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06 / 09 / 2002
KP 02 MNT
INSTRUCTIONS FOR REPLACING THE SEALS PUMPS SERIES KAPPA 30/30 "LOAD SENSING"
General Recommendations
Make sure the components have not been damaged in transport. Always work in a clean environment. Clean all parts (except seals) with a solvent and blow clean, dry air through them before reassembly. Be careful not to damage the seals. Avoid negligence or any other deterioration of machined surfaces. The parts must be assembled without resistance which would indicate incorrect assembly or the parts assembled are not exactly correctly positioned with respect to each other. If hand pressure is inadequate to place a part fully in position, use a rubber mallet. Never use a metal head!! Make sure that the torque settings used for the screws match the values given in the appropriate tables.
List of tools: Vice Special tool for installing the shaft seal Vertical press Tool for protecting the shaft seal on assembly of the front flange Special tool for the rotation test on the pump after assembly Torque wrench Oil and grease Emery cloth
ANSI B92.1 classe 1 13 Dents - 16/32 D.P. Fond plat - Centrage sur flancs Angle de pression 30
2.00
12.50
27.50
25.00
40.00
AMNMO400/0499
5.00
5.50
29.00
18.5
26.00 -0.10
+0.10 0
Arrte vive
21.80 +0.02 24.00 +0.10 25.00
+0.20 +0.10 +0.20
28.00
+0.07
3.2
1.6
19.15
1.6
14.00
15.00
3.2
1.6
Special tool for the rotation test on the pump after assembly
UPDATES Changes
15.00
4 3
M8
1.6
Fit the jaws of the vice with clamps made of aluminium or soft material to avoid damaging the machined surfaces of the pump. Position the pump vertically with the driveshaft pointing downwards, then tighten the vice. Be careful not to damage the machined parts while tightening. Draw a mark with a felt tip on the pump to ensure correct part reassembly.
A1
A2
A3
A4
A
Loosen the mounting screws using a wrench.
A5
A6
Position the pump vertically with the driveshaft pointing upwards. Remove the front cover with a rubber mallet.
A7
Draw a mark with a felt tip on the bearing and the body to ensure correct part reassembly.
A8
A
Release the bearing.
A9
A10
Release the lower bearing and draw a mark on the bearing and the body to ensure correct reassembly.
A11
A12
A
Remove the compensation ring and reinforcement on the four bearings and replace with grease.
A13
Place the lower bearing carefully into the body until it comes into contact with the body; the seal must be pointing downwards. For orientation, the previously drawn mark (on the pump body and the bearing) will prevent any error on reassembly.
A14
Insert the input and output shafts into the body of the pump until they are in contact with the lower bearing. Be careful not to reverse the positions of the shafts; respect the original position.
A15
Place the upper bearing carefully into the body until it comes into contact with the gears; the seal must be pointing upwards. For orientation, the previously drawn mark (on the pump body and the bearing) will prevent any error on reassembly.
A16
A
Place the cover on the workbench and remove the ring using pliers.
A17
Set the front cover turned downwards. Release the shaft seal using a tool. Be careful not to damage the machined parts.
A18
Smear a thin layer of grease around the shaft seal to facilitate assembly. Now use the special tool to install the shaft seal and push it into place in its housing until the seating of the ring becomes visible.
A19
A20
A
Coast the tool used to protect the shaft seal when mounting the front cover, with uncontaminated grease or oil and insert it onto the input shaft. Fit the front cover without damaging the lip of the seal, making sure that the guides are slotted into their housings.
A21
Position the pump vertically with the driveshaft pointing downwards, then tighten the vice. Be careful not the damage the machined parts while tightening.
A22
Tighten the screw using a torque wrench set to torque 14 (daNm), using diagonally opposed movements.
A23
Place the rear cover on the vice. Loosen the stopper using a wrench.
A24
A
Remove the ring seal from the stopper and replace it with a new one.
A25
Tighten the spring-loaded stopper using a torque wrench set to torque 5 (daNm).
A26
A27
Remove the ring seal from the stopper and replace it with a new one.
A28
A
Tighten the stopper using a torque wrench set to torque 5 (daNm)
A29
Position the pump vertically with the driveshaft pointing downwards, then tighten the vice. Be careful not to damage the machined parts while tightening. Assemble the valve, screwing the assembly by hand.
A30
The previously drawn marks (on the pump body and the cover) prevent any possibility of making mistakes on reassembly.
Tighten the screw using a torque wrench set to torque 7 (daNm), using diagonally opposed movements.
A31
To check the torque in operation, turn the input shaft to make sure that it turns freely and that no mistakes have been made during assembly.
A32
Our policy is to work towards constant product improvement; for this reason product characteristics are subject to change without prior notification.
PUMP (details)
10
PUMP (details)
1 SPRING PLUG FOR LS VALVE 2 PUSHING SPRING FOR LS VALVE 3 THROTTLING GRUB SCREW (RED) 4 SPRING FOR LS VALVE 5 DRIVE GEAR 6 COVER 7 CIRCLIP 8 SHAFT SEAL BAUD 9 SLEEVE BEARING 10 O-RING SEAL 11 THRUST PLATE 12 DRIVEN GEAR 13 O-RING SEAL 14 BACK-UP RING 15 BODY 16 REAR COVER 17 SCREW 18 WASHER 19 SCREW 20 WASHER 21 STEEL BUSHES 23 PLUG 24 SCREW 25 O-RING SEAL 26 FILTER 27 PLUG 28 THROTTLING GRUB SCREW 29 SPOOL 30 O-RING SEAL OR
11
12
09 / 09 / 2002
INDEX
1 - DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 - REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
On refitting, make sure the pivoting choke in the governing unit is properly positioned (Slot in line with the oil circulation holes).
- Position the pump vertically. - Note the position and remove the cylinder head.
- Position the pump horizontally. - Remove the axial piston, holding the pistons and contact plate in position.
- Extract the piston from the control cylinder. - Swivel the pump plate to release the piston more easily.
- Remove the control cylinder rod. NOTE : The head of the rod has a particular shape, so you might need to move the plate in order to remove it.
- Remove the contact cups from the tilting plate. Locking screw
- Tighten the metal screws in the dishes on the shaft seal. - Remove the shaft seal by pulling on the screws with pliers.
2 - REMOUNTING - Repeat the operations in reverse order, taking the following information into account: - Put a new shaft seal in position using a spacer. - Refit the retaining rings.
- Make sure the slide-face is correctly positioned (notch) with respect to the cylinder head (lug).
Slot Stop
- If the position of the cylinder head was not noted on dismantling, use the oil circulation holes to remount the cylinder head on the pump body.
- Make sure the control cylinder rod is properly inserted in the housing provided on the plate. Swivel the plate to help fit the rod in place.
- Pre-tension on the bearings : Pre-tension must be set to 0 to 0.05 mm. - Adjust spacer 1 to change the setting.
Fill the pump casing with hydraulic oil after each operation.
STANDARD TIGHTENING TORQUE TO USE WHEN IT IS NOT GIVEN IN THE DISMANTLING AND REMOUNTING INSTRUCTION (*) - Tightening torques are given for TIGHTENING TORQUE IN N.m (*) black or galvanized fittings with light Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9 lubrication. M3 0,54 0,76 1,16 1,7 2 - Tightening torques are given for M4 1,24 1,74 2,66 3,91 4,57 automatically triggered and reset M5 2,47 3,46 5,2 7,7 9 torque wrenches and direct display M6 4,29 6 9,1 13,4 15,7 torque wrenches. M8 10,4 14,6 22 32 38 - For further information, see standard M10 20 28 44 64 75 NF E25-030. M12 35 49 76 111 130 M14 57 79 121 178 209 M16 88 124 189 278 325 M18 122 171 261 384 449 M20 173 243 370 544 637 M22 238 334 509 748 875 M24 298 418 637 936 1095 M27 442 619 944 1386 1622 M30 600 840 1280 1880 2200
10
MT 732 Srie B-E2 MT 932 Srie B-E2 MLT 630 Turbo Srie B-E2 MLT 630 120 LSU Srie B-E2 MLT 634 Turbo LSU Srie B-E2 MLT 634 120 LSU Srie B-E2 MLT 634 120 LSU POWERSHIFT Srie B-E2 MLT 731 Turbo Srie B-E2 MLT 731 Turbo LSU Srie B-E2
30 / 09 / 2004
CONTENTS
1 - HYDRAULIC ELEVATION SYSTEM STANDARDS ............................. A - REMOVAL AND REASSEMBLY OF THE COMPLETE STEM ........... B - REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING ................................................................................................
4 5
C - REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING ........................................................................................... 10 D - REMOVAL AND REASSEMBLY OF THE LOCKING RING SEALS AND RING ........................................................................................... 11 E - APPLICATION OF THE THREAD LOCKING MATERIAL .................... 12 F - CYLINDER DIAGRAMS.................................................................................. 14
A2
INSPECTION - Degrease and clean the cylinder chamber. - Visually inspect the cylinder chamber, there should be no scratches, burrs, oxidisation, etc
REASSEMBLY - Apply hydraulic oil on the piston seals and ring, using a brush. - Reassemble the complete stem inside the cylinder body 3 (Fig. A1). - Ensure that the seals are not damaged while passing through the inside thread in the cylinder body. NOTA : The locking ring is tightened in different ways depending on whether the cylinder body has a collar or not (Fig. A4). Follow the instructions below. A3 CYLINDER WITHOUT COLLAR - Apply hydraulic oil to the outer seals of the locking ring. - Apply Loctite 222 thread lock (see section E) to the locking ring (Fig. A3). - Tighten the ring. - Lock using a pin wrench and a torque wrench. Refer to the tightening torque (Fig. A4) or use the angular tightening procedure (Fig. A4). - Rotate the stemp through one turn to ensure the seals are correctly positioned. CYLINDER WITH COLLAR - Apply hydraulic oil to the seals and thread of the locking ring. - Tighten the ring. - Lock using a pin wrench and a torque wrench. Refer to the tightening torque (Fig. A4) or use the angular tightening procedure (Fig. A4). - Rotate the stemp through one turn to ensure the seals are correctly positioned.
Bague de fermeture Locking ring Frein filet Stemp Thread lock Tige
Joint Seal
NOTE - It is recommended that the cylinder is tested hydraulically before reassembly on the machine. - Extend and retract the stemp several times.
A4
A4-1
Locking ring angular tightening procedure. - Tighten ring until it comes into contact with cylinder body. - Mark a line 1 (Fig. A4-1) on the cylinder body and on the locking ring. - Tighten the ring to obtain dimension X (Fig. A4-2). - Insert collar in one of the slots on the locking ring.
1 1
collar
A4-2
THREAD A M43 x 200 M48 x 200 M53 x 200 M58 x 200 M63 x 200 M66 x 200 M68 x 200 M73 x 200 M78 x 200 M83 x 200 M88 x 200 M93 x 200 M98 x 200 M104 x 200 M109 x 200 M114 x 200 M124 x 200 M129 x 200 M134 x 200 BORE B 40 45 50 55 60 63 65 70 75 80 85 90 95 100 105 110 120 125 130 140 150 COLLAR C 51 56 61 66 72 75 78 82 89 94 99 107 109 119 124 129 139 139 149 TIGHTENING TORQUE 200 - 250 N.m 200 - 250 N.m 200 - 250 N.m 250 - 300 N.m 250 - 300 N.m 250 - 300 N.m 250 - 300 N.m 300 - 350 N.m 300 - 350 N.m 350 - 400 N.m 350 - 400 N.m 350 - 400 N.m 400 - 450 N.m 400 - 450 N.m 400 - 450 N.m 450 - 500 N.m 450 - 500 N.m 450 - 500 N.m 450 - 500 N.m 450 - 500 N.m 450 - 500 N.m DIMENSION X
B1
Locking ring 2 Bague de fermeture 2 Stem 1 Tige Piston 4 Piston 7 Nut 5 Screw 6 Ecrou 5 Vis 6
B2
Lockingde fermeture 2 Bague ring 2 Stem 1 Tige Piston 4
B4
Comparator Comparateur Stem Tige 11
B5
Locking ring 2 Bague de fermeture 2 Stem 1 Tige 1
B6
COUPLE DE SERRAGE PISTON PISTON TIGHTENING TORQUE
1400 1200 1000
M20
M30
M60
M70
C1
Seals Joints d'tanchit
10
D2
Seal Joint
Bit 1 Embout 1
D3
Plug 2 Poinon 2
Seal Joint
Embout 1 Bit 1
11
10 - 30 minutes 3 - 6 hours
10 - 20 minutes 2 - 4 hours
Shearing strength
1,5 - 4
N/mm2
Medium thread locking material (Loctite 243) Application on the M8 screws to lock the pistons. Without activation agent Handling time Use time
(Placing of the cylinder under pressure)
10 - 20 minutes 3 - 6 hours
5 - 15 minutes 2 - 4 hours
5 - 7,5 N/mm2
If the parts fitted with locking material cannot be removed using standard tools, we recommend heating the glued area to T = 250C, preferably using a hot air pistol rather than a blowpipe. REMARK If the temperature is near 0C, we recommend using a Loctite activation agent for the assembly, in addition, this will limit the polymerisation time.
12
13
LIFTING CYLINDER
MLT 630 / 634 Srie B
S INT
9 x2 10 11 12 13 14 17 18 x 2 19 22 23
15 18 21 18 5 1 16 19 17
240 047
6 7 4
20 2
10 3 11 9 3 8 9
12
23
13
22 14
LIFTING CYLINDER
MLT 731 Srie B MT 732 / 932 Srie B
S INT
9 x2 10 11 12 13 14 15 16 19 20 x 2 21
17 20 23 20 5 1 18 21 19
240 048
6 7 4
22 2
10 3 11 9 3 8 9
12
16
15
13 14
14
COMPENSATION CYLINDER
MT 732 / 932 Srie B
11 12 13 14 15 17 18 21 x 2
20
17
224 079
18 2 19 6 16
9 8 7
11 21 12 21 3 13 14 15 10
COMPENSATION CYLINDER
MLT 630 / 634 / 731 Srie B
11 12 13 14 15 17 18
20
1 9 8
224 073
7 6 2
11 12 10 13 14 3 18 17 19 16 15
15
TELESCOPING CYLINDER
MLT 731 Srie B MT 732 Srie B
3 4 5 6 7 12 15
16 1
11 9 12 10 13 14
3 4 15
240929
5 6 7
TELESCOPING CYLINDER
MLT 630 / 634 Srie B
3 4 5 6 7 12 15
16 1
11 9 12 10 13 14
3 4 15
239125
5 6 7
16
2 3 5 6 7 12 x 2 13 16 x 2
1er MONTAGE 1ste MONTAGE 1ro MONTAJE 1st MOUNTING 1mo MONTAGGIO
17 1 11 19 18 15 14 15 14 11 10 13 12 12
2me MONTAGE 2te MONTAGE 2do MONTAJE 2nd MOUNTING 2do MONTAGGIO
236 813
4 5 6 7 16 3 16
2 3 5 6 7 12 x 2 13 16 x 2
1er MONTAGE 1ste MONTAGE 1ro MONTAJE 1st MOUNTING 1mo MONTAGGIO
17 1
2me MONTAGE 2te MONTAGE 2do MONTAJE 2nd MOUNTING 2do MONTAGGIO
12 19 11 10 15 14 11 13 12
18 15
236 812
14
16 3 16 4 5 6 7
8 9
17
TILTING CYLINDER
MLT 630 / 634 Srie B
11 12 x 2 13 14 15 16 18 x 2 19 20
22
1 18 19
20
9 8
7 17 21 18 2 6 7
224 074
11 12 13 5 3 4 5 15 16 14 10 12
TILTING CYLINDER
MLT 731 Srie B
11 12 x 2 13 14 15 16 18 x 2 19 20
22
1 20 9 8 7 7 19 17 2 18 21 6
238 842
18
11 12 13 12 5 10 14 3 4 5 16 15
18
TILTING CYLINDER
MT 732 / 932 Srie B
11 12 x 2 13 14 15 16 18 x 2 19 20
22
20 9 1 19 7 17 7 18 8
231 908
2 18
21 6
11 12 13 5 3 4 10 5 14 15 16 12
19
20