M-B MSV Maintenance And Service Manual

Multi-service vehicle generation 3 units

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Maintenance and Service Manual

M-B Multi-Service Vehicle (MSV)

MSV Generation

Units

MSV Divison

1615 Wisconsin Avenue

P.O. Box 200

New Holstein, WI 53061

Phone: 800-558-5800

Fax: 920-898-4588

PN 904-183700

062015

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Summary of Contents for M-B MSV

Page 1 Maintenance and Service Manual M-B Multi-Service Vehicle (MSV) MSV Generation Units MSV Divison 1615 Wisconsin Avenue P.O. Box 200 New Holstein, WI 53061 Phone: 800-558-5800 Fax: 920-898-4588 PN 904-183700 062015...
Page 3 ......77 ..........45 ............... 84 ..........46 ............85 ..........47 ............85 ............... 47 ............ 87 ........ 48 ............89 ..........92 M-B Multi-Service Vehicle • 3 • Table of Contents ©2015 M-B Companies Inc. All Rights Reserved...
Page 4 ............97 ..........97 ......101 ............101 ........102 ....... 104 Replacement Parts ........... 107 Appendix ......................... WorkInstructions ..............................M-B Multi-Service Vehicle • 4 • Table of Contents ©2015 M-B Companies Inc. All Rights Reserved...
Page 5 Excessive Speed PUSH TO STOP Travel at Low Speed PULL TO RUN When Turning 390-134607 Always Wear Safety Belt NO RIDERS OR 390-172409 HANGERS ON 390-152996 M-B Multi-Service Vehicle • 5 • Safety ©2015 M-B Companies Inc. All Rights Reserved...
Page 6: General Safety
• • • • THE MANUAL • • Directional Reference • • REQUIRED OPERATOR TRAINING PRE-START-UP SAFETY • • • • • • • • • M-B Multi-Service Vehicle • 6 • Safety ©2015 M-B Companies Inc. All Rights Reserved...
Page 10: Specifications
Vehicle Information INTRODUCTION SPECIFICATIONS Electronic Controls Engine MC50-20 MC38-10 110 @ 2500 RPM 115 @ 2300 RPM MC50-22 MC24-10 Chassis Ground Drive M-B Multi-Service Vehicle • 10 • Vehicle Information ©2015 M-B Companies Inc. All Rights Reserved...
Page 11 Hydraulic System Auxiliary Hydraulics Power Take Off 540 @ 2200 RPM Hitch Capacities Cooling System AC System M-B Multi-Service Vehicle • 11 • Vehicle Information ©2015 M-B Companies Inc. All Rights Reserved...
Page 13 DIMENSIONS NOTE: Overall height and ground clearance is dependant on the radius of the tires. Dimensions given are based on 32 inch radial tires. M-B Multi-Service Vehicle • 13 • Vehicle Information ©2015 M-B Companies Inc. All Rights Reserved...
Page 16 VEHICLE IDENTIFICATION FUSE PROTECTION ATTACHMENT CONTROLS SPEED CONTROLS WIRING 390-157208 SYSTEM POWER CAN NETWORK M-B Multi-Service Vehicle • 16 • Vehicle Information ©2015 M-B Companies Inc. All Rights Reserved...
Page 19 OPERATION...
Page 21: Parking Brake
Float mode Aux 3B On/Off • Aux 3A Left - Aux 1A Right - Aux 1A Trigger Up - Aux 2A Trigger Down - Aux 2B M-B Multi-Service Vehicle • 18 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 41 Faults Screens Front MVEC Faults Screen Rear MVEC Faults Screen Front Control Faults Screen Rear Control Faults Screen M-B Multi-Service Vehicle • 38 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 42 Operation - Attachment Selection Examples The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer. This setup includes adjusting outputs to the optimum levels. Selecting the Ribbon Snow Blower Attachment...
Page 44 Operation - Attachment Selection Examples The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer. This setup includes adjusting outputs to the optimum levels. Selecting the Rear Spreader Attachment Button...
Page 46 Operation - Weight Transfer Example The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer. This setup includes adjusting outputs to the optimum levels. Initial set up of the Weight Transfer feature...
Page 48 NOTE: If temperature is below 10°, turn key ON for 10 seconds, turn key OFF for 10 seconds and then back ON. This will help with starting. ® START-UP PROCEDURE Key Switch ® ® ® M-B Multi-Service Vehicle • 45 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 49 Do not use manually sprayed Ether starting aids. Using a spray type starting aid may cause the air intake to explode and cause personal injury. Intake Air Heater M-B Multi-Service Vehicle • 46 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 51 FRONT ATTACHMENT CONNECTIONS Front Hitch Connections IMPORTANT: For best performance each attachment must be setup by M-B or your authorized MSV dealer prior to use. CAUTION: M-B Multi-Service Vehicle • 48 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 52 Front Power Take Off (PTO) WARNING: Hydraulic Connections ® ® NOTE: The spline (Figure 11) should have a coating of grease before attaching the PTO shaft. M-B Multi-Service Vehicle • 49 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 53 Rear Hydraulic Connections (Optional) ® ® NOTE: Some attachments will require these connections to make them operational. M-B Multi-Service Vehicle • 50 • Operation ©2015 M-B Companies Inc. All Rights Reserved...
Page 55 MAINTENANCE...
Page 57 Maintenance DAILY OR REFUELING Preventative Maintenance Procedure Reference Page FIRST 50 HOURS Preventative Maintenance Procedure 209-157677 M-B Multi-Service Vehicle • 51 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 58 EVERY 50 HOURS OR MONTHLY Preventative Maintenance Procedure Reference Page EVERY 500 HOURS OR 6 MONTHS Preventative Maintenance Procedure M-B Multi-Service Vehicle • 52 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 59: Lubrication Chart
Reference Page 209-157683 209-186012 209-163192 EVERY 2000 HOURS OR 2 YEARS Preventative Maintenance Procedure Reference Page EVERY 5000 HOURS OR 4 YEARS Preventative Maintenance Procedure LUBRICATION CHART M-B Multi-Service Vehicle • 53 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 62 MB 209-157683 MB 209-186012 209-163257 MAINTENANCE WARNING: NOTE: If necessary, the cooler intake can be washed if forced air cleaning is unsuccessful. Cleaning the Cooler Intake CAUTION: M-B Multi-Service Vehicle • 56 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 64: Engine Coolant
ENGINE COOLANT NOTE: The inside of the housing may need cleaning. INTAKE MAINTENANCE WARNING: Air Filter M-B Multi-Service Vehicle • 58 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 65 FUEL SYSTEM MAINTENANCE WARNING: Fuel/Water Separator NOTE: Drain water from the separator more often in cooler temperatures. Fuel Filter WARNING: M-B Multi-Service Vehicle • 59 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 66 • • NOTE: The rear wheel motors do not have parking brakes. It may be easier to access the front wheel motors by lifting the cab. M-B Multi-Service Vehicle • 60 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 71 HYDRAULIC CONNECTIONS HYDRAULIC SYSTEM MAINTENANCE WARNING: System Description Brand Name of Quick Coupler - TEMA IB Series M-B Multi-Service Vehicle • 65 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 72 Draining and Filling the Tank NOTE: The sight glass is best viewed from the left side of the vehicle looking over the cooling fan. Cooling System M-B Multi-Service Vehicle • 66 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 74 BATTERY WARNING: WARNING: Disc Brake WARNING: Battery Electrolyte First Aid • • • • IMPORTANT: In case of internal contact, DO NOT induce vomiting! M-B Multi-Service Vehicle • 68 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 75: Electrical System
ELECTRICAL SYSTEM Protecting Electrical Terminals Charging IMPORTANT: DO NOT fast charge. Charging at high rates will damage or destroy battery. • • • • Battery Charger M-B Multi-Service Vehicle • 69 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 76 Front Electronic Controller NOTE: When replacing relays observe the pin locations. MSV FRONT MVEC FUSES AND RELAY FUSE SIZE RELAY DESCRIPTION 20 A FAN LO 20 A BEACON 20 A WIPPER MOTOR (LOW) 20 A FAN MED 20 A WIPER MOTOR (HI)
Page 77 CAUTION: NOTE: When replacing a relay observe the pin locations. Lable Number Description CB11 CB10 Rear Bladed Fuse and Holders Alaska Option (Bladed Fuse and Holders) M-B Multi-Service Vehicle • 71 • Maintenance ©2015 M-B Companies Inc. All Rights Reserved...
Page 78 ACCESSORY TERMINAL STRIP • • • MSV REAR MVEC FUSES AND RELAY FUSE SIZE RELAY DESCRIPTION 15 A AC CLUTCH 20 A BACK-UP ALARM 20 A REAR PLUG PIN 3 REAR CLEAR ENGINE START REAR PLUG PIN 2 FLOW DIVIDER...
Page 81 SERVICE...
Page 84 TROUBLESHOOTING BRAKES TESTING THE GROUND DRIVE PUMP WARNING: Replacement Part Numbers 202-144080 702-133633 202-144858 M-B Multi-Service Vehicle • 75 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 86 Removal IMPORTANT: the attachments will stop functioning before the ground drive pump starves • GROUND DRIVE PUMP REPLACEMENT • • Location • • • • • M-B Multi-Service Vehicle • 77 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 87 NOTE:The wheel well can be removed without removing the wheel. Removing the wheel is not required but it will provide better access to the front of the engine. M-B Multi-Service Vehicle • 78 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 88 NOTE: The pulley on the engine will be held in place by a second fan belt. Leave the pulley in place. Also, notice the spacer is held in place by a pilot shaft. M-B Multi-Service Vehicle • 79 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 89 IMPORTANT: The openings for the turbo cannot have foriegn material inside. Cover the openings. NOTE: The fan shroud has two edge pieces that and noise reduction. M-B Multi-Service Vehicle • 80 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 93 NOTE: Remember when stepping on the brakes for the brake line was removed from the caliper the brakes need to be bled to remove air. M-B Multi-Service Vehicle • 84 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 95 NOTE: Before replacing the auxillary pump, check for obstruction in hydraulic tank, intank,suction stainer, pinched hose to front To replace the auxilliary pump: WARNING: M-B Multi-Service Vehicle • 86 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 107 Testing NOTE: If the gauge is reading zero for one (not all) of the controlled units, the operation of the coil should be checked. M-B Multi-Service Vehicle • 98 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 110 RADIO AND 12 VDC CONNECTIONS AC Component Testing Component Operation Testing Location AC SYSTEM CAUTION: NOTE: For fastest cooling the fresh air vent should be closed. M-B Multi-Service Vehicle • 101 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 111 TO RGVC SPECIFICATIONS...
Page 113 6-3/4 5/16 27-2/3 46-1/3 72-1/3 100-1/2 1-1/4 101-1/2 1-1/2 Table 2: For Flat-Face “O” Ring Seal (Steel) Fractional Dash Min. Max. Min. Max. (In.) 1-1/4 1-1/2 M-B Multi-Service Vehicle • 102 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 114 When using a male tapered pipe thread with a female straight or parallel pipe thread, maximum values are 50% of those listed in the table. If threaded sealant is used, maximum values shown should be decreased by 25% M-B Multi-Service Vehicle • 103 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 115 K = 0.15 for “lubricated” conditions K = 0.17 for zinc plated and dry conditions K = 0.20 for plain and dry conditions D = Nominal Diameter F = Clamp Load M-B Multi-Service Vehicle • 104 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 116 K = 0.15 for “lubricated” conditions K = 0.17 for zinc plated and dry conditions K = 0.20 for plain and dry conditions D = Nominal Diameter F = Clamp Load M-B Multi-Service Vehicle • 105 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 117 Y = Unknown 10 + 1.5 11.5 Original Length L = 10.0 In. Extension E = 1.5 In. Y = 117 lb In. Final reading on torque wrench M-B Multi-Service Vehicle • 106 • Service ©2015 M-B Companies Inc. All Rights Reserved...
Page 119 APPENDIX Hydraulics MSV SERIAL NUMBERS 9-2052 -- 9-2084 9-2086...
Page 120 GEN 2 AND 3 SINGLE PUMP DIAGRAMS 210-162303 DIAGRAM STEERING 210-162304 DIAGRAM TANK AND COOLING 210-162305 DIAGRAM FRONT HITCH 210-162306 DIAGRAM AUX HYDRAULICS 210-162307 DIAGRAM AUX PUMP 210-162601 DIAGRAM GROUND DRIVE M-B Multi-Service Vehicle ©2014 M-B Companies Inc. All Rights Reserved...
Page 134 MSV 3.5 DUAL PUMP HYDRAULIC SCHEMATICS 210-162306 DIAGRAM, HYD AUX, STD MSV 210-162305 DIAGRAM HYD, FRONT HITCH MSV 210-162303 DIAGRAM STEERING CYLINDER 210-186561 DIAGRAM TANK AND COOLING 210-186560 DIAGRAM MSV3 GROUND DRIVE DP 213-183935K HOSE KIT DUAL PUMP M-B Multi-Service Vehicle ©2014 M-B Companies Inc.
Page 135 213 183935K REV E 6/23/15 HOSE KIT, DUAL PUMP MB PART HOSE ENDS, CRIMPED ON HOSE PRESSURE NYLON HOSE ID" OAL" DESCRIPTION NUMBER LENGTH" RATING PSI SLEEVING MB PART # DESCRIPTION 211 186254 12 12 FFORX ST 213 183950 19.5 6000 PUMP TOP LEFT, REAR B 211 186254...
Page 137 DUAL PUMP MANUAL...
Page 139 Axial Piston Variable Double Pump A22VG Series 40 Instruction manual Replaces: –.– RE 93221-01-B/07.2013 English...
Page 140 The data speciﬁed above serve to describe the product. Should information be provided on use, these are only examples of applications and suggestions. Information from the catalog are not assured properties. The information given does not release the user from the obligation of own judgment and veriﬁcation.
Page 141: Table Of Contents
Contents 3/56 Contents About this documentation Validity of the documentation Required and supplementary documentation Display of information 1.3.1 Safety instructions 1.3.2 Symbols 1.3.3 Designations 1.3.4 Abbreviations Safety instructions About this chapter Intended use Improper use Personnel qualiﬁcations General safety instructions Product-speciﬁc safety instructions Personal protection equipment General instructions on damage to equipment and the product...
Page 142 4/56 Contents Commissioning Initial commissioning 8.1.1 Filling the axial piston unit 8.1.2 Testing the hydraulic ﬂuid supply 8.1.3 Performing functional test Running-in phase Recommissioning after standstill Operation Maintenance and repair 10.1 Cleaning and care 10.2 Inspection 10.3 Maintenance 10.4 Repair 10.5 Spare parts Removal and replacement 11.1 Required tools...
Page 143: About This Documentation
About this documentation 5/56 1 About this documentation 1.1 Validity of the documentation This documentation applies to the following products: Axial piston variable double pump A22VG series 40 This documentation is intended for machine/system manufacturers, ﬁtters and service technicians. This documentation contains important information on the safe and appropriate transport, installation, commissioning, operation, maintenance, removal and simple troubleshooting of the axial piston unit.
Page 144: Display Of Information
6/56 About this documentation 1.3 Display of information Standardized safety instructions, symbols, terms and abbreviations are used so that you can use this documentation to work quickly and safely with your product. To give you a better understanding they are explained in the sections below. 1.3.1 Safety instructions This documentation includes safety instructions in chapter 2.6 “Product-speciﬁc safety instructions”...
Page 145: Designations
About this documentation 7/56 Table 3: Meaning of the symbols Symbol Meaning If this information is disregarded, the product can not be used and/or operated to the optimum extent. ▶ Single, independent step Numbered instruction: The numbers specify that the steps are completed one after the other. 1.3.3 Designations This documentation uses the following designations: Table 4: Designations...
Page 146: Safety Instructions
8/56 Safety instructions 2 Safety instructions 2.1 About this chapter The axial piston unit has been manufactured according to the generally accepted rules of current technology. There is, however, still a danger of personal injury or damage to equipment if this chapter and the safety instructions in this documentation are not complied with.
Page 147: Personnel Qualifications
Safety instructions 9/56 Using the axial piston unit when the exterior pressure is greater than the interior pressure (case pressure) Using the axial piston unit in explosive environments unless the component or machine/system has been certiﬁed as compliant with the ATEX directive 94/9/EC Using the axial piston unit in an aggressive atmosphere Using the axial piston unit in aircraft or space craft 2.4 Personnel qualiﬁcations...
Page 148: Product-Specific Safety Instructions
10/56 Safety instructions permitted in the product documentation, for example in ex-protection applications or in safety-related parts of a control system (functional safety). You may only commission the product if it has been determined that the end product (e.g. machinery or a system) into which the Rexroth products are installed complies with the country-speciﬁc provisions, safety regulations and standards of the application.
Page 149 Safety instructions 11/56 WARNING Danger from suspended loads! Danger to life or risk of injury, damage to equipment! Improper transportation may cause the axial piston unit to fall down lead to injuries e.g. crushing or broken bones or damage to the product. ▶...
Page 150: Personal Protection Equipment
12/56 Safety instructions CAUTION High noise development in operation! Danger of hearing damage, deafness! The noise emission of axial piston units depends on speed, operating pressure and installation conditions. The sound pressure level may rise above 70 dB(A) during normal application conditions. ▶...
Page 151: General Instructions On Damage To Equipment And The Product
General instructions on damage to equipment and the product 13/56 3 General instructions on damage to equipment and the product The following instructions apply for chapters 6 to 14. NOTE Danger from improper handling! Product can be damaged! ▶ Do not expose the product to an impermissible mechanical load. ▶...
Page 152 14/56 General instructions on damage to equipment and the product NOTE Mixing of hydraulic ﬂuids! Product can be damaged! ▶ Before installation, remove all ﬂuids from the axial piston unit to prevent mixing with the hydraulic ﬂuid used in the machine/system. ▶...
Page 153 General instructions on damage to equipment and the product 15/56 NOTE Escaping or spilling hydraulic ﬂuid! Environmental pollution and contamination of the ground water! ▶ Always place a drip tray under the axial piston unit when ﬁlling and draining the hydraulic ﬂuid.
Page 154: Scope Of Supply
16/56 Scope of supply 4 Scope of supply Fig. 1: Axial piston unit Included in the scope of supply are: Axial piston unit as per order conﬁrmation The following parts are also installed on delivery: Protection plug/threaded plug (1) For version with through drive, metallic protection cover and mounting bolts (2) Bosch Rexroth AG, A22VG Series 40, RE 93221-01-B/07.2013...
Page 155: Product Description
Product description 17/56 5 Product description 5.1 Performance description The axial piston variable double pump generates, controls and regulates a hydraulic- ﬂuid ﬂow. It is designed for mobile applications such as construction machinery. Refer to data sheet 93221 and the order conﬁrmation for the technical data, operating conditions and operating limits of the axial piston unit.
Page 156: Functional Description
18/56 Product description 5.2.2 Functional description Pump Torque and rotational speed are applied to the drive shaft (1) by an diesel engine. The drive shaft is connected by splines to the cylinder (8) to set this in motion. With every revolution, the pistons (9) in the cylinder bores execute one stroke whose magnitude depends on the setting of the cradle (11).
Page 157: Product Identification
Product description 19/56 CAUTION The spring feedback feature in the control module is not a safety device The control module can stick in an undeﬁned position due to internal contamination (contaminated hydraulic ﬂuid, abrasion or residual contamination from system components). As a result, the volume ﬂow of the axial piston unit will no longer respond correctly to the operator’s commands.
Page 158: Transport And Storage
20/56 Transport and storage 6 Transport and storage ▶ Always observe the required ambient conditions for transport and storage, see chapter 6.2 “Storing the axial piston unit” on page 22. Notes on unpacking can be found in chapter 7.1 “Unpacking” on page 24. 6.1 Transporting the axial piston unit The transportation options below exist depending on the weight and duration of the transport:...
Page 159 Transport and storage 21/56 You can hoist the axial piston unit as shown in Fig. 4 with the eye bolt screwed into the drive shaft. Fig. 4: Fixing the eye bolt Transport with lifting strap WARNING! Danger from suspended loads! During transport with a lifting device, the axial piston unit can fall out of the lifting strap and cause injuries.
Page 160: Storing The Axial Piston Unit
22/56 Transport and storage 6.2 Storing the axial piston unit Requirement The storage areas must be free from corrosive materials and gases. To prevent damage to the seals, ozone-forming equipment (e.g. mercury-vapor lamps, high voltage equipment, electric motors, sources of electrical sparks or electrical discharges) must not be operated in storage areas.
Page 161 Transport and storage 23/56 After removal If a removed axial piston unit is to be stored, it must be preserved against corrosion for the duration of storage. The following instructions only refer to axial piston units which are operated with a mineral-oil based hydraulic ﬂuid.
Page 162: Installation
24/56 Installation 7 Installation Prior to installation, the following documents must be ready at hand: Installation drawing for axial piston unit (can be obtained from your responsible contact person at Bosch Rexroth) Hydraulic schematic for the axial piston unit (in the installation drawing) Hydraulic schematic for the machine/system (available from the machine/system manufacturer) Order conﬁrmation (contains the order-related technical data for your axial...
Page 163 Installation 25/56 ▶ The case drain ﬂuid in the housing must be directed to the reservoir via the highest case drain port. Use the line size which is appropriate for the port. ▶ Avoid using a check valve in the reservoir line. ▶...
Page 164: Installation Position
26/56 Installation 7.3 Installation position The following installation positions are permissible. The shown piping layout illustrates the basic layout. If it is not possible to ﬁll the stroking chambers via X to X in the ﬁnal installation position, this must be done prior to installation. In order to prevent unexpected activation behavior and damage, the stroking chambers must be air bled via ports X or X...
Page 165: Above-Reservoir Installation
Installation 27/56 Air bleed port Minimum required spacing to reservoir bottom (100 mm) Suction port When designing the reservoir, ensure adequate distance between the Reservoir port (case drain) suction line and the case drain line. Baﬄe (baﬄe plate) This prevents the heated, return ﬂow Minimum required immersion depth from being drawn directly back into t min...
Page 166: Installing The Axial Piston Unit
28/56 Installation Filling / air bleed Minimum required spacing to reservoir bottom (100 mm) Air bleed port Maximum permissible suction height S max (800 mm) Suction port When designing the reservoir, ensure adequate distance between the Reservoir port (case drain) suction line and the case drain line. Baﬄe (baﬄe plate) This prevents the heated, return ﬂow Minimum required immersion depth...
Page 167: Dimensions
Installation 29/56 The direction of rotation as speciﬁed on the name plate determines the direction of rotation of the axial piston unit as viewed on the drive shaft, see chapter 5.3 “Product identiﬁcation” on page 19. 7.4.2 Dimensions The installation drawing contains the dimensions for all connections and ports on the axial piston unit.
Page 168: Installation With Coupling
30/56 Installation 7.4.4 Installation with coupling The method for installing the axial piston unit with a coupling is described below: NOTE! Danger from improper handling! Product can be damaged! ▶ Do not install the coupling hub onto the drive shaft of the axial piston unit by striking it.
Page 169: Installation With Cardan Shaft
Installation 31/56 For attachment via gear No gearing forces higher than the permissible axial and radial forces are to act on wheel or helically-toothed the shaft, if necessary the gear wheel must be supported separately at the gearbox shaft output. 7.4.6 Installation with cardan shaft To connect the axial piston unit to the diesel engine via a cardan shaft: Position the axial piston unit close to the speciﬁed installation location.
Page 170 32/56 Installation Fig. 12: Removing transport protection 1 Protection plug/threaded plug 2 Protection cover Ports intended for connecting lines are covered by protection plugs or threaded plugs, which serve as transport protection. All ports required for functional operation must be connected (see Table 10 “Ports A22VG series 40 series 40” on page 36).
Page 171: Hydraulically Connecting The Axial Piston Unit
Installation 33/56 7.4.8 Hydraulically connecting the axial piston unit NOTE Insuﬃcient suction pressure! Generally, a minimum permissible suction pressure at port “S” is speciﬁed for axial piston pumps with boost pump in all installation positions. If the pressure at port “S” drops below the speciﬁed values, damage may occur which may lead to the axial piston pump being damaged beyond repair! ▶...
Page 172 34/56 Installation Drain line – Always route the reservoir lines so that the case is constantly ﬁlled with hydraulic ﬂuid and to ensure that no air gets through the shaft seal even during extended standstill periods. – The case pressure must not exceed the limit values listed for the axial piston unit in the data sheet under any operating conditions.
Page 173 Installation 35/56 Port overview Fig. 13: Port overview A22VG, EP control with boost pump Fig. 14: Port overview A22VG, HT control with boost pump RE 93221-01-B/07.2013, A22VG Series 40, Bosch Rexroth AG...
Page 174 36/56 Installation Table 10: Ports A22VG series 40 Ports State [bar] A, B Service line port Suction port (only with boost pump) Drain port Air bleed Control pressure (upstream of oriﬁce, only HP, HW, EP and ET) Stroking chamber pressure Control pressure (upstream of oriﬁce, HT only) Pilot pressure, outlet (only with DA control valve) Boost pressure, inlet...
Page 175 Installation 37/56 Table 11: Tightening torques of the female threads and threaded plugs Maximum permissible Ports Required tightening torque of tightening torque of the hexagon socket of the the threaded plugs M Standard Thread size female threads M threaded plugs G max ISO 11926 5/16-24 UNF-2B...
Page 176: Electrically Connecting The Axial Piston Unit
38/56 Installation 7.4.9 Electrically connecting the axial piston unit NOTE Short circuit in event of penetrating hydraulic ﬂuid! Fluid can penetrate the product and cause a short circuit! ▶ Do not install axial piston units with electric components (e.g. electric controls, sensors) in a reservoir below the ﬂuid level (inside-reservoir installation).
Page 177: Commissioning
Commissioning 39/56 8 Commissioning WARNING Danger while working in the danger zone of a machine/system! Danger to life, risk of injury or serious injuries! ▶ Pay attention to and rectify potential danger sources before operating the axial piston unit. ▶ Nobody may stand in the danger zone of the machine/system.
Page 178 40/56 Commissioning Continuous suction or pressure ﬁltration must be provided by the customer for the boost pressure ﬂuid fed in at port G (or G on the version with DA control valve). At very high hydraulic ﬂuid temperatures (+90 °C to maximum +115 °C), a cleanliness level of at least 19/17/14 according to ISO 4406 is necessary.
Page 179: Testing The Hydraulic Fluid Supply
Commissioning 41/56 8.1.2 Testing the hydraulic ﬂuid supply The axial piston unit must always have a suﬃcient supply of hydraulic ﬂuid. For this reason, the supply of hydraulic ﬂuid must be ensured at the start of the commissioning process. When you test the hydraulic ﬂuid supply, constantly monitor the noise development and check the hydraulic ﬂuid level in the reservoir.
Page 180: Running-In Phase
42/56 Commissioning 8.2 Running-in phase NOTE Damage to equipment by insuﬃcient viscosity! An increased hydraulic ﬂuid temperature may reduce the viscosity values by too much and damage the product! ▶ Monitor the operating temperature during the running-in phase, e.g. by measuring the case drain temperature.
Page 181: Operation
Operation 43/56 9 Operation The product is a component which requires no settings or changes during operation. For this reason, this chapter of the manual does not contain any information on adjustment options. Use the product only within the performance range provided in the technical data.
Page 182: Inspection
44/56 Maintenance and repair 10.2 Inspection In order to enable long and reliable operation of the axial piston unit, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions: Table 12: Inspection schedule Task to be carried out Interval...
Page 183: Repair
Maintenance and repair 45/56 10.4 Repair Bosch Rexroth oﬀers a comprehensive range of services for the repair of Rexroth axial piston units. Repairs on the axial piston unit and its ﬁttings may only be performed by service centers certiﬁed by Bosch Rexroth. ▶...
Page 184: Removal And Replacement
46/56 Removal and replacement 11 Removal and replacement 11.1 Required tools Removal can be performed with standard tools. No special tools are necessary. 11.2 Preparing for removal Decommission the entire system as described in the instruction manual for the machine or system. –...
Page 185: Disposal
Disposal 47/56 12 Disposal Careless disposal of the axial piston unit, the hydraulic ﬂuid and the packaging material could lead to pollution of the environment. Observe the following points when disposing of the axial piston unit: Completely empty the axial piston unit. Dispose of the axial piston unit and packaging material in accordance with the national regulations in your country.
Page 186: Troubleshooting
48/56 Troubleshooting 14 Troubleshooting Table 13 and may help you when troubleshooting. The Table makes no claim for completeness. In practical use, problems which are not listed here may also occur. 14.1 How to proceed for troubleshooting ▶ Always act systematically and purposefully, even under pressure of time. Random and imprudent removal and changing of settings could result in the inability to ascertain the original failure cause.
Page 187: Malfunction Table
Troubleshooting 49/56 14.2 Malfunction table Table 13: Axial piston unit malfunction table Malfunction Possible cause Remedy Unusual noises Drive speed too high. Machine/system manufacturer. Wrong direction of rotation. Ensure correct direction of rotation. Insuﬃcient suction conditions, e.g. air in Machine or system manufacturer the suction line, insuﬃcient diameter of the (e.g.
Page 188 50/56 Troubleshooting Table 13: Axial piston unit malfunction table Malfunction Possible cause Remedy No or insuﬃcient pressure Faulty mechanical drive Machine/system manufacturer. (e.g. defective coupling). Drive power too low. Machine/system manufacturer. Insuﬃcient suction conditions, e.g. air in Machine or system manufacturer the suction line, insuﬃcient diameter of the (e.g.
Page 189: Technical Data
Technical data 51/56 15 Technical data The permissible values of the technical data of your axial piston unit can be found in data sheet 93221. The data sheet can be found on the Internet under www.boschrexroth.com/various/utilities/mediadirectory/ index.jsp?&language=en-GB Further information can be found in the online product catalog Mobile Hydraulics: www.boschrexroth.com/axial-piston-pumps The order-related technical data of your axial piston unit can be found in the order conﬁrmation.
Page 190: Alphabetical Index
52/56 Alphabetical index 16 Alphabetical index ▶ A ▶ I Abbreviations Identiﬁcation Above-reservoir installation Inspection Assembly Installation – Completing ▶ B – General instructions Below-reservoir installation – On a gearbox – Preparation ▶ C – With cardan shaft Care – With coupling Circuit Installation conditions –...
Page 191 Alphabetical index 53/56 ▶ R Recommissioning – after standstill Removal – Performing – Preparing Repair Replacement Required documentation Retainer plate Running-in phase ▶ S Safety instructions – General – Product-speciﬁc – Signal word Scope of supply Slipper pad Solenoid position –...
Page 192 54/56 Bosch Rexroth AG, A22VG Series 40, RE 93221-01-B/07.2013...
Page 193 55/56 RE 93221-01-B/07.2013, A22VG Series 40, Bosch Rexroth AG...
Page 194 Bosch Rexroth AG Mobile Applications Glockeraustraße 4 89275 Elchingen Germany Tel.: +49-7308-82-0 info.ma@boschrexroth.de www.boschrexroth.com Your local contact can be found at: www.boschrexroth.com/addresses Subject to change Printed in Germany RE 93221-01-B/07.2013...
Page 195 WIAS 0084...
Page 197 M-B Companies Work Instruction Title: MSV Wheel Motor Installation Document #: WIAS 0084 Prepared By: Todd Meyer Approved By: Approval Date: 09/11/2014 Revised By: Revision Date: Revision: MSV Wheel Motor Installation Turn supplied studs into two of the bottom bolt holes.
Page 199 WIAS 0081...
Page 217 WIAS 0083...
Page 225 PARKING BRAKE...
Page 237 PLUS 1 MSV GEN 3...
Page 241 Fault Code Information J1587 PID( J1939 FAUL SPN(S SID( EFFEC REASO CODE {FMI} {LAMP Engine may not start. EleC"tronic Control Module Critical Internal Failure - Bad S254 {FMI lntenigent Device or Component. Error internal to the {Red} {12} {12) electronic control module (ECM) related to memory hardware failures or internal ECM voltage supply circuits.
Page 242 J1587 FAUL PID(P) J1939 CODE SID(S SPN(S) (LAMP } {FMI) (FMI} REASON EFFECT P108 Barometric Pressure Sensor Circuit - Voltage Above Engine power derate. {Amber} Normal or Shorted to High Source. High signal volt- age detected at barometric pressure circuit. P108 Barometric Pressure Sensor Circuit - Voltage Below Engine power derate.
Page 243 J158 J1939 FAULT CODE SPN(S) PID(P) { LAMP} {FMI } REASON EFFECT SID(S) {FMI } 8005 Injector Solenoid Driver Cylinder 5 Circuit • Current Current to injector is shut off. Engine can possibly {Amber) Below Normal or Open Circuit. Current detected at misfire or run rough.
Page 244 J158 FAULT J1939 PIDn CODE SPN(S) SID S EFFECT {FMI } {FMI } REASON { LAMP} Engine Oil Level Sensor Circuit - Voltage Below Oil level sensor operation will {Amber} Normal or Shorted to Low Source. The engine oil disabled. level sensor has detected an internal failure.
Page 245 J1587 FAULT J1939 PIDn CODE SPN(S) SID S (FMI } EFFECT { LAMP} (FMI} REASON S064 Engine Camshaft Speed/Position Sensor - Data Er- Engine can run rough. Possibly poor starting capa- (Amber} ratic, Intermittent, or Incorrect. The ECM has de- tected bility.
Page 246 J1587 PID(P) FAULT J1939 CODE SID(S) SPN(S) {LAMP) {FMI } {FMI) REASON EFFECT Exhaust Gas Recirculation Valve Delta Pressure - EGR valve actuation will be disabled. 1866 P411 {Amber) Data Erratic, Intermittent, or Incorrect. An error in the EGA delta pressure signal was detected at ini- tial key-on or the sensor failed the auto-zero test.
Page 247 J1587 PID(P) FAUL J1939 SPN(S) CODE {FMI} REASON EFFECT 1 5 > {LAMP} 8327 1968 Aftertreatment Exhaust Gas Temperature 2 - Data Valid Active aftertreatment diesel particulate filter regen- {Amber} but Above Normal Operational Range - Mod- erately eration will be disabled. Severe Level.
Page 248 J1 587 PID(P) J1939 FAULT SID(S) SPN(S) CODE {FMI} {FMI} { LAMP) REASON EFFECT Turbocharger 1 Speed - Data Valid but Above Nor- Engine power derate to lower the turbocharger 2288 mal Operational Range - Least Severe Level. High speed. {None) turbocharger speed has been detected ECM.
Page 249 J158 FAUL J1939 SPN(S) SllS) PID(P) CODE {FMI } REASON EFFECT {LAMP} 2387 S027 VGT Actuator Driver Circuit (Motor) - Mechanical VGT travel may be limited. {Amber) System Not Responding Properly or Out of Adjust- ment. The smart VGT controller has detected incor- rect closed stop limits, or the VGT is unable to move to the position.
Page 250 J158 J1939 FAUL SPN(S) PID(P) {FMI} CODE REASON EFFECT SllS) { LAMP) 3481 {F I} Aftertreatment Fuel Rate - Data Valid but Above None on performance. Normal Operational Range • Moderately Severe 2778 {16) (Amber) Level 2961 Exhaust Gas Recirculation Temperature - Data Valid Slight fueling derate to bring EGA temperature un- but {None) Above Normal Operational Range - Least Se- der the maximum limit.
Page 251 PLUS 1 FRONT FAULTS...
Page 291 PLUS 1 FRONT FAULTS MVEC...
Page 323 PLUS 1 REAR FAULTS...
Page 367 PLUS 1 REAR FAULTS...
Page 399 MSV FLOW DIAGRAM...
Page 401 MSV AUX...

M-B MSV Maintenance And Service Manual

1 About this Documentation

2 Safety Instructions

3 General Instructions on Damage to Equipment and the Product

4 Scope of Supply

5 Product Description

6 Transport and Storage

7 Installation

8 Commissioning

9 Operation

10 Maintenance and Repair

11 Removal and Replacement

12 Disposal

13 Extension and Conversion

14 Troubleshooting

15 Technical Data

16 Alphabetical Index

Quick Links

Summary of Contents for M-B MSV

Table of Contents