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Summary of Contents for WALTERSCHEID SW44
- Page 1 INSTRUCTION MANUAL Special tool SW44 Disassembly tool for the repair of joints 1697108 Read and observe this Edition 04.2024 instruction manual before first Printed in Germany machine start-up! Retain for future use!
- Page 2 Formal remarks to this instruction manual Date of issue: Edition 04.2024 Copyright WALTERSCHEID GMBH, 2024 All rights are reserved. Reprinting, even in part, is only permitted with the consent of WALTERSCHEID GMBH. Printed in Germany Read and observe this...
- Page 3 Preface Dear customer, You have chosen a top quality product from the wide product range of WALTERSCHEID GMBH. We thank you for the confidence you have shown in us. Upon receiving the special tool, check to ensure that it has...
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Page 4: Table Of Contents
CONTENTS Contents Information for the user ..................6 Purpose of this document ..................... 6 Location information in the instruction manual ..............6 Presentation modes ......................6 Terms used ........................... 7 Safety instructions ..................... 8 Safety awareness at work ..................... 8 Organisational steps to be taken................... - Page 5 8.1.3 Inspection criteria for hydraulic hoses lines ............. 53 Oil level & oil changes ......................54 EC Declaration of Conformity ................55 10 Spare part list ....................56...
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Page 6: Information For The User
INFORMATION FOR THE USER Information for the user The chapter Notes for the user provides information on the use of the instruction manual. Purpose of this document This instruction manual: • explains how to operate and maintain the special tool. •... -
Page 7: Terms Used
Hazard ... the source of a possible injury or damage to health. Manufacturer ... the company WALTERSCHEID GMBH. Control devices ... the component that is directly actuated by the operator e.g. by applying pressure. An control device may be a... -
Page 8: Safety Instructions
SAFETY INSTRUCTIONS Safety instructions This chapter contains important information for the owner and the operator regarding the safe and trouble-free operation of the special tool. Observe all of the safety instructions in this instruction manual! Most accidents are caused by the simplest safety rules not being observed. -
Page 9: Organisational Steps To Be Taken
Organisational steps to be taken The instruction manual: • must always be kept in the location where the special tool is used, • must always be freely available to the operator and maintenance personnel. 2.2.1 Obligations on the part of the operating company The owner/operator is obliged: •... -
Page 10: Obligations Of The Operator
SAFETY INSTRUCTIONS Obligations of the operator 2.2.2 Before starting work, all persons entrusted to work with/on the special tool are required to: • to observe the national, generally applicable regulations for employee protection, accident prevention and environmental protection, • read and observe the chapter "Basic safety instructions", starting on page 15 of this instruction manual, •... -
Page 11: Qualification Of Persons
Qualification of persons 2.2.3 Only trained and instructed persons may work with/on the special tool. The owner/operator must clearly define and allocate the operating, maintenance and servicing tasks and responsibilities. A person in training may only work with/on the special tool under the supervision of an experienced person. - Page 12 SAFETY INSTRUCTIONS Personnel A person A specifically A person with specially instructed specialist training in trained for the person this field (technical workshop) Task Loading/transport Putting into operation Setting-up/preparation Operation Cleaning, servicing and maintaining Troubleshooting and error rectification Dispose Legend: X..permitted --..not permitted...
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Page 13: Product Safety
Product safety 2.3.1 Using the special tool safely The special tool should be operated by one person only, with no one else present in the danger zone of the tool during operation. Observe the chapter "Danger zone and danger points", page 27. Safety devices and safeguards 2.3.2 •... -
Page 14: Spare Parts And Parts Subject To Wear And Tear As Well As Auxiliary Material
SAFETY INSTRUCTIONS Spare parts and parts subject to wear and tear as well as auxiliary material 2.3.4 Replace without undue delay any components not in perfect condition. Only use original parts from the manufacturer or parts approved by the manufacturer. In the case of the use of spare and wearing parts from third manufacturers it is not guaranteed that they have been designed and fabricated in line with stress and strain and safety requirements. -
Page 15: Basic Safety Instructions
Basic safety instructions Basic safety instructions: • are generally applicable for the safe operation of the special tool, • are grouped together in the following sub-chapters. General safety and accident prevention instructions 2.4.1 • Besides the safety notes in this chapter, observe also the generally applicable national safety and accident prevention regulation! •... -
Page 16: Hydraulic System
SAFETY INSTRUCTIONS Hydraulic system 2.4.3 The hydraulic system is under high pressure. • Before working on the hydraulic system: ο depressurise the hydraulic system, ο disconnect the hydraulic system from the external power source. • Have the hydraulic hoses lines inspected by a professional at least once a year to ensure that it is in good working order! •... -
Page 17: Cleaning, Servicing And Maintaining
Cleaning, servicing and maintaining 2.4.4 • Perform the designated cleaning, maintenance and servicing tasks on schedule! • Any mechanical, hydraulic or pneumatic residual energy can trigger unexpected movements of the special tool! Beware of the presence of residual energies in the special tool when performing maintenance and service. -
Page 18: Action-Related Safety Instructions And Important Information
SAFETY INSTRUCTIONS Action-related safety instructions and important information In the instruction manual there are action-related safety instructions and important information. Signal words and symbols are used to make it possible to recognise action- related safety instructions and important information at a glance. -
Page 19: Important Information
CAUTION CAUTION identifies a possible hazard with a low risk which can result in slight or medium physical injury or damage to property if it is not avoided. In the event of non-observance of safety instructions identified with 'CAUTION', under certain circumstances slight or medium physical injury or damage to property threaten. -
Page 20: Warnings And Instruction Hints
SAFETY INSTRUCTIONS Warnings and instruction hints Warnings 2.6.1 The special tool has warning signs on it. Warning signs indicate danger points on the special tool and warn of residual risks which can arise under certain circumstances or in conjunction with certain actions. Always keep these warnings in clean and clearly legible condition! Replace illegible warnings and instruction hints. - Page 21 Direct third persons to leave the danger zone of the special tool before moving the hydraulic cylinder." Order number and explanation Warning SW44/SW45-030 Read and observe the instruction manual and safety instructions before commissioning the special tool!
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Page 22: Placement Of The Warnings And Instruction Hints
SAFETY INSTRUCTIONS Order number and explanation Warning SW44/SW45-030 Risk of crushing injuries to fingers or hand, caused by accessible moving parts of the machine! This hazard can cause extremely severe injuries with amputation of body parts. • Never reach into the danger point while machine parts are able to move. -
Page 23: Dangers In The Event Of Failure To Observe The Safety And Warning Instructions
Dangers in the event of failure to observe the safety and warning instructions Failure to observe the safety instructions and warnings can cause: • hazards for persons, the environment and the special tool, such as: ο Hazard of persons due to non-secured working areas, ο... -
Page 24: Scope Of Delivery / Scope Of Equipment
SCOPE OF DELIVERY / SCOPE OF EQUIPMENT Scope of delivery / scope of equipment Fig. 2... - Page 25 (1) Rack (2) Hydraulic hand pump (3) Pressure hose (4) Screw connection (5) Pusher (6) Ejector (7) Retainer mandrel (8) Tommy screw (9) Hydraulic cylinder, single-acting (10) Pusher support (11) Screw connection (12) Clamping spatula (journal guiding tool)
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Page 26: Product Description
This is the best way to familiarise yourself with the special tool. Intended use WALTERSCHEID Special Tool SW44 is a hydraulically assisted disassembly tool. It is intended exclusively for use by qualified personnel in the removal of needle bearing... -
Page 27: Danger Zone And Danger Points
Danger zone and danger points During the hydraulically assisted removal of a bearing bush from a yoke, the danger zone is located between the yoke, which is held by the retainer mandrel, and the pusher. Do not reach into the danger zone during the hydraulic movement of the hydraulic cylinder. -
Page 28: Technical Data
PRODUCT DESCRIPTION Technical data Ejector SW44: Weight: Dimensions • Length • Width • Height Manually actuated hydraulic pump: Weight: Dimensions • Length • Width • Height Hydraulic oil: CH 15 V Maximum operating bar 400 pressure: Total oil volume: cm³ 185... -
Page 29: Conformity
Conformity The WALTERSCHEID Special Tool SW44 for the removal of bearing bushes from connecting, inboard and double yokes of agricultural PTO driveshafts meets the essential safety and health requirements of the following directive and standards: • Directive 2006/42/EC • EN ISO 12100:2010 •... -
Page 30: Initial Commissioning
INITIAL COMMISSIONING Initial commissioning The special tool should only be operated using the manufacturer-supplied hydraulic hand pump which is described in chapter 3 Scope of delivery / scope of equipment of this instruction manual. Check the oil level of the hydraulic hand pump. If necessary, fill up hydraulic oil CH 15 V. -
Page 31: Removing Bearing Bushes From Standard Joints Up To W2500 / P500
Removing bearing bushes from standard joints up to W2500 / P500 Setting up the special tool Fig. 5 1. Set the special tool (1) down next to a vice (2). 2. Clamp ejector (3) in vice (2). → The special tool is set up. -
Page 32: Removing Bearing Bushes
REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 Removing bearing bushes Fig. 6 (1) Ejector for needle bearing bushes (2) Hydraulic cylinder, single-acting (3) Pusher support (4) Tommy screw (5) Retainer mandrel (6) Storage for pusher (7) Hydraulic pump (8) Hand lever (9) Drain valve, designed as a handwheel. - Page 33 Fig. 7 (1) Connecting yoke (2) Cross kit (3) Bearing bushes, fitted on cross journal (4) Circlip (5) Inboard yoke (A) Drift punch SW28 for needle bearing bushes Order no. 1350300 Fig. 8 WARNING Eye injuries due to ejection of dirt or paint particles during removal of bearing bushes.
- Page 34 At all stages of the bearing bush removal process, only use the special tool in the manner shown and described. The series of images shows the proper work sequences for removing bearing bushes with the SW44 special tool; the text provides the necessary instructions. 1. Select appropriate drift punch (A).
- Page 35 4. Remove all circlips. Fig. 10 → Joint is prepared for removal of bearing bushes. Fig. 11...
- Page 36 REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 5. Select appropriate pusher. Fig. 12 6. Position pusher (1) in pusher holder (2). 7. Unscrew the tommy screws (3) of the retainer mandrels (4) and position the retainer mandrels with the groove up so that they can support the universal joint (Fig.
- Page 37 8. Set the universal joint in retainer mandrels and slide both retainer mandrels against the bearing bushes. Fig. 14 9. Position the universal joint opposite the pusher as shown. FG max. 350 N 10. Tighten the tommy screws so that the retainer mandrels lightly touch the bearing bushes and securely immobilise the yoke.
- Page 38 REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 18. Actuate the hand pump and push the yoke up until it rests against the cross kit. → Both bearing bushes are now pushed part of the way out of the yoke. Fig.
- Page 39 Risk of damage to the cross journals and bearing needles of the bearing bushes when removing bearing bushes from the yoke by striking with a mallet. Fig. 21 Fig. 22 shows how the clamping spatula works. The clamping spatula pushes both the gasket and the cross journal aside slightly.
- Page 40 REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 The adjacent figure shows the fully ejected bearing bush. 26. Open the drain valve on the hand pump. Fig. 24 27. Unscrew one tommy screw so that the one retainer mandrel releases the universal joint.
- Page 41 33. Remove the yoke. Fig. 27 34. Fit the retainer mandrels as shown. Fig. 28 35. Secure the yoke between retainer mandrels as shown and align it with the pusher. Fig. 29...
- Page 42 REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 36. Actuate the hand pump and push the yoke up until it rests against the cross kit. → The bearing bush is partly ejected from the yoke. Fig. 30 37.
- Page 43 40. Insert the clamping spatula into the gap as shown in Fig. 20 and Fig. 22. 41. Actuate the hand pump and push the bearing bush all the way out. Fig. 33 42. Unscrew one tommy screw so that the one retainer mandrel releases the universal joint.
- Page 44 REMOVING BEARING BUSHES FROM STANDARD JOINTS UP TO W2500 / P500 44. Insert the clamping spatula into the gap as shown in Fig. 20 and Fig. 22. 45. Actuate the hand pump and push the bearing bush all the way out. Fig.
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Page 45: Removing Bearing Bushes From Standard Joints Of Sizes W2600 / P600 And Up And From Wide-Angle Joints (All Sizes)
Removing bearing bushes from standard joints of sizes W2600 / P600 and up and from wide-angle joints (all sizes) Fig. 38 (1) Ejector for needle bearing bushes (2) Hydraulic cylinder, single-acting (3) Pusher support (4) Tommy screw (5) Retainer mandrel (6) Storage for pusher (7) Hydraulic pump (8) Hand lever... - Page 46 REMOVING BEARING BUSHES FROM STANDARD JOINTS OF SIZES W2600 / P600 AND UP AND FROM WIDE-ANGLE JOINTS (ALL SIZES) Fig. 39 (1) Wide-angle connecting yoke (2) Wide-angle cross kit (3) Wide-angle double yoke (4) Wide-angle inboard yoke (5) Circlip (6) Circlip (7) Round plate (8) Lubricating nipples (9) Lubrication hose...
- Page 47 The proper work sequences for the removal of bearing bushes from standard joints of sizes W2600 / P600 and up and from wide-angle joints (all sizes) using the SW44 special tool is essentially identical to the work sequences for bearing bushes of standard joints up to W2500 / P500.
- Page 48 REMOVING BEARING BUSHES FROM STANDARD JOINTS OF SIZES W2600 / P600 AND UP AND FROM WIDE-ANGLE JOINTS (ALL SIZES) 5. Select appropriate pusher. Fig. 42 6. Position pusher (1) in pusher holder (2). 7. Unscrew the tommy screws (3) of the retainer mandrels (4) and position the retainer mandrels with the groove up so that they can support the universal...
- Page 49 Fig. 44 8. Set the ejector down onto the joint from above as shown and slide both retainer mandrels against the bearing bushes. 9. Position the joint opposite the pusher as shown. 10. Tighten the tommy screws so that the retainer mandrels lightly touch the bearing bushes and securely immobilise the yoke.
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Page 50: Cleaning, Servicing And Maintaining
CLEANING, SERVICING AND MAINTAINING Cleaning, servicing and maintaining During cleaning, maintaining and servicing observe in addition the hints in the chapters: • "Obligations of the operator", on page 10, • "Qualification of persons", on page 11, • "Basic safety instructions", from page 15, •... - Page 51 • Ensure that the hydraulic hoses lines are correctly connected. • Regularly check all hydraulic hoses lines and couplings for damage and contamination. • Have the hydraulic hoses lines inspected by a professional at least once a year to ensure that it is in good working order.
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Page 52: Marking Of Hydraulic Hoses Lines
CLEANING, SERVICING AND MAINTAINING Marking of hydraulic hoses lines 8.1.1 The label on the fitting (Fig. 45) provides the following information: (1) Manufacturer identification of the hydraulic hose line (XXX) (2) Date of manufacture of the hydraulic hose line (23/10 = year / month = October 2023) Fig. -
Page 53: Inspection Criteria For Hydraulic Hoses Lines
Inspection criteria for hydraulic hoses lines 8.1.3 For your own safety: Replace hydraulic hoses lines immediately in case of any of the following faults: • Damage to the outside layer down to the lining (e.g. due to chafing, cuts, cracks). •... -
Page 54: Oil Level & Oil Changes
CLEANING, SERVICING AND MAINTAINING Oil level & oil changes • Check the oil level of the hydraulic hand pump before initial commissioning and regularly thereafter. Hydraulic oil CH 15 V, fill volume 185 cm³. • Change the oil as needed but at least once a year. 1. -
Page 55: Ec Declaration Of Conformity
WALTERSCHEID GmbH Hauptstraße 150 53797 Lohmar / Germany Description and identification of the machinery: Designation: WALTERSCHEID special tool for removing needle bearing bushes from connecting, inboard and double yokes of agricultural PTO driveshafts during universal joint repair. Type: SW44... -
Page 56: Spare Part List
Screw connection 16x2P 4 - 11 SW44-004-011 Pusher set SW44-012 Supplement 1010 SW44-014 Pressure hose SW44-015 Set fixture SW44-016 Cylinder SW44-017 Screw connection 16x2Z 18 - 19 SW44-018-019 Retainer mandrel set SW44-020 Tommy screw SW44-022 Holder SW44 SW44/SW45-030 Decal sticker set...
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