION:
ANY INCREASE IN THE SIZE OF THE VEHICLE'S ENGINE, TIRES, WEIGHT, ETC., MAY PROHIBIT USE OF A
NoSPIN DIFFERENTIAL IN A HERETOFORE APPROVED APPLICATION. ANY SUCH MODIFICATION SHOULD BE
REVIEWED BY TRACTECH ENGINEERING BEFORE CONTINUING TO USE THE PRODUCT.

THE NoSPIN DIFFERENTIAL DOES NOT INCREASE THE LOAD-CARRYING CAPACITY OR PAYLOAD RATING OF
THE VEHICLE OR VEHICLE COMBINATION.

• Model Lists
Refer only to approved Tractech model lists when ordering or specifying NoSPIN/Detroit Locker differentials.
. Copies are available by writing to the Marketing Dept.

*1995 Tractech inc.

*NoSpin, Detroit Locker ,Improved Detroit Locker and Detroit C-Locker are registered Trademarks of Tractech Inc.

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VEHICLE PERFORMANCE
The performance of a vehicle equipped with a NoSPIN/Detroit Locker differential is somewhat different from that of a vehicle
equipped with a conventional differential. For example:

When turning a corner, the sound of component disengagement and re-engagement may be audible, and the transfer of
driving torque from both wheels to one wheel may be noticeable.

When going from drive (acceleration) to coast (deceleration) in a turn, a "metallic" sound may be heard as torque flow is
reversed (inside wheel engaged during acceleration; outside wheel engaged during deceleration).

These characteristics are normal because of backlash designed into the NoSPIN differential, which is of a fixed amount (1 to
2 inches of rotation at the tire tread).

Backlash or slack between the driving and driven clutch teeth is an inherent part of the NoSPIN and necessary to permit
automatic operation when driving in forward and reverse. The total backlash in the driveline is increased by the amount of the
reduction between the ring gear and pinion. If the ring gear-pinion ratio is 5 to 1, the total backlash in the driveline with the
NoSPIN would be about 30°. This in turn is increased by clearances between planetary gear, sliding splines and the ring and
pinion gear. We feel that the total driveline slack can amount to as much as 1/4th turn of the driveline without being abnormal,
but if it exceeds 1/4 turn, other parts in the drivetrain could be checked. Further clarification of operational and performance
characteristics is available through Technical Bulletin No. 81 -1044. A copy is available by writing to our Marketing Dept.

Anything that improperly causes a difference in individual wheel speeds, such as mismatched tire diameters due to
differences in tire wear or tire pressure, or unbalanced loading of the vehicle (especially cargo vehicles, or vehicles operated
on a side slope) can cause the NoSPIN differential to deliver power to only one side of the vehicle and thus cause steering
problems.

The diameter of the tires can be adjusted by varying the air pressure of the tires.
Match the distance from the top of each tire rim to the pavement.

When negotiating a turn (outside wheel disengaged), the inside wheel under conditions of poor traction may receive
excessive torque, which could cause it to break traction momentarily until its speed is equal to the outside wheel. This will
result in re-engagement of the outside wheel thus allowing both wheels to be driven. This condition is most noticeable with
lightly loaded axles.

Certain vehicles equipped with NoSPIN differentials, such as short wheelbase trucks (e.g., under 120" wheelbase) and four
wheel drive trucks with a NoSPIN differential in the front steering axle, can experience "understeer" when negotiating a turn
under power. Releasing the accelerator will reduce the torque and improve steering.

Use extreme caution when accelerating or decelerating on slippery or unstable surfaces. Vehicles/axles equipped with
traction differentials are inherently more sensitive to side-slip than vehicles equipped with conventional differentials. Stability
can be retained if side-slip occurs by decelerating (Letting off the accelerator) CAUTION: DO NOT APPLY THE BRAKE. TO
DO SO MAY RESULT IN LOSS OF VEHICLE CONTROL.

Braking capacity is reduced when a NoSPIN differential equipped vehicle makes a turn while coasting downhill in that the
inside wheel is then disconnected from the driveline. Operating in low gear will allow the engine to act as a retarder and will
improve braking capacity.

If the vehicle is stationary on a dry surface, easier steering can be achieved by moving the vehicle slightly in either forward or
reverse. (Assure that proper steering pressure is maintained.)

NOTE:
If placing limited-slip differentials in Rockwell, Eaton or-Dana axles with NoSPIN differentials, also replace the differential
case halves with the axle manufacturer's standard differential case halves NoSPIN differentials are designed to fit standard
differential case halves. NoSPIN differentials will not fit properly into limited-slip differential case halves.

THE NoSPIN DIFFERENTIAL DOES NOT INCREASE THE LOAD-CARRYING CAPACITY OR PAYLOAD RATING OF THE
VEHICLE OR VEHICLE COMBINATION.

IMPORTANT! READ THE CAUTIONARY NOTICES REFERENCED ON THE BACK COVER.

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EXPLODED VIEWS OF REPRESENTATIVE ASSEMBLIES

The following exploded views of NoSPIN differentials (there are five "styles")* illustrate the various
components that make up the complete assembly. Certain components differ slightly in appearance
between style, but their function - and the function of each of the five style NoSPIN differentials - is
the same

Assembly style not shown:

New IMPROVED Detroit Locker. See page 19
Models with central driver, external springs and retainers, without support case.
Copies of style not shown are available by writing to the Marketing Dept.

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OPERATION

The NoSPIN differential powers both wheels. Yet The NoSPIN differential allows the vehicle to perform
freely permits wheel speed differentiation when as if the axle half-shafts had been welded - the axle is
required. completely locked. This means both wheels turn at the
same speed. If one wheel loses traction or leaves the
Prime functions ground, the opposite wheel, which still has traction,
1. Assures 100% of the available torque and continues to drive the vehicle until traction is regained
increases drawbar pull. by both wheels. There can be no one wheel spinout.
(Fig. 2)
2. Prevents wheel spin and power loss when one
wheel loses traction. When the vehicle turns a corner, or when one wheel
3. Compensates for differences in wheel travel passes over an obstruction, the outside wheel, or the
when turning or operating on uneven wheel passing over the obstruction, must travel a
surfaces. greater distance and therefore faster than the other
wheel. When this occurs, the NoSPIN differential
automatically allows for the necessary difference in
The drive axle illustrated below (Fig. 1) is equipped
wheel speed.
with a NoSPIN differential. Note that there are no
spider gears, but rather two drive members, called
During a turn (Fig. 1), the inside driven clutch remains
driven clutch assemblies. They mate with a spider
completely engaged with the spider and continues to
assembly which is driven by the ring gear through
drive the vehicle. The outside driven clutch
the differential support case.
automatically disengages from the spider, allowing
As long as the vehicle is operated in a straight the outer wheel to turn freely in the turn. When the
forward or reverse direction over a smooth surface, vehicle completes the turn, the outside driven clutch
the driven clutch assemblies remain locked to the automatically reengages the spider, as both wheels
spider assembly. again travel at the same speed.

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INSTALLATION
Refer only to an approved Tractech model list when ordering or specifying the product. Copies are available by writing to the Marketing
Department.

It is essential that NoSPIN/Detroit Locker differentials be used only in applications approved by Tractech Engineering. Read pages 3-4
carefully and follow the approved guidelines.

The installation procedure presented on pages 7-11 applies to all NoSPIN differentials (except 'R' Model NoSPIN Differentials). However,
the procedure will differ slightly depending upon the specific vehicle. Therefore it is essential to consult the vehicle/axle manufacturer's
instructions for installing a differential.

Most NoSPIN/Detroit Locker differentials are designed to fit directly into the standard differential support case in the vehicle. Where it is not
possible to fit the standard support case manufactured by the vehicle/axle maker, the NoSPIN differential is supplied with a case
manufactured by Tractech. Therefore, two sets of installation instructions are provided.

NoSPIN differentials are easily installed in the field. However, it is recommended that a competent driveline mechanic do the work in that
tools of the trade are required.

The NoSPIN differential is designed to fit the components in the axle. No machining is required. The procedure is the same as it is for
installing the original differential. A competent mechanic can install the NoSPIN in the same time required to replace the original differential.
Caution: It is recommended every safety precaution be practiced while performing the work when disassembling and reassembling axle
components and when making all final adjustments.

Installation Instructions:
NoSPIN/Detroit Locker Differentials Supplied Without a Support Case

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INSTALLATION

Disassembly: (Steps 1-5)

Step 1
Refer to the vehicle/axle manufacturer's recommendations for removing the differential assembly from the axle. Ensure that all safety
precautions are implemented.

Step 2
Following the procedure recommended by the vehicle or axle
manufacturer, remove the ring gear and differential case assembly
from the axle carrier.

CAUTION:
Do not use heat to disassemble drive axles. To do so can destroy heat treat
properties, weaken or distort axle components or result in a mishap which
can cause injury, even death.

Step 3
Mark the differential case halves so they may be reassembled in
their original position. Open the case. Remove and store the
original differential components. Retain the original differential
case, ring gear, and differential case bolts. Do not remove
bearing cone assemblies from the case halves; do not remove
the ring gear from the case half.

Step 4
Wash the differential case, ring gear, differential case bolts and
bearing assemblies using a non-flammable, non-toxic cleaning
solvent that will not etch, scratch or oxidize the components. Rinse
in clean solvent and dry. Inspect for damage, wear or corrosion.
Replace if necessary with identical, axle/vehicle manufacturer
approved components.

NOTE:
Be sure all thrust washers have been removed from the differential case.
Failure to do so will cause the NoSPIN differential to malfunction.

Step 5
Clean and examine the splined ends of the axle shafts. Remove
any roughness or burrs with a tile or stone. Examine the shafts for
straightness, cracks or other damage. Replace if necessary.
Make sure splines on axle match the splines on NoSPIN
differential side gear.

Step 6
Position the NoSPIN differential assembly in the case half which is
attached to the ring gear.

CAUTION:
Do not remove the retainer bolt, nut and washers at this time. To do so will
release the compressed springs, which can cause injury.

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Step 7
Position the remaining differential case half over the NoSPIN
differential.

NOTE:
Be sure both case halves are in the original (marked) position.

Step 8
Using a torque wrench, tighten the differential case bolts
securely to the torque limit recommended by the vehicle/axle
manufacturer's instructions. Assure that there is a tight fit
between the spider trunnions and the case.

NOTE:
A loose fit between the spider and the case can cause malfunction of the
NoSPIN Differential.

Step 9
Remove the retainer bolt, nut and washers.
(Retain for future service work.)

Step 10
Insert axle shafts into splined side gears of the NoSPIN
differential. The shafts should slide in freely but fit correctly.

Step 11
Install the differential and ring gear assembly in the axle housing.
Complete the reassembly of associated components as
recommended by the vehicle/axle manufacturer's instructions.

NOTE:
Contamination, such as metal particles in the differential case, can cause
the differential to malfunction. Be sure the axle housing is clean before
proceeding.

Step 12 Step 14
Refill the axle housing with lubricant recommended for Follow the test procedures outlined on page 12 to assure proper
differentials by the vehicle/axle manufacturer. installation and operation of the NoSPIN differential.

NOTE:
If the NoSpin differential is disassembled, be sure to reassemble both
Step 13 clutch assemblies to the spider assembly with the 'slot' in each holdout
Apply Caution Label to instrument panel in full view of operator ring over the long tooth of the spider.
or mechanic. If you did not receive this label, contact Tractech's
Marketing Department.

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INSTALLATION
Installation Instructions for NoSPIN/Detroit Locker Differentials - Supplied with a Support Case

Disassembly: (Steps 1-5)

Step 1
Refer to the vehicle/axle manufacturer's recommendations for removing the differential assembly from the axle. Ensure that all safety
precautions are implemented.

Step 2 Following the procedure recommended by the vehicle or

axle manufacturer, remove the ring gear and differential case
assembly from the axle carrier.

CAUTION:
Do not use heat to disassemble drive axles. To do so can destroy heat treat
properties, weaken or distort axle components or result in a mishap which
can cause injury, even death.

Step 3
Using the proper bearing puller, carefully remove the bearing cone
assemblies from the original differential case. Replace bearings if
worn or damaged during disassembly. If shims are used behind the
bearing cone assemblies, record the amount of shim pack under
each bearing.

Step 4
Remove the ring gear from the original differential case. Record the
dimension from the ring gear flange face to the nearest bearing
shoulder. Record the dimension from one bearing face to the other.

Step 5
Store the original differential and case for use if the NoSPIN
differential requires service. Protect parts from damage or
Corrosion.

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Step 6
Wash the ring gear, ring gear bolts, shims, and bearing races
using a nonflammable, non-toxic cleaning solvent that will not
etch, scratch or oxidize the parts. Rinse in clean solvent and dry.
Inspect for damage, wear or corrosion. Replace if necessary with
identical axle/vehicle manufacturer approved components.

Step 7
Clean and examine the splined ends of the axle shafts. Remove
any roughness or burrs with a file or stone. Examine the shafts
for straightness, cracks or other damage. Replace if necessary.
Make sure splines on axle match splines on NoSPIN differential
side gear.

Step 8
If shims are used behind the bearing cone assemblies, measure
the NoSPIN differential support case from the ring gear flange
face to the nearest bearing shoulder and from one bearing
shoulder to the other. Adjust the shim pack at each bearing journal
to the dimension recorded previously from the original differential
case.

Step 9
Using a torque wrench, bolt the ring gear to the NoSPIN
differential and case assembly. Tighten the ring gear bolts
securely to the torque limit recommended by the vehicle/axle
manufacturer.

Step 10
Using an Arbor press with an arbor of the correct size, press the
bearing cone and roller assemblies onto the hubs of the NoSPIN
differential support case until they are properly and squarely
seated.

Step 11
Install the differential and ring gear assembly in the axle housing.
Complete the reassembly of associated components as
recommended by the vehicle/axle manufacturer's instructions.
Note: Contamination, such as metal particles in the differential
case, can cause the differential to malfunction. Be sure the axle
housing is clean before Proceeding.

Step 12 Step 14
Refill the axle housing with lubricant recommended for differentials Follow the test procedures outlined on page 12 to assure proper
by the vehicle/axle manufacturer. installation and operation of the NoSPIN differential.

Step 13 NOTE: if the NoSPIN differential is disassembled, be sure to reassemble

Apply Caution Label to instrument panel in full view of operator or both clutch assemblies to the spider assembly with the 'slot' in each holdout
mechanic. If you did not receive this label, contact Tractech's ring over the long tooth of the spider.
Marketing Department.

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TEST FOR PROPER INSTALLATION AND OPERATION

INSTALLATION TEST

Step1
With the engine turned off, raise NoSPIN equipped driving axle(s) until
all wheels are out of contact with any surface. Place the transmission
in gear or park so that the driveshaft is locked and does not rotate.
NOTE: Test for forward disengagement:

Step 2
With two people, rotate both wheels rearward, as far as possible to
lock both wheels.

Step 3
With the left wheel securely held in the rearward direction, rotate the
right wheel slowly forward. A faint indexing or clicking sound should be
heard as the NoSPIN disengages on the right side.

Step 4
With the right wheel slowly rotating forward, the left wheel should be
rotated slightly forward. This will lock both wheels.

Step 5
Again, rotate both wheels rearward, as far as possible to lock both
wheels.

Step 6
With the right wheel securely held in the rearward direction, rotate the
left wheel slowly forward. A faint indexing or clicking sound should be
heard as the NoSPIN is disengaged on the left side.

Step 7
With the left wheel slowly rotating forward, the right wheel should be
rotated slightly forward. This will lock both wheels.

Repeat steps 2-7 except, test for reverse disengagement. If the above
steps are completed successfully and rotating wheels disengage
easily by hand, rotate freely and evenly, lock both wheels when
required, and produce a faint indexing or clicking sound, then the
NoSPIN is properly installed and is functioning correctly.

IF EITHER WHEEL DOES NOT ROTATE FREELY IN EITHER

DIRECTION or does not lock both wheels as required, recheck the
installation of the NoSPIN in the axle. Also check hand and foot brakes
for possible drag caused by improper adjustment. Be sure that all
thrust washers have been removed from the standard differential
support case.

To check normal NoSPIN operation, drive the vehicle on a flat surface

with good traction, in a right or left circle in forward and reverse to be
sure that the outside wheel is free to overrun (i.e. that the outside tire
does not scuff). A clicking or indexing sound may be heard. The sound
of gear re-engagement may also be heard upon completion of the turn.
This is normal.

OPERATION TEST
Check to see that both wheels of each NoSPIN differential equipped
axle are driving. Make this test under load, so that engine torque is
applied through the NoSPIN differential with the wheels on the ground.
One way to achieve this load is to drive up against a solid obstruction
(on loose dirt or gravel, if possible) and attempt to spin both wheels
together. Perform this test in forward and reverse. (Exercise caution
when performing this test to avoid damage to vehicle or obstruction.)

CAUTION: DO NOT OPERATE THE VEHICLE IF BOTH WHEELS OF

A NoSPIN/DETROIT LOCKER EQUIPPED AXLE ARE NOT
DRIVING. POWER TO ONLY ONE WHEEL CAN CAUSE SERIOUS
STEERING PROBLEMS AND LOSS OF VEHICLE CONTROL AND
RESULT IN A MISHAP WHICH CAN CAUSE PROPERTY DAMAGE,
INJURY, EVEN DEATH.

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MAINTENANCE
Caution:
When servicing any driveline components of a NoSPIN differential equipped axle, ensure that the engine is switched off and all wheels are
free of the ground to prevent the vehicle from moving. Axles equipped with NoSPIN/Detroit Locker differentials deliver power to both wheels -
even when only one wheel is on the ground. Failure to observe these cautionary measures may cause the vehicle to move which can result in
a mishap which can cause property damage, personal injury, even death.

Caution Label:
Vehicles equipped with NoSPIN differentials should be identified by a Caution label mounted on the instrument panel.

Lubrication:
All NoSPIN differentials are designed to operate in those lubricants recommended by the vehicle/axle manufacturer. No special lubricant is
needed. For very cold weather applications, use the lightest oil the axle manufacturer will allow to overcome possible sluggish re-
engagement of the driven clutch assemblies.

Routine Inspection
Carefully follow the recommended lubrication, preventative maintenance and inspection procedures of the vehicle/axle manufacturer as part
of all NoSPIN differential preventative maintenance. Except for testing for proper operation, and a possible change in the way brake
adjustments are made (as explained below), maintenance, inspection and lubrication requirements of NoSPIN differential equipped vehicles
are the same as for vehicles with standard differentials.

Check for Proper Operation of NoSPIN Differential

At 90 day intervals, the drive axles should be raised and the NoSPIN differential checked (see page 12) to be sure it is operating properly.
This test will also determine if both axle shafts are intact.

Adjustments
No adjustments or alterations should be made to the NoSPIN differential. Refer to the vehicle/axle manufacturer's instructions for
adjustments to other components in the axle. When making brake adjustments, the wheels on both sides of the vehicle must be raised and
the transmission placed in neutral so that the ring gear and opposite wheels are free to rotate with the wheels
on the side being adjusted.

Servicing NoSPIN Differentials

Any decision to disassemble the axle for inspection should be made only after performing the installation and operation tests stated on page
12 and after consulting the vehicle/axle manufacturer's manual and determining that the NoSPIN differential, or some other axle component,
is not working properly. Review the "Trouble shooting" section on pages 17-18 to determine whether the situation requires removal of the
NoSPIN differential from the vehicle.

Removal of the NoSPIN Differential From the Axle

Refer to the vehicle/axle manufacturer's instructions. The procedure for removing the NoSPIN differential case and ring gear assembly is the
same as for the original differential. It is not necessary to remove the ring gear from the differential case half unless the standard support case
is being replaced or the NoSPIN, differential was supplied with a case manufactured by Tractech.

Retaining Bolt
A retaining bolt, washers and wing nut are useful to keep the NoSPIN differential assembly intact when removing it from the differential case
and when reinstalling it in the axle housing.

CAUTION:
FAILURE TO USE A RETAINING BOLT OR SOME OTHER RESTRAINING MEANS WHEN SEPARATING THE DIFFERENTIAL CASE
HALVES CAN CAUSE INJURY IN THAT NoSPIN DIFFERENTIALS HAVE COMPRESSED SPRINGS.

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The bolt washers and wing nut used to retain the NoSPIN differential assembly when it was shipped from the factory as illustrated on page
13, are best for this purpose.You will note that the retaining washers must be small enough to pass through the case ends (dimension "A"),
yet large enough to restrain the two side gears (dimension "B") and the balance of the NoSPIN differential assembly when all parts are
assembled and the springs are compressed.

Disassembly of the NoSPIN Differential

1. Mark the differential case halves so they can be reassembled in their original position when repair or inspection is completed.

2 Insert the NoSPIN differential retaining bolt and washer assembly. Thread the nut tingertight against the washer (Fig 3) If a retaining bolt
and washer assembly are not available, hold the differential case firmly as the last bolts are being removed from the case halves to absorb
spring pressure and prevent possible injury.

Fig. 3

3. Separate the case halves and remove the NoSPIN differential assembly.

4. Release the retaining bolt and washer assembly while firmly holding the NoSPIN differential to absorb the spring pressure.

5. Remove side gears, springs, spring retainers, driven clutch assemblies and spider assembly.

Inspection of Components
1. Wash all components thoroughly with a non-flammable solvent that will not etch, scratch or oxidize the parts. Rinse in clean solvent and
dry.

2 Inspect the splines on the driven clutches. Remove any burrs or small chips with an abrasive stone or electric burr grinder. If sections of the
spline are broken away, replace the components.

Inspect the teeth on the driven clutches. If wear or chipping is present, replace the component. Check holdout rings for fractures and
chipping or excessive wear of the lugs. Replace as required.

NOTE: The holdout ring and driven clutch are serviced as an assembly.

3. Inspect the teeth on the spider and center cam. If wear or chipping is present, replace the component. Check the center cam for free
movement.

NOTE: The spider and center cam are serviced as an assembly.

4. Inspect the splines on the side gears. Remove any burrs or small chips. If splines are broken or badly chipped, or if hub walls are fractured,
replace the component. Inspect the side gear spline fit on its mating axle shaft. Be sure the splines do not bind.

5. Check the spring load at the operating height. (See chart on page 16)

6. Carefully examine the differential case. If worn or scored, the case should be replaced.

7. Examine the bearings, ring gear, ring gear bolts and nuts. Replace if necessary with new components that meet the vehicle/axle
manufacturer's specifications.

CAUTION:
If major components (e.g. spider assembly or driven clutch assemblies) show excessive wear, the complete NoSPIN differential should be
replaced. If a component is replaced, mating components should also be replaced in that it is likely that they too are damaged. Use of worn or
damaged components can lead to a recurrence of the original problem. NOTE: Use only Tractech approved components when repairing
NoSPIN/Detroit Locker differentials.

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Reassembly Procedure for NoSPIN Differentials

1. Assemble a spring retainer over the side gear splines with the retaining lip pointed up.
It should seat against the side gear shoulder. Place a spring over the side gear spline
and against the retainer lip with the smaller diameter of the spring against the retainer
(Fig. 4).

Fig. 4

NOTE: Verify that the spring is functioning freely. Be sure the spring is not binding, that
the coils do not overlap and that there is good contact between the coil and the spring
retainer.

2. Assemble the two clutch assemblies to the spider assembly.

IMPORTANT:
Be sure the 'slot' in each holdout ring is properly aligned over the long tooth of the spider
assembly.

3. Position the spider assembly and clutch assembly on top of the spring.

4. Assemble the other retainer and spring on the other side gear as previously
indicated, and position on top of the spider and clutch assembly.

5. Using a mechanical press (or other safe means) compress the springs and fasten the
NoSPIN together with a retaining bolt, washers and wing nut (Fig. 5). Be sure the side
gear splines are completely meshed with the clutch spline.

Fig. 5

CAUTION:
Failure to use a retaining bolt or some other restraining means when assembling the
NoSPIN can cause injury in that all NoSPIN differentials have compressed springs.

6 Lay the ring gear and flanged half of the differential case on a bench with the bearing
end of the case hub down and the inner case facing up. ENSURE NO THRUST
WASHERS ARE INSIDE THE CASE.

7. Install the NoSPIN differential in the flanged differential case half.

8. Mount the plain case half over the side gear. ENSURE NO THRUST WASHERS ARE
INSIDE THE CASE.

9. Position the case halves firmly together with the punch marks aligned and install the
case bolts.

10 Tighten case bolts to the torque specified by the vehicle/axle manufacturer. Check to
be certain of a tight fit between the two case halves at all points and between the
trunnion mounts in the case and the spider trunnions (Fig. 6).

Fig. 6

11. Remove the wing nut, washers and retainer bolt.

12. Follow the vehicle/axle manufacturer's instructions for reinstallation of the ring gear
and differential case assembly into the axle carrier.

13. BEFORE OPERATING THE VEHICLE PERFORM INSTALLATION AND

OPERATION TEST STATED ON PAGE 12 TO ENSURE CORRECT RE-ASSEMBLY
OF COMPONENTS.

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SPRING LOAD (in Ibs. Minimum) AT OPERATING HEIGHT

Spring load should be checked at the operating height specified in the above table for an approximate reading. A
dial indicator type spring tester is the best tool for this procedure. However, if one is not available, a weight equal to
the load specified in the table can be placed on the spring and the height can be measured with the weight in place
on the spring. Tech Data Report #80-1038 can be used to assist in making a decision as to whether the spring
should be replaced.

Model Series Part No. Operating Height Load (Ibs. Minimum)

137S 69978 .45" 40

162S 69427 .54" 45
187S 68264 .61" 46
187S 69076 .61" 72
187S 72008 .61" 72
187S 72016 .61" 72
225S 66622 .73" 53
225S 69640 .73" 52
250S 67085 .62" 61
275S 67115 .86" 69
306S 66842 .90" 104
350S 67204 1.04" 101
400S 65461 1.41" 144
450S 64718 1.30" 162
550S 65423 1.43" 198
600S 68707 1.56" 297

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TROUBLE SHOOTING
An important function of an owner/operator in the field is that, one of the many hats he is required to wear is the one labeled "trouble shooter."
Trouble shooting can be a very frustrating, elusive job. However, if some basic rules are followed in a systematic order, solutions can be
easily obtained. The following guidelines can be utilized for trouble shooting both on and off highway vehicle applications. However, some
techniques used for on/highway vehicles are not as important for off/highway vehicles:

1. Before tearing down an axle and differential make sure you get the correct “story” from a reliable source. Then actually try the vehicle
yourself, Inspect any previously remove components, Question associated failures, ask if it has occurred before. In other words, get the
facts. And don t over-react.

2. Read the Trouble Shooting Section. (Enclosed)

3. Perform a Functional Check. (Enclosed)

4. Check tire rolling radii. Assure that all tires are within specifications. (This applies primarily to on/highway vehicles.)

5 If all the previous checks do not reveal the problem or offer a solution, then the NoSPIN must be removed. Upon removal, look for the
following:
A. Contamination in the oil or on the components.
B. Obvious broken or worn parts.
C. Mis-assembly...i.e., retainers installed backwards, thrust washers left in, spring jumping over retainer, etc.
D Heavy wear on spider and clutch drive teeth... i.e., Tooth rounding, 5° negative angle gone, corner chipping of teeth.
(These components are usually the main areas of wear.)
E. Telltale signs of eccentric wear, patterns on components, indicating possible cause of shaft problems.
F. Check NoSPIN assembly for pair-up, hand cam, H.O.R. tension, backlash, etc.

6 After inspection of the NoSPIN and associated axle components a new unit should be installed and a complete functional check and
vehicle performance check should be made.

7 If during the visual inspection a solution to the problem is not obtained, the unit should be returned to Tractech attention of the
Customer Services Manager. Call first for a return authorization number.

The following chart will assist owners and operators of NoSPIN differential equipped vehicles diagnose and correct
problems related to vehicle performance. Potential problems are stated on the left; possible causes for those problems
are listed, by number, on the right. The explanation of these "possible causes" follows on page 18.

PROBLEM POSSIBLE CAUSE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Hub studs shearing; rear tire scuffing;

axle shaft breakage

Steering difficulty; vehicle pulls on

straight forward driving or tends to go
straight when making turns

No differential action; binding in turns

Excessive driveline noise*

Excessive tire wear

Grinding noises

Continuous "clicking" sound in straight

forward driving

Excessive backlash in vehicle drivetrain;

engine lug or vehicle surge during turns

Tendency to side-slip or "fishtail" on icyroads

Sluggish reengagement of NoSPIN

differential clutch assemblies

Difficulty in turning vehicle from

standing start

Erratic operation of NoSPIN differential;

premature wear or failure of NoSPIN
differential components

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TROUBLE SHOOTING
* NOTE: NoSPIN differentials will emit occasional "metallic" sounds due to backlash built into the unit. This is normal! See backlash under
Vehicle Performance on pages 4.

Possible Causes for Vehicular Problems

1. Improper installation; defective NoSPIN differential. Follow test procedures outlined on page 12 Correct installation or repair or replace
the NoSPIN differential if the vehicle fails any step of the test procedure
.
2. Overloading and/or improper weight distribution. Remove excess weight and redistribute the load from side to side, according to the
vehicle/axle manufacturer's instructions.

3. Unequal rolling radii of the drive wheel. A smaller rolling radius tire will cause the tire to overrun constantly when power is applied. The
other tire (with the larger rolling radii) will do all the driving replace tires or adjust tire pressures until rolling radii are equal.

4. Broken axle shaft. Replace. NOTE: It is possible to operate a NoSPIN equipped vehicle on one axle shaft. However, this practice is not
recommended in that serious damage can occur to other axle components.

5. Bent axle shaft or housing; axle shafts on different center lines. Replace bent axle shafts or housing or realign hub faces and bolt circles in
both the differential carrier and axle housing.

6. Larger than normal steering angle; short turning radius. Vehicles designed with high turning angles may surge, have steering difficulty and
cause tire wear during sharp turns. Reduce maximum turning angle and have the driver decelerate when engine surge begins.

7. Incorrect wheel alignment. Correct as required.

8. Worn or defective axle components. Check the condition of the ring gear, pinion gear, bearings, seals, etc. Replace as required.

9. Foreign matter in axle housing or improper assembly of axle components. Inspect for contamination. Check assembly of axle
components.

10. Incorrect ring and pinion adjustments; worn driveline components (transmission gears, U-joints, etc). Replace or adjust components as
required.

11 High crown in road; poor traction surface under all drive wheels. The tendency to side-slip or ' "fishtail" on icy roads sloping toward the
curb is more pronounced when using a traction differential than when using a conventional differential. Stability can be retained when side-
slip occurs by decelerating (letting off the accelerator). CAUTION: Do not apply the brake. To do so may result in loss of vehicle control.

12 High Viscosity Lubricant. In very low temperatures, gear lubricant can thicken and impede the normal ' function of the NoSPIN differential.
Tractech recommends that the axle oil be changed for very cold weather operation to the lightest acceptable lubricant allowable by the
axle/vehicle manufacturer Heat control devices, garaging and a warm up period may also provide relief from this problem in extreme low
temperatures.

13 Low steering cylinder pressure, undersized steering cylinder, excessive angle of articulation, excessive vehicle weight. Correct as
required.

14 Improper application of product. Review application guidelines on pages 3.

15 Insufficient front axle overrun ratio (lead) for (arm tractors (straight frame with front wheel assist power) Take physical measurement,
increase to minimum of plus three (+3) percent by increasing tire pressure in front tires and/or reducing tire pressure in rear tires, within the
tire manufacturer’s recommendations.

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NEW IMPROVED DETROIT LOCKER DIFFERENTIAL

SPECIAL INSTRUCTIONS

TO IDENTIFY
New IMPROVED Detroit Locker differential models in the 187S and 225S series' have an "L" added to the model number, such as 187SL-
16A. They replace the previous model.

APPLICATIONS
These units are designed for light trucks including 2 wheel drive and 4 wheel drive vehicles and high performance passenger cars.

VEHICLE PERFORMANCE
Performance is similar to that of NoSPIN/Detroit Locker - equipped light trucks, pages 3-4. The new IMPROVED Detroit Locker operates in
the drive - coast mode without the familiar harsh feel and sound. Everyday driving is quieter and smoother, yet maximum traction is
immediately available.

EXPLODED VIEW

Note the additional parts compared to NoSPIN/Detroit locker differentials, page 5. New IMPROVED Detroit Locker models are supplied with
either a spider or central driver and a support case.

OPERATION
Operation is identical to that of NoSPIN/Detroit Locker - equipped vehicles, page 6.

INSTALLATION
Installation of a new IMPROVED Detroit Locker is similar to that of a NoSPIN/Detroit Locker differential, pages 7,10 and 11. Important: Thrust
washers are supplied installed inside the support case. The instructions on pages 8, 12 and 15 to "Be sure all thrust washers have been
removed" DOES NOT APPLY to the two thrust washers supplied with the new IMPROVED Detroit Locker models.

Caution: If for any reason the thrust washers supplied have been removed from the support case halves supplied, reinstall only the two thrust
washers supplied by Tractech by locating the tabs in slots, with the oil groove facing you.

Caution: If for any reason the new IMPROVED Detroit Locker unit Is disassembled, reinstall the disc (Belleville) springs - there will be one,
three or four on each side - with the large diameter against the side gear.

Be sure to install the Caution label and this Manual in the vehicle.

TEST FOR PROPER INSTALLATION AND OPERATION

Perform this test as described on page 12.

MAINTENANCE
Follow the instructions and cautions as described on pages 13-16 except that the instruction on page 16 to "Be sure all thrust washers have
been removed" DOES NOT APPLY to the thrust washers supplied with the new IMPROVED Detroit Locker models.

TROUBLE SHOOTING
The help provided on pages 17-18 apply to the new IMPROVED Detroit Locker differential.

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NEW Detroit C-LOCKER™ DIFFERENTIAL

SPECIAL INSTRUCTIONS
Detroit Lockers for C-Clip retained axles in the 187 and 225 series have a "C" instead of an"S"
in their model number, such as 187C-145A.

APPLICATIONS
These units are designed for light trucks including 2-wheel-drive and four-wheel-drive
vehicles, and high performance passenger cars.

VEHICLE PERFORMANCE
Performance is identical to that of NoSPIN/Detroit Locker - equipped vehicles, page 4.

EXPLODED VIEW

C-Clip Installation
OPERATION
Operation is identical to that of NoSPIN/Detroit Locker - equipped vehicles, page 6.

INSTALLATION
Installation of a Detroit C-Locker for differential is similar to that of a Detroit Locker differential,
pages 7-11 up to Step 11. The following steps must be carried-out before proceeding to Step
12.

Step 11a Install the differential and ring gear assembly in the axle, setting pre-loaded and
backlash per the vehicle manufacturers instructions Note: Contamination, such as metal
particles in the differential case, can cause the differential to malfunction. Be sure the axle
housing is clean before proceeding.

Step 11b Install the C-Clip as in the conventional deferential utilizing the window in the side of
the differential case.

Step 11c If the plain side (the side opposite the ring-gear side) bearing cap has already been
installed, it will be necessary to remove it before proceeding.

Step 11d Install the spacer pin (in plastic bag) through the case and between the ends of the
axle shafts.

Step 11e Insert the long socket-head cap screw (in plastic bag) through the differential plain-
side cover and thread into differential housing. The end of the screw will engage the hole in the
spacer pin thus holding it in place. Torque the screw to 23-25 ft.-Ibs. (31-34Nm). Note: this
screw has a thread locking patch pre-applied to it. If for any reason it is removed after
installation, a thread locking compound must be re-applied before reassembly.

Step 11f Install the plain-side bearing cap and torque per the vehicle manufacturer's
instructions. Bearing cap bolts must have a thread locking compound applied to them.

Step 11g Complete the reassembly of the associated components as recommended by the
vehicle manufacturer's instructions.

Complete Steps 12,13, and 14 on page 9. Be sure to install Caution Label and this Manual in
the vehicle.
TEST FOR PROPER INSTALLATION AND OPERATION
Perform this test as described on page 12.

MAINTENANCE
Follow the Instruction and Cautions as described on pages 13-16.

TROUBLE SHOOTING
The help provided on pages 17-18 apply to the Detroit C-Locker for C-Clip retained axles.

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GLOSSARY
ARTICULATED - Refers to vehicles that are joined in the middle LOCKING DIFFERENTIAL- A differential that provides a locked
and turn around this joint, as in "articulated farm tractor." axle condition. Can be manual or automatic, as in hydraulic
AXLE CARRIER - The differential and ring and pinion gears are locking differential or NoSPIN differential.
mounted on the axle carrier; the "center section" of the axle MACHINED SPLINES - Splines that have been manufactured by
housing. shaping, hobbing, broaching, or slotting.
AXLE GEAR RATIO -The ratio between the number of teeth on NoSPIN DIFFERENTIAL -Trademark of automatic, positive-
the ring gear and the number of teeth on the pinion gear (e.g., locking differential. Manufactured by Tractech.
3.92:1.00). OVERRUN RATIO - On unequal wheeled four wheel drive
AXLE HOUSING -The support member of the axle which tractors the transmission is so geared that any difference in road
sustains the weight of the vehicle and houses the axle carrier speed of the two axles results in a faster speed for the front wheels
assembly. (overrun or lead), this prevents the front wheels from being
BACKLASH - The designed clearance between mating pushed.
components in the driveline (e.g., Gear sets, spline couplings, PARALLEL SPLINES - Series of parallel keys cut along the axle
etc.). shaft which mate with corresponding slots in the differential side
CASE ASSEMBLY - The differential housing (usually consisting gear.
of two case halves; contains the differential assembly). PAYLOAD - Actual weight of useful cargo carried by vehicle.
CASE BEARING (CARRIER BEARING) -The bearings that PINION (INPUT) GEAR - The gear that is directly connected to
mount to the hubs on the differential support case. the driveshaft which propels the differential and ring gear and
CASE PILOT BORE - The locating diameter in the differential provides power to the axle.
case from which the differential side gear is installed. PLANETARY AXLE - Axle having a gearset arrangement in a
CENTER CAM - The control element of the NoSPIN differential. concentric pattern; consisting of a sun gear surrounded by pinion
The center cam is used to lift the drive members from gears which mesh with an annulus ring gear. This gearset
engagement by means of cam ramps. provides torque multiplication in a reduced area on the same
CENTRAL DRIVER - An outer splined member (similar to the center line as the axle shaft usually located on the hub ends of
spider) having torque carrying teeth on both sides; the "center axle.
piece" of the NoSPIN differential. PRE-LOAD - Differential bearing adjustment achieved by adding
CLUTCH PACK DIFFERENTIAL - A limited-slip differential or subtracting shims.
which uses friction clutch plates and/or springs to partially reduce R.P.M. - Revolutions Per Minute. Term used to define rotation.
wheel spin. RING GEAR - The gear that is attached to the differential case
DETROIT LOCKER DIFFERENTIAL - Trademark given to "light and driven by the pinion gear.
duty" NoSPIN differentials. (NoSPIN and Detroit Locker are ROLLED SPLINES - Splines that are manufactured by use of
operationally identical.) Manufactured by Tractech. rolling dies to form the spline configuration.
DIFFERENTIAL - Axle gear assembly which allows one axle SHIM - "Spacer" used to achieve differential bearing adjustment.
shaft and wheel to turn slower or faster than the other when SIDE GEAR - The gear that is mounted in the differential case;
negotiating a turn. has the axle shaft splined to it; driven by the pinion gear.
DIFFERENTIATION - The different rate of speed between two SINGLE SPEED - Axle or transfer case having a single gear ratio.
wheels of an axle when making a turn or over uneven surfaces. SHOCKLOAD - A force caused by sudden impact.
DRIVELINE - Components used to propel the vehicle driveshaft SPIDER -The "center piece" of a standard, clutch pack or NoSPIN
and universal joints, transmitting torque from transmission to differential; having a spider-like shape.
drive axle (same as drivetrain). SPIDER CROSS - Two or four armed member used to mount the
DRIVEN CLUTCH - Member that is used to provide torque to standard differential pinion gears.
another member, such as to the side gear. Each NoSPIN SPIDER GEAR(S) - Bevel pinion gears that are mounted on
differential has two driven clutches. spider cross that drive the side gears of standard or clutch type
DRIVETRAIN - A series of components which transmit power differentials.
from the engine to the wheels/tires (i.e., transmission, propeller SPLINES - "Teeth" on axles that mate with "teeth" (splines) on
shafts, transfer case, axle, differential, shafts, etc.). differential side gear.
DOUBLE REDUCTION - Dual gear reduction used in rear axles. SNAP RING - A circular expandable ring that is used to retain two
FISHTAILING - Side slipping of the vehicle caused by traction members together, as the snap ring in a NoSPIN differential that
instability. retains the spider and center cam.
G.C.W. - Gross Combination Weight. G.V.W. plus vehicle weight STANDARD DIFFERENTIAL - Open or conventional differential
and payload of towed vehicle. G.V.W. - Gross Vehicle Weight. with no means of traction control.
Total weight of vehicle and payload. TAG AXLE (TANDEM) - Non-powered rear axle which follows
GEAR SUPPORT CASE - Case used to support the differential. drive axle. Provides additional load carrying capacity and
Same as case assembly. distribution.
GROUND COEFFICIENT-The horizontal force required to move TAPERED SPLINES - Cone shaped spline configuration.
a body, divided by the weight of the body. The amount of friction at THRUST BLOCKS - Support mechanism used to prevent ring
the ground; the "quality" of the ground surface (e.g., ice, snow, and pinion gear deflection.
dirt, etc.). THRUST WASHER - Used in conventional differential to reduce
HELICAL - "Angled" gear tooth form. wear to the support case.
HOLDOUT RING - Ring which assembles to NoSPIN differential TORQUE - Force having a twisting or turning effect. Also used in
clutch; maintains clutch disengagement in a turning mode. conjunction with the term "power."
INDEXING - A passing of one member over another, causing a TRUNNION - Journals allowing pivoting or turning, such as on a
slight audible sound from their contact (usually associated with spider cross. On a NoSPIN differential, the arm (there are four)
NoSPIN differential). which supports the differential in the case assembly.
INPUT TORQUE- Measurement of available power. TWO-SPEED - Axle or transfer case having two selective gear
LEAD RATIO - On unequal wheeled four wheel drive tractors the ratios.
transmission is so geared that any difference in road speed of the UNDERSTEER - The condition of steering when making a turn
two axles results in a faster speed for the front wheels (lead or that causes the vehicle to go straight rather than turn freely.
overrun), this prevents the front wheels from being pushed. WHEELBASE - Distance between center lines of front and rear
LIMITED-SLIP DIFFERENTIAL - A differential which utilizes axles or to the center line of tandem axles.
some means of partially reducing, but not totally eliminating,
individual wheel spin (e.g., clutches, springs, biasing pinion
gears, etc.).

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TRACTECH DIFFERENTIAL LIMITED WARRANTY, AND LIMITATIONS

Tractech (TRACTECH) expressly warrants each TRACTECH product or part to be free from defects in materials and workmanship under
NORMAL USE AND SERVICE.

A. Differentials
1. In new vehicles
a. For licensed vehicles, when not used in competition of any type, for the lesser of: 1) the same period
(of time, mileage or hours of use) as the other drive axle parts are warranted by the axle manufacturer in that vehicle or 2)
one year from date of delivery or 100,000 miles of differential use by the first user; or

b. For non-licensed vehicles, for the same period (of time, mileage or hours of use) as the other drive axle parts are warranted by the
axle manufacturer in that vehicle.
2. In used vehicles
a. For licensed vehicles, when not used in competition of any type, for the earlier of 100,000 miles of differential use or one year from
the date of delivery to the first user; or

b. For non-licensed vehicles, for the same period (of time, mileage, or hours of use) remaining, if any, as the other drive axle parts
are warranted by the axle manufacturer in the vehicle.
3. For vehicles used in competition of any type, for 30 days from the date of delivery to the first user.
B. Clutches and Brakes For six (6) months from date of delivery.

There exist specific MANUALS for each TRACTECH differential indicating the appropriate application, operation inspection and
maintenance criteria. IT IS MOST IMPORTANT THAT ANY SELECTOR, PURCHASER, INSTALLER, MAINTAINER OR USER
CAREFULLY READ the relevant MANUAL before any application is selected or any operation or maintenance is attempted.

Also TRACTECH strongly encourages each designer, prospective customer or user to submit an application approval request using
TRACTECH Differential Application form 7003, Clutch Application form 3003, or Brake Application form 8003 as applicable.

NORMAL USE AND SERVICE means that:

A. The product or part will be applied, installed, operated, inspected and maintained in accordance with the TRACTECH Operation
and Maintenance Manual, and Owner's Manuals for the specific product;
B. The maintenance of the product must meet or exceed the level specified by the vehicle or equipment manufacturer for the
TRACTECH product or similar product; and
C. The product will be applied and operated within the boundaries of any written TRACTECH APPLICATION APPROVAL by the
TRACTECH Engineering Department.

EXCLUSIONS
THE FOREGOING WARRANTY IS EXCLUSIVE, AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (WHETHER
ORAL OR WRITTEN), INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE. No person, including any dealer or representative of TRACTECH, except the President of TRACTECH, is
authorized to make any representation or warranty concerning TRACTECH products on behalf of TRACTECH or to assume for TRACTECH
any obligation not contained in this warranty, including a warranty of fitness for any particular purpose. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. ANY IMPLIED WARRANTIES, INCLUDING THE IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, TO THE EXTENT THE SAME CANNOT BE
DISCLAIMED UNDER APPLICABLE LAW ARE LIMITED IN DURATION TO THE EXPRESS WARRANTIES SET FORTH ABOVE
EXCEPT IN THOSE STATES THAT DO NOT ALLOW TIME LIMITATIONS ON IMPLIED WARRANTIES. THERE IS NO IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY PURPOSE WHEN THE PRODUCT IS
PUT TO AN INDUSTRIAL, COMMERCIAL OR RENTAL USE.

In no event does any warranty, express or implied, apply to loss, harm or damage to the extent caused by any or all of the following; wear to or
failure of other drive train parts; freight damage; use of components, parts and/or accessories not obtained from or approved by TRACTECH
or which do not meet TRACTECH quality and performance specifications; improper installation, maintenance, repair, misuse, or abuse,
normal wear of moving parts or components affected by moving parts; and/or unauthorized alterations or Modifications.

TRACTECH SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES (i.e. Broken ring & pinion,
axles, bearings, differential covers, towing & labor charges) OR EXPENSE ARISING DIRECTLY OR INDIRECTLY FROM A DEFECT IN
PRODUCTS MANUFACTURED OR SOLD BY IT OR FROM THE USE OF ANY SUCH DEFECTIVE PRODUCT, INCLUDING BUT NOT
LIMITED TO DAMAGES, EXCEPT TO THE EXTENT THAT EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES IS PROHIBITED BY APPLICABLE LAW.

TRACTECH RESERVES THE RIGHT TO MAKE CHANGES IN DESIGN AND OTHER CHANGES, MODIFICATIONS, ALTERATIONS OR
IMPROVEMENTS TO ANY OF ITS PRODUCTS WITHOUT THERE RESULTING ANY OBLIGATION UPON TRACTECH TO FURNISH
OR INSTALL THE SAME UPON ANY PRODUCTS PREVIOUSLY SOLD AND DELIVERED OR PRODUCTS THEN IN PROCESS,
MANUFACTURE OR DISTRIBUTION.

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LIMITATION OF REMEDIES
At TRACTECH'S option, TRACTECH will credit the buyer's account for the purchase price of, or repair or replace without charge for
materials, any TRACTECH product that failed within the warranty period that is finally determined by TRACTECH to have been defective in
material or workmanship.

Any suit or action arising out of or relating to this Warranty, or the breach thereof, must be commenced within one (1) year after the cause of
action has accrued. The foregoing shall not limit the time within which any suit or action must be brought to collect an amount agreed to be
paid by the buyer or to enforce a judgement for or to collect any such amount.

It is expressly agreed that the liability of TRACTECH is limited, and TRACTECH does not function as an insurer. All buyers of TRACTECH
products waive subrogation on all claims covered under their own or any other insurance.

If TRACTECH should be found liable to anyone on any theory (except breach of any express warranty, where the exclusive remedy is as set
forth above), the liability of TRACTECH shall not exceed the purchase price of the involved TRACTECH product (or service) when sold (or
when service is performed) by TRACTECH to the first buyer. THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU
OF ALL OTHER REMEDIES, EXPRESS OR IMPLIED, regardless of theory, cause or origin of any loss, harm or damage resulting directly or
indirectly to any person, organization, entity or property, including without limitation: the performance or non-performance of any obligation
set forth in this Warranty; breach of any agreement (oral or written including specifications) between TRACTECH and its customer or the
buyer; negligence, active, passive or otherwise, of TRACTECH or any of its distributors, agents or employees; breach of any warranty or
covenant implied or imposed by law; misrepresentation; and/or strict liability.

The sole purpose of the stipulated exclusive remedies shall be to provide the buyer with a credit or replacement for, or the repair of, defective
products or services in the manner provided herein. The exclusive remedies shall not be deemed to have failed of their essential purpose so
long as TRACTECH is willing to credit the buyer's account for the purchase price of, provided replacement for, or repair, the defective
products or services in the manner prescribed herein.

ADJUSTMENTS
When adjustment is sought under this Warranty, a claim should be made within six (6) months of the date of failure, as follows:

A. Users in North America

1. If the product or part was purchased installed by the original equipment manufacturer (or its dealer), follow the manufacturer's
procedures for warranty claims; or

2. If the product or part was purchased through a distributor of TRACTECH products, have the distributor write or phone
TRACTECH Customer Service Department and ask for an Authorization to Return Material number. Supply the distributor with all
requested information. Have the distributor ship the entire product (freight prepaid) to our Warren, Michigan factory. Evaluation of
claims take 4-6 weeks from the time the unit is received.
B. OEM's in North America Contact TRACTECH to receive a written Authorization to Return Material with number.
Then return material to TRACTECH (freight prepaid) and include a copy of Authorization to Return Material and reason for return.
NOTE: At the option of TRACTECH, material may not need to be returned, but written confirmation must be obtained prior to
TRACTECH'S approval of a credit memo.

C. Outside North America

Follow the procedure in Paragraph A or B immediately above but do not return product or part. You will be contacted regarding your claim.

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

Automatic Positive Locking Traction Differential

OWNER'S MANUAL
Warnings & Precautions
Mechanic: Operator:
Any increase in the size of the vehicle's engine, tires, weight, etc., All NoSPIN/Detroit Locker differential equipped vehicles must
may prohibit use of a NoSPIN/Detroit Locker differential in a be identified by a Caution Label. mounted on the instrument
heretofore approved application. Any such modifications should panel. Contact Tractech if this label was not received.
be reviewed by Tractech Engineering before continuing to use
the product. Do not operate the vehicle if both wheels of a NoSPIN/Detroit
Locker differential equipped axle are not driving. Power to only
Do not use heat to disassemble drive axles. To do so can destroy one wheel can cause serious steering problems. Perform the
heat treat properties and weaken or distort axle components. installation and operation tests illustrated on page 12 before
putting the vehicle into service.
Turn the engine off and raise all driving wheels of a
NoSPIN/Detroit Locker differential equipped axle when servicing Use extreme caution when accelerating or decelerating on
wheels, brakes, axles or tires to prevent the vehicle from moving. slippery or unstable surfaces. Vehicles/axles equipped with
Axles equipped with NoSPIN/Detroit Locker differentials deliver traction differentials are inherently more sensitive to side-slip.
power to both wheels - even when only one wheel is on the
ground. Distribute the load evenly side-to-side; do not exceed the
vehicle's rated payload capacity; keep the diameter of the tires
NoSPIN/Detroit Locker differentials have compressed springs. equal. Failure to observe these measures can create a
Use a retaining bolt or some other restraining means when difference in individual wheel speeds which can cause the
separating the differential case halves. (See pages 13-14) Do not NoSPIN/Detroit Locker differential to deliver power to only one
lift the heavier (75 Ibs. or over) units by the retaining bolt, as the side of the vehicle and thus cause steering problems.
washers may collapse or the threads may strip.
Turn the engine off and raise all driving wheels of a
When repairing NoSPIN/Detroit Locker differentials, if major NoSPIN/Detroit Locker differential equipped axle when
components show excessive wear, the complete differential changing tires to prevent the vehicle from moving. Axles
should be replaced. If a component is replaced, mating equipped with NoSPIN/Detroit Locker differentials deliver
components should also be replaced in that it is likely that they power to both wheels - even when only one wheel is on the
too are damaged. Use of worn or damaged components can lead ground.
to a recurrence of the original problem. (See page 15) Note: Use
only Tractech approved components when repairing Operate in low gear when coasting downhill into a turn. Braking
NoSPIN/Detroit Locker differentials. capacity is reduced when a NoSPIN/Detroit Locker differential
equipped vehicle makes a turn while coasting downhill.

IMPORTANT! RE-READ THE WARNING NOTICES REFERENCED ABOVE. IN ADDITION TO THE CONSEQUENCES NOTED
FAILURE TO OBSERVE ANY OR ALL OF THESE MEASURES, CAN CAUSE PART FAILURE OR RESULT IN A MISHAP WHICH CAN
CAUSE PROPERTY DAMAGE, PERSONAL INJURY, EVEN DEATH

Axle Manufacture
Attach this envelope axle assemblies equipped with NoSPIN/Detroit Locker differentials.

Chassis Assembly Plant

Attach the enclosed Caution lable to the instrument panel of NoSPIN/Detroit Locker differential equipped vehicles in plain view of operator or
mechanic Place this manual in glove compartment of the vehicle.

11445 Stephens Drive P.O. Box 882

Warren, Michigan 48090 U.S.A.
PHONE - 586-759-3850 FAX - 586-759-1645

840 5/2012
BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

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BW177 D/DH/PDH-50 INSTRUCTIONS FOR REPAIR

BOMAG Americas,Inc.
2000 Kentville Road
Kewanee, Illinois 61443
U.S.A.
Tel.:(309) 853-3571
Fax:(309) 852-0350
e-mail: [email protected]

BOMAG (Canada),Inc.
13000 Areowood Drive
Mississauga, Ontario L4W 1B7
CANADA
Tel.:(905) 625-6611
Fax:(905) 625-9570
e-mail: [email protected]

842 5/2012