REPAIR MANUAL MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZI RIPARAZIONE ONE This document has been printed printed from my
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Contents GENERAL INSTRUCTIONS AND SAFETY NOTICE
CHARACTERISTICS
1-1
AXLE ASSEMBLY - AXLE
DISMANTLING AXLE 416 - 100
2-1
TELESCOPIC BOOM
DISASSEMBLY OF THE JIB
3-1
HYDRAULIC
HYDRAULIC DIAGRAM
4-1
ELECTRICITY
ELECTRIC DIAGRAM
5-1
TRANSMISSION
OPERATION (ADJUSTMENT) OF TRANSMISSION
6-1
CHARACTERISTICS BT 420 Série 3-E2 BT 425 Série 3-E2 0-1-M127 EN
28 / 01 / 2006
2
BT 420 S ÉRIE 3-E2 - BT 425 S ÉRIE 3-E2
BT 420 S ÉRIE 3-E2 - BT 425 S ÉRIE 3-E2
3
CHARACTERISTICS I.C.
BT 420 Série 3-E2 - BT 425 Série 3-E2
ENGINE
- Type
PERKINS 404C-22
- Number of cylinders - Number of strokes - Inlet system - Injection system - Ignition sequence - Clearance of rocker valve (cold) . Inlet . Exhaust - Capacity - Bore - Stroke - Compression ratio - Nominal rating loaded - Rating slow unladen - Max. rating unladen - Power ISO/TR 14396 - Maximum torque ISO/TR 14396 - Air cleaner
4 in line 4 Natural aspiration Indirect 1.3.4.2.
C OOLING
CIRCUIT
- Type - Fan . Number of blades . Diameter - Thermostat . Start opening . Full opening
E LECTRIC
0,20 mm 0,20 mm 2200 cm³ 84 mm 100 mm 23,3/1 2800 rpm 930 ± 20 rpm 2990 rpm 50 cv/38 kw 143 Nm at 1800 rpm Sec 3 µ
By water Blowing 7 406 mm 77 °C 82 °C
CIRCUIT
- Earth - Battery - Alternator - Tension regulator - Starter
Négative 12 V - 110 Ah 12 V - 65 A Incorporated into the alternator 12 V
4
H YDROSTATIC
TRANSMISSION
HYDROSTATIC PUMP - Type
MANNESMANN REXROTH
- Gear reverser
Electromagnetic 12V
MAIN PUMP - Displacement MAX. MIN.
40 cm3/r 0 cm3/r
- Flow rate at 2990 rpm MAX. MIN.
120 l/min 0 l/min
- Working pressure
420 bar
BOOST PUMP - Cubic capacity - Flow rate at 2990 rpm MAX. MIN.
8,4 cm3/r 25,2 l/min 0 l/min
- Boost pressure Max. rpm
28/30 bar
HYDROSTATIC ENGINE - Type - Displacement MAX. MIN.
MANNESMANN REXROTH
A4 VG 40 DA variable displacement pump with automatic power governor
A6 VM 80 DA with variable cubic capacity
80 cm3/r 37,2 cm3/r
T RANSFER BOX - Type - Number of forward speeds - Number of reverse speeds
F RONT
AXLE
- Type
R EAR
HURT Coupled to front axle 1 1
DANA 304_140_85
AXLE
- Type - Hub reducers
DANA 416/104 Epicyclic
B RAKE - Type - Service brakes - Parking brakes
Drum brake Foot pedal. Mechanical applied on the front wheels. Hand lever. Mechanical applied on the front wheels.
5
CHARACTERISTICS
BT 420 Série 3-E2
F RONT TYRE DIMENSIONS
PRESSURE
11,5/80-15,3 12PR AS FARM CONTINENTAL / TUBELESS 265/70 R19,5 XTA MICHELIN / TUBELESS
5,3 BAR
R EAR
8 BAR
TYRE LOAD FRONT UNLADEN FRONT LADEN FRONT UNLADEN FRONT LADEN
837.5 KG 2922.5 KG KG KG
PRESSURE ON THE CONTACT SURFACE HARD GROUND LIGHT GROUND KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2
AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND CM2 CM2 CM2 CM2 CM2 CM2 CM2 CM2
1467.5 KG 382.5 KG 1467.5 KG
PRESSURE ON THE CONTACT SURFACE HARD GROUND LIGHT GROUND KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2
AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND CM2 CM2 CM2 CM2 CM2 CM2
TYRE DIMENSIONS
PRESSURE
28X9,15 14PR IC40 CONTINENTAL 27.10.12 14PR IC30
4,5 BAR 7 BAR
CONTINENTAL
TYRE LOAD REAR UNLADEN REAR LADEN AREAR UNLADEN REAR LADEN
382.5 KG
KG/CM2
H YDRAULIC CIRCUIT - Type of pump . Capacity . Flow rate at full speed
Gear 18 cm3/r 50 L/min
- Pressure . Lifting, tilting, telescoping, equipment circuit . Steering direction
250 Bar 120 Bar
- Filtration . Suction . Return . Air contained in the tank
15 µ 15 µ 5µ
6
KG/CM2
CM2
CM2
S PECIFICATIONS - Level of sound pressure in the driver's cab LpA (accordng to standard prEN 12053 : 1995)
dB
- Level of sound power in the LwA environment (according to directive 2000/14 CE guaranteed)
dB
- Speed of movement of lift truck in standard configuration on horizontal ground . Forward unladen 20 km/h . Reverse unladen 20 km/h - Standard lift height
4000 mm
- Rated capacity with standard attachment
2000 kg
- Load center
500 mm
- Weight of forks (each)
43 kg
- Lifting motions (Telescopes retracted) . Unladen lifting . Rated load lifting . Unladen lowering . Rated load lowering
6,2 6,4 4,5 4,7
s s s s
25,5 24,9 35,2 33,8
m/min m/min m/min m/min
- Telescoping motions (Lifting jib) . Extending of telescopes unladen . Extending of telescopes laden . Retracting of telescopes unladen . Retracting of telescopes laden
8,4 8,5 4,1 4,1
s s s s
12,5 12,3 25,7 25,6
m/min m/min m/min m/min
- Reverse tilt time unladen
4s
30,1 °/s
- Forward tilt time unladen
4,4 s
28,5 °/s
- Lift truck weight with standard attachment . Unladen . Rated load
4610 kg 6610 kg
- Axle weight with standard attachment (Transport position) . Front unladen rated load . Rear unladen rated load
1675 kg 5845 kg 2935 kg 765 kg
- Tensible strain at coupling hook . Unladen . Rated load
2400 daN 2900 daN
- Break out force with bucket (according to standard iso 8313)
3430 daN
7
CHARACTERISTICS
BT 425 Série 3-E2
F RONT TYRE DIMENSIONS
PRESSURE
11,5/80-15,3 12PR AS FARM CONTINENTAL / TUBELESS 265/70 R19,5 XTA MICHELIN / TUBELESS
5,3 BAR
R EAR
8 BAR
TYRE LOAD FRONT UNLADEN FRONT LADEN FRONT UNLADEN FRONT LADEN
837.5 KG 2922.5 KG KG KG
PRESSURE ON THE CONTACT SURFACE HARD GROUND LIGHT GROUND KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2
AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND CM2 CM2 CM2 CM2 CM2 CM2 CM2 CM2
1467.5 KG 382.5 KG 1467.5 KG
PRESSURE ON THE CONTACT SURFACE HARD GROUND LIGHT GROUND KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2 KG/CM2
AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND CM2 CM2 CM2 CM2 CM2 CM2
TYRE DIMENSIONS
PRESSURE
28X9,15 14PR IC40 CONTINENTAL 27.10.12 14PR IC30
4,5 BAR 7 BAR
CONTINENTAL
TYRE LOAD REAR UNLADEN REAR LADEN REAR UNLADEN REAR LADEN
382.5 KG
KG/CM2
H YDRAULIC CIRCUIT - Type of pump . Capacity . Flow rate at full speed
Gear 18 cm3/r 50 L/min
- Pressure . Lifting, tilting, telescoping, equipment circuit . Steering direction
250 Bar 120 Bar
- Filtration . Suction . Return . Air contained in the tank
15 µ 15 µ 5µ
8
KG/CM2
CM2
CM2
S PECIFICATIONS - Level of sound pressure in the driver's cab LpA (accordng to standard prEN 12053 : 1995)
dB
- Level of sound power in the LwA environment (according to directive 2000/14 CE guaranteed)
dB
- Speed of movement of lift truck in standard configuration on horizontal ground . Forward unladen 20 km/h . Reverse unladen 20 km/h - Standard lift height
3960 mm
- Rated capacity with standard attachment
2500 kg
- Load center
500 mm
- Weight of forks (each)
43 kg
- Lifting motions (Telescopes retracted) . Unladen lifting . Rated load lifting . Unladen lowering . Rated load lowering
6,2 6,4 4,5 4,7
s s s s
25,5 24,9 35,2 33,8
m/min m/min m/min m/min
- Telescoping motions (Lifting jib) . Extending of telescopes unladen . Extending of telescopes laden . Retracting of telescopes unladen . Retracting of telescopes laden
8,4 8,5 4,1 4,1
s s s s
12,5 12,3 25,7 25,6
m/min m/min m/min m/min
- Reverse tilt time unladen
4s
30,1 °/s
- Forward tilt time unladen
4,4 s
28,5 °/s
- Lift truck weight with standard attachment . Unladen . Rated load
4530 kg 7030 kg
- Axle weight with standard attachment (Transport position) . Front unladen rated load . Rear unladen rated load
1675 kg 6251 kg 2905 kg 779 kg
- Tensible strain at coupling hook . Unladen . Rated load
2400 daN 2900 daN
- Break out force with bucket (according to standard iso 8313)
3430 daN
9
DIMENSIONS AND LOAD CHART
BT 420 / BT 425 Série 3-E2
:
BT 420 Série 3-E2
50°
BT 425 Série 3-E2
0.5m
50°
0.5 m
40°
40° 5
5
1500 3.86
4
4
3.90 30°
30°
3
3
20° g K 0 g 0 K 5 0 1 g K 0 2 0 1 0 9
2
10° 1
0°
g K 0 0 0 2
g K g 0 0 K 0 5 g 0 2 K 0 0 2 g 0 K 5 0 1 g 0 K 2 0 1 0 0 1
20° 2
10° 1
0°
0m
-2°
0m
-2°
-1
-1
3 2.86
2 2.35 1.90
1
0m
3
1.45
2 2.7
1.95 2.35
Suivant norme EN 1459 annexe B
1 1.45 1.14
Suivant norme EN 1459 annexe B
N° 722026
10
0m
N° 722027
BT 420
BT 425
Série 3
Série 3
A
1100 mm
1100 mm
B
1800 mm
1800 mm
C
1065 mm
896 mm
C1
925 mm
D
3550 mm
D1
3410 mm
E
4650 mm
4481 mm
F
1146 mm
1146 mm
F1
1105 mm
1105 mm
G
235 mm
235 mm
G1
235 mm
235 mm
G2
245 mm
245 mm
I
685 mm
685 mm
J
640 mm
640 mm
1020 mm
1020 mm
L
40 mm
40 mm
N
1180 mm
1180 mm
O
100 mm
100 mm
K
3381 mm
P2
34 °
34 °
P3
40 °
40 °
R
3240 mm
3240 mm
S
5690 mm
5690 mm
T
2200 mm
2200 mm
U1
1980 mm
1980 mm
U2
2180 mm
2180 mm
V
3510 mm
3510 mm
V1
1250 mm
1250 mm
V2
3350 mm
3350 mm
W
1436 mm
1436 mm
Y
107 °
107 °
Z
16 °
16 °
11
FILTERS CARTRIDGES AND BELTS
I.C. ENGINE
I.C. ENGINE OIL FILTER Part number : 702577 Change : 500 H
ALTERNATOR BELT Part number : 703259 Change : 1000 H
DRY AIR FILTER CARTRIDGE Part number : 227959 Clean : 50 H* Change : 500 H*
AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION) Part number : 240334
SAFETY DRY AIR FILTER CARTRIDGE Part number : 227960 Change : 1000 H*
INTERNAL COMBUSTION ENGINE'S SNIFFLER Part number : 703289 Change : 2000 H
FUEL FILTER CARTRIDGE Part number : 109401 Change : 500 H * : This periodicity is given for information only (see : 3 - MAINTENANCE : SERVICING SCHEDULE) for cleaning and changing.
HYDRAULICS
SUCTION OIL AND HYDRAULIC RETURN FILTER CARTRIDGE Part number : 686237 Change : 500 H
OIL TANK AIR BREATHER Part number: 457509 Clean : 500 H
12
LUBRICANTS AND FUEL I.C. ENGINE ORGANS TO BE LUBRICATED I.C. ENGINE
CAPACITY 10 Liters
COOLING CIRCUIT
11 Liters
RECOMMENDATION MANITOU Oil MOTEUR SAE 15W / 40 Cooling liquid(**) (protection - 25 °C)
Cooling liquid(**) (protection - 30 °C)
FUEL TANK
54 Liters
PACKAGING
PART NUMBER
5 L. 25 L. 2 L. 5 L. 20 L.
485 297 161 584 554002 554003 554004
2 L. 5 L. 20 L.
473076 473077 473078
PACKAGING
PART NUMBER
Diesel fuel (*)
TRANSMISSION ORGANS TO BE LUBRICATED
TRANSFER BOX
CAPACITY
RECOMMENDATION
0,4 Liters
MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90
2 L. 20 L. 55 L. 209 L.
499237 546330 546221 546220
CAPACITY
RECOMMENDATION MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90
PACKAGING
PART NUMBER
2 L. 20 L. 55 L. 209 L. 2 L. 20 L. 55 L. 209 L. 2 L. 20 L. 55 L. 209 L. 2 L. 20 L. 55 L. 209 L.
499237 546330 546221 546220 545976 546330 546221 546220 499237 546330 546221 546220 499237 546330 546221 546220
FRONT AND REAR AXLES ORGANS TO BE LUBRICATED FRONT AXLE DIFFERENTIAL
REAR AXLE DIFFERENTIAL
4 Liters
3,2 Liters
MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90
FRONT WHEELS REDUCERS
2x0,55 Liter MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90
REAR WHEELS REDUCERS
2x0,3 Liter
MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90
13
LUBRICANTS AND FUEL JIB ORGANS TO BE LUBRICATED
RECOMMENDATION
JIB PADS GREASING OF THE JIB
PACKAGING
PART NUMBER
MANITOU Grease Multipurpose NLGI 2 MANITOU Grease Multipurpose HD NLGI 2
1 Kg.
161 590
1 Kg. 5 Kg.
554 973 554 974
RECOMMENDATION MANITOU Oil Hydraulic ISO 46
PACKAGING
PART NUMBER
25 L. 55 L. 209 L.
161 588 546 108 546 109
RECOMMENDATION MANITOU Grease Multipurpose HD NLGI 2
PACKAGING
PART NUMBER
1 Kg. 5 Kg.
554 973 554 974
PACKAGING
PART NUMBER
HYDRAULICS ORGANS TO BE LUBRICATED HYDRAULIC OIL TANK
CAPACITY 55 Liters
CHASSIS ORGANS TO BE LUBRICATED
STEERING PIVOT
CAB ORGANS TO BE LUBRICATED
WINDSCREEN WASHER TANK
RECOMMENDATION
Windscreen washer fluid
14
1 L. 5 L. 30 L. 225 L.
490 486 505 490
402 424 527 432
DÉMONTAGE PONT 416 - 100 30-3-9 FR
13 / 07 / 2001
D1240203
2
1 3
MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY D1240011
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F1241572
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F1241575
8 27 19
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D1240206
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D1240207
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D1240208
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25 mm
9
F1241624
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DG1 T18 T19
8 mm
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R5
Ø20
° 5 4 x 1
D1240255
Ø38.8 Ø48
Ø20
Ø58.5
Ø34.8 D1240258
D1240259
Ø19.01
R 2 5
8 . 0
R 2 5
Ø30
Ø30
M6
05 x 45°
0 1
5 . 3 3
e r a n i r g i Z 0 0 1
0 1 1 5 3 1
e r a n i r g i Z 0 0 1
0 2 1 5 3 1
R5
Ø40
5 x 45
°
0 1 5 1
1 x 45
R10
°
5 x 45
°
20°
Ø50.5
5 . 3
8 . 0
8 . 0
8 . 0
Ø57.4
Ø51
4
1
D1240264
+ 0.05
Ø53 --0.1
+ 0.1
Ø64 --0.2
D12402
D1240257
M5
5 . 1 1
3
3 R
05 x 45°
Ø5.25
Ø158.5
Ø134
Ø90 Ø50
Ø85
5 R
n° 4 fori
Ø50
5 R
n° 4 fori
1 x 45°
0.8 0 3
0.8
5 2 6 1
0 3
5 2
3 1
2 0 °
Ø22 Ø148
8 . 0
Ø127.6
D1240253
R 2 5
20° 30'
Ø22 8 . 0
D1240254
Ø40
Ø30
e r a n i r g i Z 0 0 1
R35
e r a n i r g i Z 0 0 1
0 2 1
0 7 1
5 3 1
2 1
5 . 1
5 1 0 5 0 4
8 1
3 x 15
0 2
°
8 6
3 x 30
°
+ 0.1
Ø29.9--0.2
Ø25
0 3
+ 0.1
Ø34.9--0.2
Ø80
Ø52 Ø96
+ 0.1
Ø60--0.2
D1240252
Ø105
D1240251
50
235 205 1 x 45°
0 1
+ 0.0 --0.05
Ø30
Attacco 1/2" 5 2
0 1
5 6
1 x 45°
+ 0.2
Ø18 --0.0
Ø25
D1240250
R 2 5
R 5 0 Ø30
Ø40
e r a n i r g i Z
0 8
e r a n i r g i Z 0 0 1
0 5 5 2 1 1
0 6
0 0 1
0 2 1
5 5 1
60
R10
Ø12
5 x 45
°
5 1
0 1
R10
2 x 45
°
Ø60
5 , 0
0 4
Ø90 9
45
°
6 1
2.5 x 20
°
9 1
2
Ø135 8 . 0
29.8+ 0.1 --0
Ø150
Ø45
Ø160
Ø54
Ø179 D1240247
Ø188
D1240248
11 8
Ø100 Ø79.4 Ø45
0 6
22
15
Ø22.5
0 1 M
32 0 2
n 2 pezzi °
11 8
0 5
0 0 3
Ø18.5
32 5 1
n 2 pezzi °
D1240263
D1240261
150
5
R 4 0
5 2
50
125 Ø13.5 0 2
e r a n i r g i Z 0 0 1
5 2 1
n 2 pezzi °
D1240262
0 5 1
0 9
R10
2 x 45°
5 5 1
8 0 1 0.8
2 x 30°
1 x 45°
+ 0.0
37
Ø79.9 --0.05
0.02
Ø38.5
8 . 0
Ø41 + 0.1
Ø59.8 --0 Ø80 + 0
Ø89 --0.1 D1240246
R3 D1240249
244 9
9
0 3
5 1 0.8
85
9 2
+ 0.1
Ø8 --0.0
M6 D1240265
93
51
62
15
0.5x45
°
8 . 0
16
16 0.5x45
0 . 8
20
°
R2
0. 8
15
0 . 8
8 . 0
12 45' °
o c i r o e 8 . t 5 . 6 4 9 6 7 7 Ø Ø Ø
2 0 6 2 Ø Ø
o c i r o e t 8 . 4 6 7 6 Ø Ø
0 2 5 . 2 6 9 Ø Ø 7 Ø
12 45' °
0. 8
2x45
°
3
3
300
M18 n 2 pezzi °
62 20
0 1
n 2 pezzi °
D1240260
312
270
R 2
3.2
Temp
4 9 Ø
a c i r o e t 3 . 0 9 Ø
Acciaio Ni Cr Mo 5
Zigrinato
Forzato
R 4 5 . 8 8 Ø
5 6 Ø
°
5 1
0 3 Ø
2 4 Ø
0 4 Ø
7 15
R 6 0
3 .2
30
2 x 45° 0.5 x 45° 2 . 3
15 27 D1240245
DISASSEMBLY OF THE JIB 50-3-M127
EN
28 / 01 / 2006
2
CONTENTS
- ELEMENTS OF THE JIB
P5à9
- AD ADJUSTMENT AN AND IMMOBILIZATION OF TH THE JI JIB WEAR PADS
P 1 et 11
- REMOVAL OF THE TILTING CYLINDER
P 12 et 13
- REMOVAL OF THE CARRIAGE
P 14 et 15
- REMOVAL OF THE TELESCOPE
P 16 et 17
- REMOVAL OF THE TELESCOPING CYLINDER
P 18 et 19 19
3
4
HEAD OF THE JIB BT 420 Série 3-E2 - BT 425 Série 3-E2
5
CARRIER BT 420 Série 3-E2
6
CARRIER BT 425 Série 3-E2
7
FOOT OF THE JIB BT 420 Série 3-E2 / BT 425 Série 3-E2
8
JIB HYDRAULIC CIRCUIT BT 420 Série 3-E2 / BT 425 Série 3-E2
9
ADJUSTMENT AND IMMOBILIZATION OF THE JIB WEAR PADS
- Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral.
- Set the jib horizontal. FRONT PADS
- Telescope approximately 200 mm and check the play in the lower, upper and side wear pads for clearance (allowable clearances: 0 to 0.5 mmm Fig. A). - If necessary, immobilize. Fig. A
Fig. B 1
1
- Untighten the nuts (Item. 1) completely (Fig. B). - Add the shims required, balancing the thicknesses on both sides of the telescope. NB: Shims are available in the following thicknesses : 0,5 ; 1 ; 2 et 4 mm. - Check that the screws are fully tightened to the end of the thread. - Apply MANITOU locking compound Réf. 187526 on the nuts item. 1 (Fig. B). - Replace and tighten the nuts item. 1 (Fig. B) (tightening torque 92.6 N.m ± 25 %).
10
REAR PADS - Raise the jib to the maximum extent. - Retract the telescope completely and check the play in the lower, upper and side wear pads (permissible play: 0 to 0.5 mm Fig. C). - If necessary, wedge it in position.
Fig. C
Fig. D 1
1
- Untighten the nuts item. 1 completely (Fig. C). - Add the shims required, balancingthe thicknesses on both sides of the telescope. NB: The shims are available in thicknesses of 0,5 ; 1 ; 2 et 4 mm. - Check that the screws are tightened right to the end of the thread. - Apply MANITOU locking compound Réf. 187526 on the nuts item. 1 (Fig. D).. - Replace and tighten the nuts item. 1 (Fig. D) (tightening torque 92.6 N.m ± 25 %).
11
REMOVAL OF THE TILTING CYLINDER
REMOVAL OF THE TILTING CYLINDER - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Set the jib horizontal - Hold the carriage in position with lifting equipment as shown in figure A. - Stop the engine. - Release the hydraulic pressure by operating the levers on the distributor. - Remove the circlips retaining the plate for the shaft in the head of the tilting cylinder (Item. 1 Fig. B). - Expel the shaft fron the head of the cylinder (Item. 1 Fig. B) - Remove the retaining screw from the plate for the shaft in the base of the tilting cylinder and expel the shaft (Item. 2 Fig. C) - Mark the position of the cylinder’s supply hoses and disconnect them (Item. 3 and 4 Fig. D). - Remove the cylinder fron its housing.
Fig. A
Fig. B
Fig. C
Fig. D
2
1
4 3
12
REASSEMBLY OF THE TILTING CYLINDER - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE TILTING CYLINDER”, also complying with the following instructions. Fig. E
5
6 5
6
- Check that the tilting cylinder is in good working order. - Clean the articulation axles (item. 5 Fig. E) before reassembling and apply a thin layer of grease (See chapter: CHARACTERISTICS OF THE LIFT TRUCK in group 0 - GENERAL). - Also clean and grease the articulations (Item. 7 F ig. E) with the same grease.
13
REMOVAL OF THE CARRIAGE
REMOVAL OF THE CARRIAGE - Hold the carriage in position with lifting equipment as shown in figure A. - Remove the circlips retaining the tilting cylinder’s shaft plate and then expel the shaft (Item. 1 Fig. B) If there is an accessory fitted, hold the carriage in position with weges (risk of tipping over).
- Remove the retaining screw from the carriage shaft plate and then expel the shaft (Item. 2 Fig. B). - Remove the carriage. If the “hydraulic accessory locking system” option is fitted, disconnect the hoses connecting the locking cylinder.
Fig. B
Fig. A
2
1
14
REASSEMBLY OF THE CARRIAGE - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE CARRIAGE”, also complying with the following instructions.
Fig. D
3
4 4
3
4
- Clean the articulation axles (item. 3 Fig. D) before reassembling and apply a thin layer of grease (See chapter: CHARACTERISTICS OF THE LIFT TRUCK in group 0 - GENERAL). - Also clean and grease the articulations (Item. 4 F ig. D) with the same grease.
15
REMOVAL OF THE TELESCOPE
REMOVAL OF THE TELESCOPE - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Telescope the jib to the maximum. - Set the jib horizontal. Stop the engine. Release the hydraulic pressure by operating the levers on the distributor. - Remove the plate from the head of the jib (Item. 1 Fig. A) to access the hose connectors. - Mark the position of the cylinder’s supply hoses (Item. 2 and 3 Fig. B) and disconnect them. Also remove the flange (Item. 4 Fig. B) - Plug the orifices of the four hoses and pull them towards the back of the jib. - Remove the shaft from the base of the telescoping cylinder (Item. 5 Fig. C) - Remove the plate from the base of the jib (Item. 6 Fig. C) - Attach a sling to the telescope (Fig. D) - Remove the pads and the shims from the base of the jib, taking care to mark them and their position for subsequent re-installation.
Fig. A
Fig. B
Fig. C 4
1
3
6 5
2
Fig. D
16
- Remove the pads and the shims from the head of the jib, taking care to mark them and their position for subsequent re-installation. - Remove the telescope completely from the front of the jib (Fig. D). Ensure the the whole assembly remains balanced and take care when drawing out the four hoses attached to the telescope (Fig. E) Fig. E
REASSEMBLY OF THE TELESCOPE - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE TELESCOPE”, also complying with the following instructions. - Check that the position of the hoses is correct (F ig. E) Fig. A (drawing of assembly of jib wear pad)
Legend : 1 2 3 4 5 3
2
1
4
SCREW NUT SHIM INSERT WEAR PAD
5
- After re-assembling all the jib components, adjust and secure the jib wear pads. - Check that the jib is in good working order.
17
REMOVING THE TELESCOPING CYLINDER
REMOVING OF THE TELESCOPING CYINDER - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Telescope slightly to access the shaft in the head of the telescoping cylinder and then expel it (Item. 1 Fig. A) - Remove the plate in the base of the jib (Item. 2 Fig. B). - Disconnect the telescoping cylinder’s hoses. Plug the orifices of the telescoping cylinder’s two hoses (Item. 3 and 4 Fig. C). - Expel the shaft from the base of the telescoping cylinder (Item. 5 Fig. D). - Remove the cylinder from the back of the jib taking care when drawing out the hoses (Fig. E).
Fig. A
Fig. B
Fig. C
1
Fig. D
2
Fig. E
5
18
4
3
REASSEMBLY OF THE TELESCOPING CYLINDER - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE TELESCOPing CYLINDER”, also complying with the following instructions. Fig. E
6 7
6
7
- Clean the articulation axles (item. 6 Fig. E) before reassembling and apply a thin layer of grease (See chapter: CHARACTERISTICS OF THE LIFT TRUCK in group 0 - GENERAL). - Also clean and grease the articulations (Item. 7 F ig. E) with the same grease.
19
HYDRAULIC DIAGRAM 70-6-721670 EN
28 / 01 / 2006
CONTENTS HYDRAULIC DIAGRAM BT 420 S3-E2 / BT 425 S3-E2
3
5
et
7
4
H Y D R A U L I C D I A G R A M
1 7 C 1 C 1
1 2
1 3 T E L E S C O P A G E
C 2
C O M P E N S A T I O N
C 2
2
B T 4 2 0 S é r i e 3 - E 2 / B T 4 2 5 S é r i e 3 - E 2
1 7 C 1
1 4 5
I N C L I N A I S O N
C 2
1 7 8 ,4 c m 3 / t
1 C
1 5
A M A
S
P
L E V A G E
2 C
F s
T
3
A N T I C A L A G E
P S
T
A R P E I L G O L T A A B G L E E
B 4
G
A 4
5 B 3 A 3 a
X 2
1 8 0 b
2 5 0 b
1 1 1 2 V c c
B 2 A 2
Y X 1
b
4 0 c m 3 / t
2 5 5 b
1 2 V c c
1 2 V c c
B 1 A 1
T 1
T 2
1 2 V c c
2 3 0 b
M
4 2 b
V A
6
9
M
1 0 . 5 b
L S
T
R
1 0
L S
7
P
8
1 8 c m 3 / t
1 0 0 c m 3 / t
P
L
E F
C 2
1 6
C 1
D I R E C T I O N
HYDRAULIC DIAGRAM BT 420 Série 3-E2 - BT 425 Série 3-E2
1
Accessory connector
2
Hydrostatic motor
3
TH7 valve (inching)
4
Suction and return filter
5
Hydrostatic pump
6
I.C. engine
7
Oil tank
8
Hydraulic main pump
9
Oil cooler
10
Steering pump manual
11
Vale bank
12
Telescoping cylinder
13
Compensation cylinder
14
Tilting cylinder
15
Lifting cylinder
16
Steering cylinder
17
Balancing valve
7
C B A
n
j v t D E T R A V A I L : A V D , A V G , A R R
4 7
4 8
m
2
5
1
1 0 A
1
m/bc
j 4
m
b l
4 5
m
j v t
5
1
r o
b c
1 0 A j v t
j v t
m
5
1
v
1 0
7 1
b l
j
1 0 A
j v t
j
1 1 4 7
m
5
1
O P
5 A
C
1 6 A v
r
b l
j v t
1 0 A
j v t
4 0
2
5
1
3
r o
r j v t
5
j v t
r
v
6 7
j v t
b l
3 4
3 5
3 6
m
5
4 0
1 7
1 0 A
a 3 v 2 4
3 7
n b l
b
j v t
5
2
n
r
1
3
r
1
n a r r
1 0 A
1 5
1 0 A
v t m
B U Z Z E R O D P E T I O R N E C U L
r n
3 8
1 0 A
j v t
2 0
1 6 A r
r
7 2
3 9
1 0 A
r
j
b l
b l
5 2
r
7 3
5 A j b c
5 3
r b l
B 5
j v t
b l
5 4
5 A
r
B 4
B 7
r
7 4 B 6
5 5 5
1
2
3
j
5 6
O P T I O N E C L A I R A G E R O U T E
1 0 A
7 6
b l
B 1
B 3
C o u p u r e
j
5 7
0 1 0 A
O P T I O N C H A U F F A G E
1 2
5 7 / 5 8
b c
3 0 J
5 9
1 5 A
5 6 b
7 7
7 8
j v t
6 1
j v t -
R
j v t
F G
+
L
C
F D H
o
n
O P T I O N T U V
+
m
6 2
F G
6 3
1 2
1 5
1 3
1 0 A
2 6 8
j
r
2 1
1 0 n
g
1 0 A
2
g
6
6 6
j v t
n
M
j
8
8 6
8 1 2
5 A
3
1 0
5
1
7 9 r 2
r
r
5
1
7
1 0 7
j v t
j v t
v 2 i f
8 2
r a z
v
3
-
4
4
4 9
1 + p e r m
5 A
5 0
r
r
r o
2
r
1 2 V c c
j / v
j v t
O P T I O N C A B I N E
r
7 2
v 2 i f
8 3
r
r a z
v
3
4
4 1 + p e r m
T E L E S C O P A G E
r
b l
3
r
2
r
2 2
1 0 A r
R 2
r
4 1
2
7
8
5
j v t
6 9
1 6 r
1
b l
1 0 A
r
1 2 V c c
r
R 1
r
A C C E S S O I R E
5 6 7 8 1 2
K2 FREIN
2 8
2 3 bl/sa
4 2
1
j v t
K1 CHARGE
2 4
n
J4 FILTREAIR
n j v t 5
1
2
3
4 0
7 5
H Y D R A U L I Q U E T S
8 7
O P T I O N V E R R O U I L L A G E
r j v t
r
C 3
P 2
P 1
C 4
C 1 C 2
r
1 8
1 4 5
2
1
3
1 9
r o
8 4
8 5
4 4
1
1 0 A
5
-
m
1 2 V c c
j / v
j v t
r
R 1
8
j v t
o
r
4 3
2
r
r
2 7
r
R 2
r
8 0
0
j v t
3 r
2 1
6 9
1 6 1 2 V c c
1 0
9
r
r
j v t
r
7
g 5 A
b c
6 5
j v t
n
g
n
6 4
5 1
0 F D
5 A
n
j
7 4
1 0 A
1
5 6 a
6 0
6 8
r
3
5
S U R 4 e m e E L E M E N T
O P T I O N K I T E L E C T R O V A N N E
o
O P T I O N K I T E L E C T R O V A N N E + V E R R O U I L L A G E A C C E S S .
2 9
2 5 J3 COLM.FILTR.H.
o
v t
3 0
r
g
J2 T°CEAU
3 1
2 7 g
J1 PRESS° HUILEMOTEUR
3 2 j v t
1 0 A
2 6 v t
3 3 b
B 2
b c
b c
5 8
B
b
7 0 b l
8
r
b l
4 8
3 0 3 0 1 7 1 7 5 0 r o 1 9 1 9 5 4 1 5 5 8
o
9
r
b l
4 5
5
1 0 A
7 0
b l
3
b c
r
j v t
j v t
6 0 A
b c
j v t
D E T O R P A T V I A O I L N A 1 R P R H . A G R A E U C H E
1
3
6
5
1
b l
D E T O R P A T V I A O I L N A 1 V P . G H A A U R C E H E
2
7 1
4 5 j v t
O P T I O N 2 P H A R E S
7
j v t
j v t
D E T R A V A I L A V A N T
j
r
b l O P T I O N 3 P H A R E S
5
j
7 0 b l
E L E C T R I C D I A G R A M
n
4
A
B T 4 2 0 / B T 4 2 5
OPERATION (ADJUSTMENT) OF TRANSMISSION
75-8-M127 EN
28 / 01 / 2006
CONTENTS
-
Technicals Characteristics.........................................................................................................
1 and 2
-
Hydrostatic Circuit ....................................................................................................................
3
-
Hydrostatic Diagram..................................................................................................................
4
-
Pump A4VG/DA ........................................................................................................................
5 to 12
-
Operation of TH7 Valve (inching) ................................................................................................
13
-
Hydrostatic Transmission Adjustment Sheet ...............................................................................
14
HYDROSTATIC TRANSMISSION LIFT TRUCK SPECIFICATIONS TYPE OF LIFT TRUCK : BT 420 - BT 425
I.C. ENGINE Type PERKINS 404 C 22 • Rated rpm ........................................................................................... • Idle rpm .............................................................................................. • Max. rpm (unloaden) ............................................................................ • Power DIN (70-020) .............................................................................
2800 930 2990 38
tr/mn tr/mn ± 25 tr/mn ± 50 Kw
HYDROSTATIC PUMP Ref. : - 225421 Type A4VG40DA1D7/32RNZC02F005S • Min./max. displacement....................................................................... • Max. capacity at 3000 rpm T 27 bar HP ................................................ • Governing start HP 50 bar ................................ • Governing end HP 400 bar ..............................
0 à 40 120 1150 2500
cc/rev l./mn rpm ± 50 rpm ± 100
BOOST PUMP • Displacement ...................................................................................... • Max. capacity at 3000 rpm...................................................................
8,4 25,2
cm 3 l./mn
HYDRAULIC MOTOR - BT 420 - BT 425 • Hydraulic motor Réf. MANITOU : 208700 MOT-A6VM 80DA/63W-VZB027B(0327 Fixed displacement.................................................................................................... 80
Maximum travel speed (front)................................................................................ Maximum travel speed (rear).................................................................................
20 20
BT 420 - BT 425 Drawbar pull in load condition ...............................................................................
2900
1
3 cm /tr
Km/h Km/h
daN
TRANSMISSION OPERATING PRESSURE • DR valve set pressure .......................................................................... • HP relief valve set pressure .................................................................. • Boost pressure at neutral mini speed.................................................... max. speed ................................................... • Pilot pressure at beginning of governed speed ....................................... • Governing end pilot pressure at 2500 rpm............................................. at rated rpm in load condition ................... • Maximum pressure in housings............................................................. • By-pass set pressure on oil coder ......................................................... Recommended oil type in the transmission ............................................................ Capacity of transmission oil tank + equipment ....................................................... Ref. of transmission filter cartridge : 686 237
2
430 450 25 28 6à7 15 18 1,6 2
bar bar ± 10 bar ±2 bar ±2 bar bar ±1 bar bar à 50° C bar
MANITOU HYDRAULIQUE ISO 46
55
l.
HYDROSTATIC TRANSMISSION CIRCUIT BT 420 - BT 425
A T P
1 T
Y S P
a M
2 X
R 1 X 2 T
3
b M
HYDROSTATIC DIAGRAM BT 420 - BT 425
t / 3 m c 8 1
F E
7
P
6
S L
b 5 . 0
M 5
8
A b V 2
3
2 T
1 T
t / 3 m c 0 4
b
1 X Y
2 X
a
4 E E L G B A A T L O G L I E P R
G
A E G A L A C I T N A
S P
2 T
s F S
A M A
t / 3 m c 4 , 8
1 4
P
r e t l i p ) f m g n r n r p u o p u m t i t h o c e u n i n r p m a i c ( d c e m i i n t 7 a t n c r a H t a i l i e t k u l s T n s g o n n o i o o a o e t a t r e r r v c d . d c l d l l y a u y C y i . i H V S H I O H O - - - - - - - 1 2 3 4 5 6 7 8
PUMP A 4 VG / DA
PUMP A 4 VG / DA
5
A4VG | RDE 92 003-01-R/03.03
Instructions de réparations - Vanne basse pression ( pression de gavage) Adjustment instructions - Low pressure valve (Boost pressure)
Attention! Respectez les règles de sécurité!
Attention! Observe safety regulations!
Remarque! Réajustage uniquement à la température de service.
Note: Readjusting only at operating temperature.
Raccordez la jauge de pression su “G”.
Connect pressure gauge to "G".
Attention! *Réglage de la pression de gavage! Pression nominal p H - 20 bar Pression maximal p H - 40 bar à la vitesse max.
Attention! * Boost pressure setting! Nominal pressure p H - 20 bar Peak pressure p H - 40bar at max. speed.
Remarque: Les données de réglage sont conformes à la commande 1) Avec la version DA
Note: Setting data is in accordance to the works order. 1)
with theDA version
"G" 1)
*
6
RDE 92 003-01-R/03.03
| A4VG
Instructions générales de réparations - Position d’origine hydraulique Adjustment instructions - Mechanical "zero position"
HW
HD
EP
DA
Attention! Respectez les règles de sécurité! Raccordez les deux chambres de commande avec un flexible de taille nominal 6. Evitement des signaux résiduels du syst ème hydraulique. Raccordez les jauges de pression à M Aet M B . Réglez la position d’origine de sorte que , lorsque l ’entrainement est bloqué, les deux jauges de pression indiquent la même pression. Remarque: Vérifiez la zone morte de la position d’origine. Attention! Observe safety regulations! Connectbothcontrol chamberswitha nominalsize 6 hose.Avoidance of residualsignals fromhydraulic zero position. Connect pressure gauges to M A and M B . Adjust thezeroposition sothatwithat blockeddriveboth pressuregaugesindicatethe samepressurevalve. Note: Ascertain the zero position dead band.
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A4VG | RDE 92 003-01-R/03.03
Instructions générales de réparations - Position d’origine hydraulique Adjustment instructions - Hydraulic "zero position"
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*
HW
HD
EP
Raccordez les jauges de pression à X 1 et X 2 . Réglez la position d’origine de sorte que, lorsqu’un bloc est entra î né, les deux jauges de pression indiquent la même pression. Remarque: *Réglage excentrique Ne tournez pas plus de ±90 °.
Connect pressure gauges to X 1 and X 2 . Adjust the zero position so that with a block drive both pressure gauges indicate the same pressure value. Note: * Eccentric adjusting Do not turn more than ± 90°.
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RDE 92 003-01-R/03.03
| A4VG
Instructions de réparations - HP - valves (Haute pression) et coupure de pression Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Attention! Respectez les règles de sécurité
Vanne HP sans fonction Bypass
Druckabschneidung Pressure cut-off
1. Les vannes HP sont toujours r églées sur une valeur sup érieure de 10% à la valeur de coupure de pression.
X
2. Réajustement uniquement à la température de service. Raccordez la jauge de pression (600 bar) à MA et M B . Coupure de pression: Pour bloquer la coupure de pressionlors de l ’essai des vannes haute pression, la vis de r églage (élt 1) avec l’écrou de bloquage (élt 2) desserréedoit être vissée à un couple max. de 2 Nm à l’état dépressurisé, jusqu’à ce que la butée finale soit atteinte. Vannes HP: actionnez les vannes avec la pompe à faible régime. Vérifiez la valeur de réglage. (”température” seulement brièvement). Modifiez la valeur de r églage - voir les informations de service.
Coupure de pression: Vissez à nouveau la vis de r églage en position de mesure(*). Vérifiez la pression et réajustez-la si nécessaire. Attention! Respectez une diff érence de pression de 10% entre les vannes HP et la coupure de pression ! Remarque! Les données de réglage sont conformes à la commande. Attention! Observe safety regulations.
HP valve without bypass-function 1. HP valves are always adjusted10% higher thanthe pressure cut-off. 2. Readjusting only at operating temperature. Connect pressure gauge (600 bar) to M A and M B . Pressure cut-off: To block the pressure cut-off when testing the high pressure valves, the adjustment screw (item 1), with the lock-nut (item 2) loosened, has to be screwed in
withamax.torqueof2Nminthedepressurisedcondition until the end stop is reached. HPvalves:Operatethe valves with smallpumpflowoverthe valves. Check setting value. (only for a short time "temperature “). Change setting value - see service information. Pressure cut-off: Turn back setting screw to measurement (*). Check pressure value and readjust if necessary. Attention! Observe the 10% pressure difference between the HP valvesand the pressure cut-off! Note: Setting data is in accordance with the works order.
HD- Ventile HP- valves
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A4VG | RDE 92 003-01-R/03.03
Instructions de réparation - Valve Bypass Adjustment instructions - Bypass valve
1 1
1 Véhicule équipé d’une transmission hydrostatique pure ou d ’un entra î nement hydrostatique avec bo î te à engrenage sans position roue libre.
Vehicle witha purehydrostatictransmissionor witha hydrostatic drive with gear box without free wheel position.
Hydrostatic transmission / Bypass condition Transmission hydrostatique / Condition bypass Dans ce cas, l’entrainement est activ é sur la position roue libre. Pour cela, les vannes haute pression de la pompe à débit variable sont dotées d’une fonction dite de d érivation. Il suffit de tourner la vis correspondante ( élément 1) pour relâcher la vanne de sorte à permettre la libre circulation de l ’huile. Bypass: Vissez l ’élément 1 jusqu’à ce qu’il soit aligné sur l’écrou.
Vitesse de remorquage La vitesse de remorquage max. de 2 km/h ne doit pas être dépassée. Il se peut que des vitesses sup érieures soient possibles selon la vitesse du moteur hydraulique ou le pignon sélectionné.
In this case the travel drive is switched on to the free wheel position.For thispurpose thehigh pressurevalves of thevariable displacement pump have a so-called bypass function. By turning the relevant screw (item 1) the valve is so released that free oil circulationis made possible. Bypass: Screw in item1 until it is level with the nut.
Towing speed The max. towing speed of 2 km/h should not be exceeded. Higher permissible speeds are dependedon the hydraulic motor speed or the selected gear.
Towing distance The towing distance should not exceed 1 km. With no boost avaiable thehydraulic circuit drains. The heat generation in the hydraulic motor rotary group hasto be taken into account.
Distance de remorquage La distance de remorquage ne doit pas d épasser 1 km. Aucune suralimentation possible sur les d égorgeurs du circuit hydraulique. La chaleur générée dans le groupe rotatif du moteur hydraulique doit être prise en compte.
Termination of the towing operation After termination of the towing operation turn back item 1. The original set pressure value is thereby avaiable. Valve function: Screw back item 1 up to stop. Screw up the nut.
Fin de l’opération de remorquage Une fois l’opération de remorquage terminée, resserrez l’élément 1. Vous retrouverez alors la pression réglée à l’origine. Fonctionnement des vannes: revissez l ’élément 1 jusqu’à la butée. Vissez l’écrou.
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RDE 92 003-01-R/03.03
| A4VG
Instructions de réparation - Commande DA Adjustment instructions - DA control
Attention ! Respectez les règles de sécurité ! Vérifiez les données de réglage. Pendant la procédure de contrôle, la température de service doit généralement être maintenue à un niveau constant. Démarrez le moteur principal au ralenti.
Position du bloc Commutateur d’entra î nement -”0”. Augmentez lentement la vitesse du moteur jusqu’à la vitesse max. et observez les instruments de mesure. Pression de suralimentation: Moteur principal au ralenti Psp = approx.15-20 bar Vitesse max. du moteur Psp=........bar*
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Position du bloc Commutateur de direction d’entra î nement - avant (Vitesse conduite sur route et frein serré au maximum) Contrôle des données de réglage de la pompe A4VIDA
* Début du contrôle HD 40 - 50 bar Vitesse du moteur . . . . . . tr/min* Psp . . . . . . bar* Réajustement du démarrage de la vis de commande. Réglage de la vis
Début du contrôle
* Fin du contrôle HD . . . . . bar* Vitesse du moteur . . . . . tr/min* Psp . . . . . . bar* Réajustement de la vis d ’indexage Remarque: Réglage excentrique - respetez le sens de rotation
Remarque: * Les données de réglage sont conformes à la commande !
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A4VG | RDE 92 003-01-R/03.03
Instructions de réparation - Commande DA Adjustment instructions - DA control
Attention! Observe safety regulations! Check setting data. Operating temperature should be generally kept constant during the checking procedure. Start prime mover, idle speed.
Block position Drive direction switch - "0“ . Slowlyincreasemotor speedup to themax. motor speed and observe measuring instruments. Boost pressure: Idle speed of prime mover Psp = approx. 15 - 20 bar max. motor speed Psp=.........bar*
Block position
*
Drive direction switch - forwards (Road gear and fully applied brake) Check setting data pumpA4VIDA
* Start of control: HD 40 - 50 bar Motor speed . . . . . rpm* Psp . . . . . . . bar* HD . . . . . . . bar* Readjustment of start of control screw
Begin of control
End of control HD . . . . . . . . bar Motor speed . . . . . . rpm* Psp . . . . . . . bar* Readjustment of the indexing screw
Timing adjustment screw
Note: Eccentric adjusting - observe direction of rotation. Note: * Setting data is in accordance to the order work!
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INCHING VALVE OPERATION (TH 7 Valve)
With the foot off the inching pedal, the tappet 1 is fully in and the oil passes unhindered between port P (pilot pressure in) and port A (pilot pressure out). The oil flows freely through the opening 3 in the slide valve 2. The pilot pressure, injected into the control cylinder of the pump cam plate, is therefore identical to that which would be obtained without this TH 7 valve.
With the foot on the inching pedal for a slow approach, the tappet 1 is partially out; the oil passage is calibrated by the opening 3 in the slide valve 2. The pilot outlet pressure through port A will therefore be controlled and the value of this pressure will be constant. If the pilot pressure entering through port P were to increase, as this pressure would be applied to the section S of the slide valve 2, the springs 4 and 5 would be slightly compressed and the slide valve 2 would move in the direction of the arrow F. This would reduce the oil passage through the opening 3 and in turn create a drop in pressure between port P and port A. The pilot outlet pressure through port A is therefore controlled and the value of this pressure is constant whatever the level of pilot pressure entering through the port P. This means that the pressure injected into the control cylinder of the pump cam plate will be constant, and therefore the angle of the cam plate will also be constant. This allows the truck to approach slowly and at a constant speed selected according to the pressure exerted on the inching pedal.
With the inching pedal pressed to the limit of travel the tappet 1 is fully out. With the tappet 1 in this position, there is no pilot pressure at port A, and therefore no pressure in the control cylinder of the pump cam plate. The pump displacement is therefore nil.
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