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HBM GP Gunter Papenburg BG 110 Repair Manual

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Repair Manual
Graders BG 110 / 130 / 160 / 190 / 240

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  • Page 1 Repair Manual Graders BG 110 / 130 / 160 / 190 / 240...

  • Page 2: Copyright

    Copyright © Copyright © GP Günter Papenburg AG BT Nordhausen Rothenburgstr. 20 99734 Nordhausen. Germany Telephone: +49 3631 695-0 Telefax: +49 3631 695-275 Internet: www.gp-papenburg.de Country of origin: Made in Germany Document no.: Forwarding this repair manual, copying and duplication, even excerpts, utilization and notification of the contents without express approval from is not permitted.

  • Page 3: Table Of Contents

    Contents Contents Copyright © ............................. 2 Contents ............................3 Overview of Illustrations ....................5 General Instructions ....................... 12 Notes on the Repair Manual ..................12 Liability Limitation ......................12 Qualified Personnel ......................12 Intended Use ........................12 Safety Instructions ......................13 Specific safety information and symbols used ............
  • Page 4 Contents 5.1.7.2 Assembling draw bar on ball bearing slewing gear ............58 Cylinder assemblies ....................... 69 5.2.1 Replacing slewing cylinder ....................69 5.2.1.1 Dismounting slewing cylinder ................... 70 5.2.1.2 Mounting slewing cylinder ....................74 5.2.2 Replacing lifting cylinder ....................80 5.2.2.1 Dismounting lifting cylinder ....................

  • Page 5: Overview Of Illustrations

    Overview of Illustrations Overview of Illustrations Fig. 1 Grader BG 110 / BG 130 ....................18 Fig. 2 Grader BG 160 / BG 190 ....................19 Fig. 3 Grader BG 240 ......................20 Fig. 4 Rear rippers, draw bar, swivelling bridge and cylinder assemblies......21 Fig.
  • Page 6 Overview of Illustrations Fig. 54 Adjust tooth face clearance ..................65 Fig. 55 Depending on tooth face clearance – tighten screws ..........66 Fig. 56 Positioning the hardness step to the pinion ..............67 Fig. 57 Separate slewing gear motor from grader ..............68 Fig.
  • Page 7 Overview of Illustrations Fig. 110 Insert lock (locking cylinder) ..................111 Fig. 111 Press lock (locking cylinder) ..................111 Fig. 112 Secure lock (locking cylinder) ..................112 Fig. 113 Loosen the screwed connections on the BG 110 ............113 Fig. 114 Loosen depth indicator on left console ...............
  • Page 8 Overview of Illustrations Fig. 166 All hex screws with Loctite on sealing cover below ............ 166 Fig. 167 Tighten all screws on the sealing cover below ............167 Fig. 168 Tighten all if necessary on the sealing cover below ........... 168 Fig.
  • Page 9 Overview of Illustrations Fig. 222 Remove and close hose lines..................211 Fig. 223 Push palettes under front axle ..................212 Fig. 224 Loosen hex nut from the axle ..................213 Fig. 225 Knock axle out of the front axle .................. 214 Fig.
  • Page 10 Overview of Illustrations Fig. 278 Tandem oil change - fill opening................. 270 Fig. 279 Tandem oil change - drain opening ................270 Fig. 280 Oil change wheel hubs ....................271 Fig. 281 Oil change wheel hubs - lock screws ................. 271 Fig.
  • Page 11 Overview of Illustrations Fig. 334 Insert differential in insert shaft on left axle carrier ............. 306 Fig. 335 Screw in screws on the left axle carrier to the differential.......... 307 Fig. 336 Insert right axle carrier with insert shaft into differential ..........308 Fig.

  • Page 12: General Instructions

    General Instructions General Instructions Notes on the Repair Manual This repair manual applies only in combination with the original operating and maintenance instructions that were a component of the scope of delivery. This repair manual describes the disassembly and assembly of the draw bar with cylinders, the swivelling bridge as well as the rear mounted ripper for the purpose of eliminating malfunctions and overhauling.

  • Page 13: Safety Instructions

    Safety Instructions Safety Instructions Specific safety information and symbols used In the following repair instructions, specific safety information is provided in order to reference the additional risks that cannot be avoided when operating the grader. These residual risks imply dangers to persons Product and grader Environment...

  • Page 14: Fundamental Safety Measures For Normal Operation

    Safety Instructions Fundamental safety measures for normal operation The grader may only be operated by people who have been trained and are authorized to do so, who are familiar with the operating instructions and can work in accordance with them! Before switching on the grader, check and ensure that only authorized persons are present in the work area of the grader, nobody can get injured through the starting up of the grader.

  • Page 15: Environmental Protection Regulations

    Safety Instructions DANGER Risk from sudden lowering assemblies! Assemblies that are lowered suddenly can cause serious injuries! The grader may only be lifted out by pushers, blade or rear rippers for placing support bearing frames at suitable points or for mounting slewing tools. No repairs can be made after lifting up! Lifting up does not provide a stop function! WARNING...

  • Page 16: Preparing For Repairs

    Safety Instructions Preparing for repairs 3.6.1 Basic notes Ensure that all areas are clean. Clean the grader prior to disassembly. Caution and cleanliness are essential to a proper repair. Replace parts or assemblies when worn or damaged. Parts installed incorrectly cause damages. Adhere to the step sequence and perform work in technically correct manner.

  • Page 17: Tightening Torques For Screws And Nuts

    Safety Instructions Consumables: cleaner (brake cleaner) abrasive, sandpaper Loctite 243, 586 lubricating grease molybdenum disulfide lubricant varnish (Gleitmo-900 Spray) 3.6.3 Tightening torques for screws and nuts Tightening torques taken from information on the individual steps. If no information is provided, reference the applicable tightening torques from the tables in the appendix.

  • Page 18: Overview Of Assemblies

    Overview of assemblies Overview of assemblies Vehicle types 4.1.1 Grader BG 110 / BG130 Fig. 1 Grader BG 110 / BG 130 Motor Grader Repair Manual Page 18...

  • Page 19: Grader Bg160 / Bg 190

    Overview of assemblies 4.1.2 Grader BG160 / BG 190 Fig. 2 Grader BG 160 / BG 190 Motor Grader Repair Manual Page 19...

  • Page 20: Grader Bg 240

    Overview of assemblies 4.1.3 Grader BG 240 Fig. 3 Grader BG 240 Motor Grader Repair Manual Page 20...

  • Page 21: Main Machine Parts

    Overview of assemblies Main machine parts Fig. 4 Rear rippers, draw bar, swivelling bridge and cylinder assemblies Lifting cylinder, right Slewing gear drive Slewing cylinder Swivelling bridge Blade Draw bar Cutting angle cylinder Lifting cylinder, left Slewing joint Motor Grader Repair Manual Page 21...
  • Page 22 Overview of assemblies Fig. 5 Rear mounted rippers, draw bar, swivelling bridge and cylinder assemblies Rear mounted ripper Slewing cylinder Left rear ripper cylinder Draw bar Right rear ripper cylinder Lifting cylinder, right Depth indicator 10 Cutting angle cylinder Swivelling bridge 11 Blade sliding cylinder Lifting cylinder, left Motor Grader Repair Manual...

  • Page 23: Assembly Change

    Assembly change: Draw bar assembly: Replacing draw bar Assembly change Draw bar assembly 5.1.1 Replacing draw bar 5.1.1.1 Disassembling draw bar Step 1 Retract blade (Fig. 1, Item 3) to side and move the cutting angle cylinder (Fig. 1, Item 4). Step 2 Remove all lubricant and hose lines (1) to the draw bar assembly (2) with the appropriate flat...
  • Page 24 Assembly change: Draw bar assembly: Replacing draw bar Step 4a BG 110 / BG 130 Loosen the bolted assemblies on the ball socket (1) using a flat wrench and remove 3 screws (2). Leave a screw (3) as a safety when dismantling the draw bar.
  • Page 25 Assembly change: Draw bar assembly: Replacing draw bar Step 4b BG 160 / BG 190 / 240 Loosen the bolted assemblies on the ball socket (1) using a flat wrench and remove 3 nuts (2). Leave a screw (3) as a safety when dismantling the draw bar.
  • Page 26 Assembly change: Draw bar assembly: Replacing draw bar Step 7 Sling draw bar (3) with 3 hook chains (1). Front chain lines (2) approx. 35 mm longer than the other hook chains. Equipment: 3 hook chains, lift apparatus Weight BG 110: approx. 1800 kg BG 130 approx.
  • Page 27 Assembly change: Draw bar assembly: Replacing draw bar Step 8b BG 160 / BG 190 / BG 240 Unscrew the last nut (3) on the ball socket (1). Move out draw bar (1) backward and then sideways. Tools: open-end wrench BG 160: sizes 36 BG 190: sizes 36 BG 240: sizes 36...
  • Page 28 Assembly change: Draw bar assembly: Replacing draw bar Step 10 Section 4.1.3.1 Dismounting slewing gear drive Step 11 Section 4.1.5.1 Dismantle ball bolt from draw bar Step 12 Section 4.1.6.1 Disassembling the draw bar from the slewing gear Step 13 Section 4.1.7.1 Dismantle four-point bearing from draw bar Motor Grader Repair Manual...

  • Page 29: Draw Bar Assembly

    Assembly change: Draw bar assembly: Replacing draw bar 5.1.1.2 Draw bar assembly Step 1 Section 4.1.3.2 Assembly of slewing gear drive on draw bar Step 2 Section 4.1.2.2 Assembly of slewing joint on draw bar Step 3 Section 4.1.7.2 Assembly of four-point bearing on draw bar Step 4 Section 4.1.5.2 Assembly of ball bolt on draw bar...
  • Page 30 Assembly change: Draw bar assembly: Replacing draw bar Step 6a BG 110 / BG 130 Clean off old Loctite from screws (6) and recoat with Loctite (7). Suspend draw bar (1) with 3 hook chains (2) and install sideways next to the front frame (3) Screw the ball socket (5) to the frame front part (4) with 4 screws (6).
  • Page 31 Assembly change: Draw bar assembly: Replacing draw bar Step 6b BG 160 / BG 190 / BG 240 Clean the old Loctite from the screws (7) on the front frame (4) and coat with new Loctite. Suspend draw bar (2) with 3 hook chains (3) and install sideways next to the front frame (1) Screw and lock the ball socket (5) with nuts (5) to the frame front part (4).
  • Page 32 Assembly change: Draw bar assembly: Replacing draw bar Step 7 Offset draw bar (2) onto floor. Loosen a chain line (3) and reconnect it over the front frame (1). Lift draw bar (2) and set down in middle. Equipment: 3 hook chains, lift apparatus, Fig.

  • Page 33: Changing Slewing Joint

    Assembly change: Draw bar assembly: Changing slewing joint 5.1.2 Changing slewing joint 5.1.2.1 Dismounting slewing joint Step 1 Use a flat wrench to remove the hose lines (2) on the slewing joint (1) and close with closure material. Closure material*: ROV 15-LA, M15-LA and VK15-LA.
  • Page 34 Assembly change: Draw bar assembly: Changing slewing joint Step 2 Dismantle the cover (3) from the slewing joint (1): Use torque wrench to loosen 2 hex screws (4). Use a torque wrench to remove the hose lines (2) on the slewing joint (1) and close with closure material.
  • Page 35 Assembly change: Draw bar assembly: Changing slewing joint Step 4 Secure the slewing joint (2) with 2 cotter pins (1) on the draw bar. Use a screwdriver to loosen and remove the slewing joint (2). Tools: screwdriver Fig. 19 Loosen slewing joint Motor Grader Repair Manual Page 35...

  • Page 36: Assembling Slewing Joint

    Assembly change: Draw bar assembly: Changing slewing joint 5.1.2.2 Assembling slewing joint Step 1 Knock 2 cotter pins (2) into the swivel joint (1) until they stick out approx. 1 mm on the bottom (3) as centring. Tools: hammer Fig. 20 Knock cotter pins into the swivel joint Step 2 Place swivel joint (1) on and knock the 2 cotter...
  • Page 37 Assembly change: Draw bar assembly: Changing slewing joint Step 3 Secure 3 screws (1) using Loctite 243 (4) and thus tightly screw the swivel joint (2) to the draw bar (3) using a torque wrench. Tools: hexagon socket, torque wrench BG 110: sizes 19 BG 130: sizes 19 BG 160: sizes 19...

  • Page 38: Replace Slewing Gear Drive

    Assembly change: Draw bar assembly: Replace slewing gear drive 5.1.3 Replace slewing gear drive 5.1.3.1 Dismounting slewing gear drive Step 1 Remove plastic stopper (1) from the threaded holes of the slewing gear drive (2). Tools: screwdriver Fig. 23 Loosen plastic stoppers from slewing gear drive Step 2 Screw ring bolts (1) into the threaded holes of the slewing gear drive (2).
  • Page 39 Assembly change: Draw bar assembly: Replace slewing gear drive Step 3a BG 110 / BG 130 / BG 160 Use a socket wrench to remove 7 screws (1) for securing the slewing gear drive (2) to the draw bar (3) above. Tools: socket wrench BG 110: sizes 24...
  • Page 40 Assembly change: Draw bar assembly: Replace slewing gear drive Step 4 Suspend hook chains (1) from the ring bolts (3). Using a crane, lift the slewing gear drive (2) from the draw bar (4). Equipment: 4 hook chains, lift apparatus Weight BG 110: approx.

  • Page 41: Assemblying Slewing Gear Drive

    Assembly change: Draw bar assembly: Replace slewing gear drive 5.1.3.2 Assemblying slewing gear drive NOTE Prior to assembly of the screwed connections, apply Loctite to the thread of the screws. The connection must be clean and free of grease. Step 1 When assembling the draw bar (1) to 2 metal supports (3), seat securely.
  • Page 42 Assembly change: Draw bar assembly: Replace slewing gear drive Step 2 Suspend hook chains (1) in the ring bolts (2) on the slewing gear drive (slewing gear) (3). Using the crane, place the slewing gear drive (slewing gear transmission) (3) on the draw bar (4).
  • Page 43 Assembly change: Draw bar assembly: Replace slewing gear drive BG 110 / BG 130 / BG 160 Step 3a Secure 7 screws (1) using Loctite 243 (3) and thus tightly screw the slewing gear drive (slewing gear transmission) (2) onto the draw bar (3) using a torque wrench from above.
  • Page 44 Assembly change: Draw bar assembly: Replace slewing gear drive BG 190 / BG 240 Step 3b Secure 5 screws (1) and 2 countersunk screws (1) using Loctite 243 (5) and tightly screw the slewing gear drive (slewing gear) (2) onto the draw bar (3) using a torque wrench from below.

  • Page 45: Replacing Slewing Gear Motor

    Assembly change: Draw bar assembly: Replacing slewing gear motor 5.1.4 Replacing slewing gear motor 5.1.4.1 Dismounting slewing gear motor Step 1 Use a flat wrench to remove the hose lines (2) on the motor (1) (slewing gear motor) and close with closure material.

  • Page 46: Assembling Slewing Gear Motor

    Assembly change: Draw bar assembly: Replacing slewing gear motor 5.1.4.2 Assembling slewing gear motor Working Steps The slewing gear motor is installed in reverse order. NOTE No lock washers are used under the screws with internal hex DIN 912! Motor Grader Repair Manual Page 46...

  • Page 47: Changing Ball Bolt

    Assembly change: Draw bar assembly: Changing ball bolt 5.1.5 Changing ball bolt 5.1.5.1 Dismounting ball bolt BG 110 / BG 130 Step 1 Using a socket wrench, loosen nut (4), nut (5) and washer (4) from the ball bolt (1). Remove ball bolt (1) and ball socket (2) from the draw bar (6).

  • Page 48: Dismounting Ball Bolt Bg 160 / Bg 190 / Bg 240

    Assembly change: Draw bar assembly: Changing ball bolt 5.1.5.2 Dismounting ball bolt BG 160 / BG 190 / BG 240 Step 1 Using a socket wrench, loosen nut (2), nut (3) and washer (4) from the ball bolt (1). Knock out ball bolt (1) with aluminum front retainer (5) and hammer from the draw bar (6).

  • Page 49: Assemblying Ball Bolt Bg 110 / Bg 130

    Assembly change: Draw bar assembly: Changing ball bolt 5.1.5.3 Assemblying ball bolt BG 110 / BG 130 Step 1 Spray the ball socket (2) and ball bolt (1) sliding surfaces with molybdenum disulfide lubricating varnish (Gleitmo-900 spray) and let dry. Lubricate the ball bolt (1) with lubricant and mount with ball socket (2) in the draw bar (6).

  • Page 50: Assembling Ball Bolt Bg 160 / Bg 190 / Bg 240

    Assembly change: Draw bar assembly: Changing ball bolt 5.1.5.4 Assembling ball bolt BG 160 / BG 190 / BG 240 Step 1 Spray the ball socket (1) and ball bolt (2) sliding surfaces with molybdenum disulfide lubricating varnish (Gleitmo-900 spray) and let dry. Lubricate the ball bolt with lubricant and mount in the draw bar (6).

  • Page 51: Change The Slewing Gear Draw Bar

    Assembly change: Draw bar assembly: Change the slewing gear draw bar 5.1.6 Change the slewing gear draw bar 5.1.6.1 Disassembling the draw bar from the slewing gear Step 1 Unscrew 4 hex screws (1) on top of draw bar (2) with socket wrench.
  • Page 52 Assembly change: Draw bar assembly: Change the slewing gear draw bar Step 3 Suspend draw bar (2) from crane with 3 hook chains (1) and lift out of the slewing gear (3). Equipment: 3 hook chains, lift apparatus Weight BG 110: approx. 400 kg BG 130: approx.

  • Page 53: Assembly Of Draw Bar To Slewing Gear

    Assembly change: Draw bar assembly: Change the slewing gear draw bar 5.1.6.2 Assembly of draw bar to slewing gear Step 1 Clean the contact surface (1) for the four-point bearing (ball bearing slewing gear) of the slewing gear (2) with sandpaper (3) of rust and old surface adhesive (Loctite).
  • Page 54 Assembly change: Draw bar assembly: Change the slewing gear draw bar Step 2 Suspend draw bar (1) from crane with 3 hook chains (2) and place on the bearing surface of the slewing gear (3). Equipment: 3 hook chains, lift apparatus Weight BG 110: approx.
  • Page 55 Assembly change: Draw bar assembly: Change the slewing gear draw bar Step 3 Secure all hex screws (4) with Loctite 243 (1) and affix on the four-point bearing (ball bearing slewing gear) (2) with HT washers (3). Then tighten all hex screws (4) with torque wrench.

  • Page 56: Changing Ball Bearing Slewing Gear

    Assembly change: Draw bar assembly: Changing ball bearing slewing gear 5.1.7 Changing ball bearing slewing gear 5.1.7.1 Disassembling the ball bearing slewing gear from the draw bar Step 1 Using the crane and cable (1), turn the draw bar (2) onto its back and place on the floor or metal supports.
  • Page 57 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 2 Screw in 3 ring bolts (1) in the threaded holes of the ball bearing slewing gear (four-point bearing) (3) in the draw bar (2). Equipment: 3 M16 ring screws Fig.

  • Page 58: Assembling Draw Bar On Ball Bearing Slewing Gear

    Assembly change: Draw bar assembly: Changing ball bearing slewing gear 5.1.7.2 Assembling draw bar on ball bearing slewing gear Step 1 Using the crane and cable (1), turn the draw bar (2) onto its back and place it securely on the metal supports (4) for further installation.
  • Page 59 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 2 Clean contact surface (Tectyl) from contact surface (1) of the ball bearing slewing gear (four- point bearing) using cleansing agent. The surface must be metallic bright. Apply Loctite 586 to contact surface (1) with a putty knife.
  • Page 60 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 3 The slewing gear drive is connected to the grader so that the adjustments can be made to the tooth face clearance of the ball bearing slewing gear. Loosen closure material from the hose lines and valves (2) for the motor (slewing gear motor) (3).
  • Page 61 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 4 Suspend 3 hook chains (1) in the ring bolts (2) on the ball bearing slewing gear (four-point bearing) (3). Using the crane, place the ball bearing slewing gear (four-point bearing) (3) on the contact surface (4) on the draw bar.
  • Page 62 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 5 When placing the ball bearing slewing gear (four- point bearing) (2), ensure that the lubrication hole (8) of the external ring of the ball bearing slewing gear (four-point bearing) (2) matches the lubrication hole (7) of the draw bar (3).
  • Page 63 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 6 Use the marked locations for orientation. Using a screwdriver, align the hole pattern of the external ring of the ball bearing slewing gear (four-point bearing) (1) and the draw bar (2). Equipment: lift apparatus, screwdriver...
  • Page 64 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 7 Provisionally fasten the ball bearing slewing gear (four-point bearing) (2) with the prepared screws (1) and HT washers (4) to the draw bar (3). Tools: torque wrench BG 110: sizes 19 BG 130: sizes 19 BG 160: sizes 19 BG 190: sizes 19...
  • Page 65 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 8 Gently tighten 4 screws (2) crosswise. Check the tooth face clearance between ball bearing slewing gear (four-point bearing) (4) and pinion (5) using measuring gage. Turn the ball bearing slewing gear (four-point bearing) (4).
  • Page 66 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 9 Start the grader. Using the operating lever (1), turn the ball bearing slewing gear (four-point bearing) (2) all the way around and check the tooth face clearance. When the tooth flank clearance is correct, tighten all screws (4) crosswise with torque wrench.
  • Page 67 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 10 Start the grader. Using the operating lever (1), turn the ball bearing slewing gear (four-point bearing) (3) so that the hardness step “S” of the internal ring (4) of the ball bearing slewing gear (four-point bearing) is positioned across from the engagement point of the pinion (2).
  • Page 68 Assembly change: Draw bar assembly: Changing ball bearing slewing gear Step 11 Disassemble the lengthened hose lines (2) from the motor (slewing gear motor) (3) with flat wrench and close off with closure material. Closure material: ROV 15-LA, M15-LA and VK15-LA Tools: open-end wrench BG 110: size 27 hose and socket...

  • Page 69: Cylinder Assemblies

    Assembly change: Cylinder assemblies: Replacing slewing cylinder Cylinder assemblies 5.2.1 Replacing slewing cylinder Fig. 58 Slewing cylinder Slewing cylinder Motor Grader Repair Manual Page 69...

  • Page 70: Dismounting Slewing Cylinder

    Assembly change: Cylinder assemblies: Replacing slewing cylinder 5.2.1.1 Dismounting slewing cylinder Step 1 Loosen the 3 cylinder screws (5) on the cover (4) using a screwdriver. Remove the key (2) with fencing pliers. Loosen and remove the nuts (crown nuts) (3) with flat wrench.
  • Page 71 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 3 Remove hose lines (3) from the slewing cylinder (5) with flat wrench and close with closure material (4). Disassemble lubrication lines (1) on fork head bearing (2) with flat wrench. Item (5) represents the following cylinder: - slewing cylinder (Fig.
  • Page 72 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 4 Mark (3) the installation position of the fork head (2) with a marking pen completely prior to disassembly. Suspend slewing cylinder (4) on crane with a cable (1) and remove screws (5) from fork head bearing (2) with Allen wrench.
  • Page 73 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 5 Using a screwdriver, leverage the front part of the fork head bearing (2) off of the slewing cylinder (3). For the further disassembly, place the slewing cylinder (3) securely on the floor using crane and cable (1).

  • Page 74: Mounting Slewing Cylinder

    Assembly change: Cylinder assemblies: Replacing slewing cylinder 5.2.1.2 Mounting slewing cylinder Step 1 Reuse lowering valve (2) to assemble the slewing cylinder (4). Replace pipelines (1 and 3). Attach one side and adapt pipe length on other side. Item (4) represents the following cylinder: - slewing cylinder (Fig.
  • Page 75 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 3 First disassemble new fork head: Loosen screws (6) with Allen wrench and remove upper part (5) from fork head (4). Coat screws (6) with Loctite 243. Attach slewing cylinder (1) with bushing (2) to fork head (4).
  • Page 76 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 4 Reconnect all hose lines (3) on lowering valve (2) to the slewing cylinder (1) with flat wrench. Item (1) represents the following cylinder: - slewing cylinder (Fig. 2, Item 7) Tools: open-end wrench BG 110: sizes 27 BG 130: sizes 27...
  • Page 77 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 5 Start the drive motor of the grader and extend the slewing cylinder (2) until it fits on the journal pin (1). Using an aluminium mandrel (4) and hammer, raise the slewing cylinder (2) on journal pins (1). Item (2) represents the following cylinder: - slewing cylinder (Fig.
  • Page 78 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 6 Place the washer (3) on the journal pin. Tighten the nuts (crown nuts) (4) with flat wrench on the journal pin until the key (2) fits. Secure the key (2) with flat nose pliers. Fill inside of cover (5) with grease and fasten with 3 cylinder screws (6).
  • Page 79 Assembly change: Cylinder assemblies: Replacing slewing cylinder Step 7 Reconnect the lubrication points (2) to the slewing cylinder (1) with the connecting pieces (3) and the lubrication lines (4). Item (1) represents the following cylinders: - slewing cylinder (Fig. 2, Item 7) Tools: open-end wrench BG 110: sizes 11, 12, 14...

  • Page 80: Replacing Lifting Cylinder

    Assembly change: Cylinder assemblies: Replacing lifting cylinder 5.2.2 Replacing lifting cylinder Fig. 72 lifting cylinder Lifting cylinder, left Lifting cylinder, right Motor Grader Repair Manual Page 80...

  • Page 81: Dismounting Lifting Cylinder

    Assembly change: Cylinder assemblies: Replacing lifting cylinder 5.2.2.1 Dismounting lifting cylinder Step 1 Loosen the 3 cylinder screws (5) on the cover (4) using a screwdriver. Remove the key (2) 4x40 with flat nose pliers. Loosen and remove the nuts (crown nuts) (3) with flat wrench.
  • Page 82 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 3 Remove hose lines (3) from the lifting cylinders (5) with flat wrench and close with closure material (4). Disassemble lubrication lines (1) on fork head bearing (2) with flat wrench. Item (5) represents the following cylinders: - lifting cylinder (Fig.
  • Page 83 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 4 Mark (3) the installation position of the fork head (2) with a marking pen completely prior to disassembly. Suspend lifting cylinder (4) on crane with a cable (1) and remove screws (5) from fork head bearing (2) with Allen wrench.
  • Page 84 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 5 Using a screwdriver, leverage the front part of the fork head bearing (2) off of the lifting cylinders (3). For the further disassembly, place the lifting cylinders (3) securely on the floor using crane and rope (1).

  • Page 85: Mounting Lifting Cylinder

    Assembly change: Cylinder assemblies: Replacing lifting cylinder 5.2.2.2 Mounting lifting cylinder Step 1 Reuse lowering valves (2) and hose lines (1) to assemble the lifting cylinders (4). Item (4) represents the following cylinders: - lifting cylinder (Fig. 2, Item 6 and 9) Tools: open-end wrench BG 110: sizes 24...
  • Page 86 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 3 First disassemble new fork head: Loosen screws (6) with Allen wrench and remove upper part (5) from fork head (4). Coat screws (6) with Loctite. Attach the lifting cylinders (1) with bushing (2) to fork head (4).
  • Page 87 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 4 Reconnect all hose lines (3) on lowering valve (2) to the lifting cylinders (1) with flat wrench. Item (1) represents the following cylinders: - lifting cylinder (Fig. 2, Item 6 and 9) Tools: open-end wrench BG 110: size 27 hose...
  • Page 88 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 5 Start the drive motor of the grader and extend the lifting cylinders (2) until they fit on the journal pins (1). Using an aluminium mandrel (4) and hammer, raise the lifting cylinders (2) on journal pins (1). Item (2) represents the following cylinders: - lifting cylinder (Fig.
  • Page 89 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 6 Place the washer (3) on the journal pin. Tighten the nuts (crown nuts) (4) with flat wrench on the journal pin. Secure the key (2) with flat nose pliers. Fill inside of cover (5) with grease and fasten with 3 cylinder screws (6).
  • Page 90 Assembly change: Cylinder assemblies: Replacing lifting cylinder Step 7 Reconnect the lubrication points (2) to the cylinder (1) with the connecting pieces (3) and the lubrication lines (4). Item (1) represents the following cylinders: - lifting cylinder (Fig. 2, Item 6 and 9) Tools: open-end wrench BG 110: sizes 11, 12, 14...

  • Page 91: Change Cutting Angle Cylinder

    Assembly change: Cylinder assemblies: Change cutting angle cylinder 5.2.3 Change cutting angle cylinder Fig. 86 Cutting angle cylinder, vertical position Cutting angle cylinder, left Cutting angle cylinder, right Motor Grader Repair Manual Page 91...

  • Page 92: Dismounting Cutting Angle Cylinder

    Assembly change: Cylinder assemblies: Change cutting angle cylinder 5.2.3.1 Dismounting cutting angle cylinder Step 1 Position blade at a right angle to the grader and set down on the floor. Retract the cutting angle cylinder. Secure the upper edge of the blade against tipping forward by laying squared timber or other suitable material underneath.

  • Page 93: Mounting Cutting Angle Cylinder

    Assembly change: Cylinder assemblies: Change cutting angle cylinder 5.2.3.2 Mounting cutting angle cylinder Step 1 Remove the plugs on the new cutting angle cylinder. Provisionally fasten the banjos. Clean and lubricate the bearings in the piston rod and piston head. Press the bearing onto the journal pin.

  • Page 94: Replacing Blade Sliding Cylinder

    Assembly change: Cylinder assemblies: Replacing blade sliding cylinder 5.2.4 Replacing blade sliding cylinder Fig. 87 Blade sliding cylinder Blade sliding cylinder Motor Grader Repair Manual Page 94...

  • Page 95: Dismounting Blade Sliding Cylinder

    Assembly change: Cylinder assemblies: Replacing blade sliding cylinder 5.2.4.1 Dismounting blade sliding cylinder Step 1 Set down the blade. Remove cylinder cover. Loosen all screws with a flat wrench. Disassemble 5x covering sheets. See spare parts catalogues: BG 110: Item 14.040-01 BG 130: Item 14.040-01 BG 160: Item 14.024-01 BG 190: Item 14.025-01...

  • Page 96: Mounting Blade Sliding Cylinder

    Assembly change: Cylinder assemblies: Replacing blade sliding cylinder 5.2.4.2 Mounting blade sliding cylinder Step 1 Connect hose lines to the new blade sliding cylinder. Push the sealing ring onto the journal pin. Clean bearing and press towards floor onto journal pin. Secure the cylinder with guard rings.

  • Page 97: Swivelling Bridge Assembly

    Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Swivelling bridge assembly 5.3.1 Replacing swivelling bridge 5.3.1.1 Dismounting swivelling bridge NOTE On BG 110 and BG 130 the lock is on the left in the direction of travel. On BG 160, BG 190 and BG 240 the lock is on the right.
  • Page 98 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 3 Secure the lock (locking cylinder) (1) with the device on the swivelling bridge (2). Equipment: fixture Fig. 90 Secure lock on swivelling bridge Step 4 Loosen the guard ring (2) on the lock (locking cylinder) (1) with snapring pliers.
  • Page 99 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 5 Loosen the fixture again. Remove the lock (locking cylinder) (1) and the bushings (2) and (3) completely from the lock mount (4). Fig. 92 Pull the lock from the lock mount Step 6 Loosen and remove all screws (1) and HT washers (2) but one on the top swivelling bridge...
  • Page 100 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 7 Loosen and remove all screws (1) and HT washers (3) but one on the bottom swivelling bridge fixture with socket wrench. Leave one screw (2) on each side as a safety. Tools: open-end wrench BG 110: sizes 24...
  • Page 101 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 9 Secure the lower half of the swivelling bridge (1) using a forklift (2) and pallet (3). Equipment: forklift truck, pallet Fig. 96 Secure lower half of swivelling bridge Step 10 Unscrew the last screws (1) on top (2) and bottom (3) swivelling bridge fixture with socket wrench.
  • Page 102 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 11 Securely set down the lower half of the swivelling bridge (1) on the floor using a forklift (2) and pallet (3). Equipment: forklift truck, pallet Fig. 98 Remove lower half of swivelling bridge Step 12 Sling the top half of the swivelling bridge (2) using a crane and cable (1).
  • Page 103 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 13 Remove the anti-rotation device (3) and raise the top half of the swivelling bridge (2) using a crane and cable (1) and safely set it down. Equipment: lift apparatus, cable Fig.

  • Page 104: Mounting Swivelling Bridge

    Assembly change: Swivelling bridge assembly: Replacing swivelling bridge 5.3.1.2 Mounting swivelling bridge NOTE On BG 110 and BG 130 the lock is on the left in the direction of travel. On BG 160, BG 190 and BG 240 the lock is on the right. The construction is the same for all grader types. Step 1 Dismantle the new swivelling bridge (1) consisting of the top half (4) and bottom half (5) of the...
  • Page 105 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 2 Turn the top and bottom halves of the swivelling bridge so that the wide collar (8) faces upwards. Install the fork head (1) 2x in the top half of the swivelling bridge and in the bottom half 1x as follows: Mount guard ring (4) and intermediate ring (6),...
  • Page 106 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 2 Step 2 in cross section. Fig. 103 Swivelling bridge, complete forkhead assembly Step 3 Install the bushings (2) in the rear lock mount (based on direction of travel), in the top half of the swivelling bridge (1).
  • Page 107 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 4 Spray the running surface (2) on the front part of the frame with molybdenum disulfide lubricant (Gleitmo-900 spray) (1) and let dry. After drying, lubricate the running surfaces (2) with lubricating grease. Equipment: molybdenum disulfide lubricating varnish (Gleitmo-900 spray),...
  • Page 108 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 6 Secure the top half of the swivelling bridge (1) against turning with anti-rotation device (2). Antirotation device: Thick squared timber or similar Fig. 107 Secure upper swivelling bridge against turning Motor Grader Repair Manual Page 108...
  • Page 109 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 7 Apply Loctite 586 to the contact surfaces (7). Lift the lower half of the swivelling bridge (3) on the pallet (5) up to the running surface (2) on the front part of the frame using a forklift (4). To lock the top (1) and bottom (3) halves of the swivelling bridge, ensure the correct seating of the cotter pins!
  • Page 110 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 8 Secure all hex screws (5) with Loctite 243 (3) and screw down the top (1) and bottom (2) halves of the swivelling bridge with HT washers (4) using a torque wrench. Tools: torque wrench BG 110 size: 24...
  • Page 111 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 9 Fill the locking cylinder (2) with oil prior to installation. Spread grease on the spring assembly. Pull the anti-rotation device (5) out of the lock mount (1) and push into the opening of the bottom swivelling bridge.
  • Page 112 Assembly change: Swivelling bridge assembly: Replacing swivelling bridge Step 11 Secure the lock (locking cylinder) (1) with guard ring (2) in the lock mount. (If necessary turn away the difference of the spacer bushing). Afterwards loosen it again. Tighten the adjusting springs of the bushings (Fig.

  • Page 113: Rear Ripper Assembly

    Assembly change: Rear ripper assembly: Replacing rear ripper Rear ripper assembly 5.4.1 Replacing rear ripper 5.4.1.1 Dismounting rear ripper Step 1a BG 110 Loosen screw (2) of the rear lights (1) with flat wrench. Loosen screws (3) on the console (4) with flat wrench.
  • Page 114 Assembly change: Rear ripper assembly: Replacing rear ripper Step 1b BG 130 / BG 160 / BG 190 / BG 240 Disconnect holder with eyelet (2) on left console (3) with flat wrench. Disconnect eyelet joint (4) from rod (1). Loosen dowel screw and spacer ring inside and outside on the traverse (5) of the rear mounted ripper.
  • Page 115 Assembly change: Rear ripper assembly: Replacing rear ripper Step 2 Remove screws (1) on the rear part of the frame on the back side. Disconnect threaded bushing (2) GE 15-L OMD. Loosen pipelines of the lowering valve (5) and on the cylinders (4).
  • Page 116 Assembly change: Rear ripper assembly: Replacing rear ripper Step 3 Disassemble the rear lights (2) on both consoles (1) by loosening the screws (3) using a flat wrench. Remove rear lights (2) and store to the side. Loosen the remaining screws (4) on both consoles (1) with flat wrench.
  • Page 117 Assembly change: Rear ripper assembly: Replacing rear ripper Step 4 Suspend rear mounted ripper from left and right console (2) using cable (1). Remove guard rings (6) with snapring pliers from the console (2). Screw the bolts (5) out of the console (2) with pull-off device (4).

  • Page 118: Mounting Rear Ripper

    Assembly change: Rear ripper assembly: Replacing rear ripper 5.4.1.2 Mounting rear ripper Step 1 Prepare pre-assembled new rear mounted ripper. Clean paint residue and dirt from all holes (2) on the left and right console (1). Equipment: cutter or similar, brake cleaner or similar, sandpaper Fig.
  • Page 119 Assembly change: Rear ripper assembly: Replacing rear ripper Step 2 Clean paint residue and dirt from all location holes (2) for the rear mounted ripper in the left and right frame (1). Equipment: cutter or similar, brake cleaner or similar, sandpaper Fig.
  • Page 120 Assembly change: Rear ripper assembly: Replacing rear ripper Step 3 Clean and grease 6 bolts (4). Suspend rear mounted ripper from left and right console (2) using cable (1), advance to rear part of frame (3) and align one hole of the rear part of frame (3) with one of console (2).
  • Page 121 Assembly change: Rear ripper assembly: Replacing rear ripper Step 4 Remove screws (1) on the rear part of the frame on the back side. Screw in threaded bushings (2) GE 15-L OMD. Connect pipelines of the pre-assembled lowering brake valve (5) and rotate upwards until the bottom edge of the lowering brake valve (5) no longer projects below the bottom edge (6) of the frame.
  • Page 122 Assembly change: Rear ripper assembly: Replacing rear ripper Step 5a BG 110 Secure screws with Loctite. Screw in (2) the rear lights (1) with torque wrench. Screw in the screws (3) on the console (4) with torque wrench. Tools: torque wrench BG 110 sizes: 27 / 30 Standardized parts: BG 110: screw M 10-10.9 (4)
  • Page 123 Assembly change: Rear ripper assembly: Replacing rear ripper Step 5b BG 130 / BG 160 / BG190 / BG 240 Secure screws with Loctite. Attach holder with eyelet (2) on left console (3) with screws. Fasten eyelet joint (4) on rod (1). Tighten dowel screw and spacer ring internal and external on the traverse (5) of the rear mounted ripper.

  • Page 124: Dozer Blade Assembly

    Assembly change: Dozer blade assembly: Replacing dozer blade Dozer blade assembly 5.5.1 Replacing dozer blade 5.5.1.1 Dismounting dozer blade Step 1 Set the dozer blade (5) and the blade (4) crosswise to the direction of travel, lower and thus lift the grader (1) such that the wheels have space from the ground.
  • Page 125 Assembly change: Dozer blade assembly: Replacing dozer blade Step 2 Secure suitable stopping means on the dozer blade. Disconnect and close all hose lines from the dozer blade cylinder. Use socket wrench to loosen all hex screws (3) on the dozer blade (2). Remove dozer blade (2) from front frame (1).

  • Page 126: Mounting Dozer Blade

    Assembly change: Dozer blade assembly: Replacing dozer blade 5.5.1.2 Mounting dozer blade Step 1 Secure suitable hitching gear on the dozer blade (2). Set dozer blade (2) down on a horizontal surface using crane, place up against front frame (1) and align.
  • Page 127 Assembly change: Dozer blade assembly: Replacing dozer blade Weight BG 110 764 kg BG 130 995 kg BG 160 764 kg BG 190 948 kg BG 240 1112 kg Equipment: crane, hitching gear NOTE Install washer (6) under the screw (3). The recess under the washer (6) must face towards the screw head (3).

  • Page 128: Center Pivot Steering Assembly

    Assembly change: Center pivot steering assembly: Center pivot steering overview Center pivot steering assembly 5.6.1 Center pivot steering overview Fig. 127 Center pivot steering overview 1 Bearing above - cover above Bearing above - cover below Chassis front section Bearing below - cover above Chassis rear section Bearing below - cover below Motor Grader Repair Manual...

  • Page 129: Centre Pivot Steering Mounting Sequence

    Assembly change: Center pivot steering assembly:Centre pivot steering mounting sequence 5.6.2 Centre pivot steering mounting sequence The assembly takes place in the order of items 1 through 9. Fig. 128 Centre pivot steering mounting sequence Item BG110 BG130/BG160 BG190/240 M8 / size 13 / M =22 Nm M12 / size 19 / M =70 Nm...

  • Page 130: Screwed Connections On The Pivot Joint

    Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint 5.6.3 Screwed connections on the pivot joint Carry out the final tightening of the screwed connections on the pivot joint in the following order using the corresponding torque wrench: Step 1 Bearing below - front part of frame Tighten 8x hex screws (1) on sealing cover...
  • Page 131 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 2 Bearing below - front part of frame cover below Firmly tighten 4x cylinder screws (2) on sealing cover crosswise with torque wrench. Tools: torque wrench hex wrench BG 110 size: 10 BG 130 size: 12 BG 160 size: 12...
  • Page 132 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 3 Bearing below - front part of frame: Firmly tighten 4x cylinder screws (3) on bushing crosswise with torque wrench. Tools: hex wrench BG 110 size: 8 BG 130 size: 10 BG 160 size: 10 BG 190 size: 10 BG 240 size: 10...
  • Page 133 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 4 Bearing below - rear part of frame Tighten hex screws (4) on sealing cover crosswise with torque wrench. Tools: open-end wrench BG 110 size: 17 BG 130 size: 19 BG 160 size: 19 hex wrench BG 190 size: 10...
  • Page 134 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 5 Bearing below - rear part of frame Tighten hex screws (5) on sealing cover crosswise with torque wrench. Tools: open-end wrench BG 110 size: 17 BG 130 size: 19 BG 160 size: 19 hex wrench BG 190 size: 10...
  • Page 135 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 6 Bearing above Firmly tighten 4x cylinder screws (6) on cover above crosswise with torque wrench. Tools: hex wrench BG 110 size: 8 BG 130 size: 8 BG 160 size: 8 BG 190 size: 10 BG 240 size: 10 Standardized parts:...
  • Page 136 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 7 Bearing above Firmly tighten 4x cylinder screws (7) on cover below crosswise with torque wrench. Tools: hex wrench BG 110 size: 8 BG 130 size: 8 BG 160 size: 8 BG 190 size: 10 BG 240 size: 10 Standardized parts:...
  • Page 137 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 8 Bearing above Tighten hex screws (8) on sealing cover crosswise with torque wrench. Tools: open-end wrench BG 110 size: 13 BG 130 size: 13 BG 160 size: 13 BG 190 size: 13 BG 240 size: 13 Standardized parts:...
  • Page 138 Assembly change: Center pivot steering assembly:Screwed connections on the pivot joint Step 9 Bearing above Tighten hex screws (9) on sealing cover crosswise with torque wrench. Tools: open-end wrench BG 110 size: 13 BG 130 size: 13 BG 160 size: 13 BG 190 size: 13 BG 240 size: 13 Standardized parts:...

  • Page 139: Replacing Center Pivot Steering

    Assembly change: Center pivot steering assembly: Replacing center pivot steering 5.6.4 Replacing center pivot steering 5.6.4.1 Dismounting center pivot steering Step 1 Bearing above on front part of frame: Use a pneumatic wrench (1) to loosen all cylinder screws (2) on the cover (3) above. Tools: pneumatic wrench + internal hex attachment BG 110 size: 10...
  • Page 140 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 2 Bearing above on front part of frame: Remove the cover (1) above and remove the clamping pieces (2 + 3) from the bolts (5) Tools: screwdriver Fig. 138 Remove upper cover and clamping pieces Motor Grader Repair Manual Page 140...
  • Page 141 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 3 Bearing above on front part of frame: Use a pneumatic wrench (1) to loosen all cylinder screws (3) on the cover (2) below. Tools: pneumatic wrench + attachment hexagon socket BG 110 size: 10 BG 130 size: 10...
  • Page 142 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 4 Bearing above on front part of frame: Remove the cover (5) below and remove the clamping pieces (2 + 3 + 4) from the bolts (1) Tools: screwdriver Fig.
  • Page 143 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 5 Bearing above on front part of frame: Knock the bolts (3) above with mandrel (2) and hammer (1) from the bearing. Tools: Hammer, mandrel Fig. 141 Knock bolts out of bearing Motor Grader Repair Manual Page 143...
  • Page 144 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 6 Bearing below on front part of frame: Use a pneumatic wrench (1) to loosen all cylinder screws (2) on the cover (3) above. Tools: pneumatic wrench + attachment hexagon socket BG 110 size: 10 BG 130 size: 10...
  • Page 145 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 7 Bearing below on front part of frame: Remove the cover (1) above and remove the clamping pieces (2 + 3) from the bolts (4) Tools: screwdriver Fig. 143 Remove upper cover and clamping pieces Motor Grader Repair Manual Page 145...
  • Page 146 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 8 Bearing below on rear part of frame: Loose all hex screws (3) and all cylinder screws (4) on the sealing cover (2) bottom with pneumatic wrench (1). Tools: pneumatic wrench + attachment hexagon socket (4) BG 110 size: 10...
  • Page 147 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 9 Bearing below Remove the sealing cover (5) below and the clamping pieces (3 + 4) and the bushing (2) from the bolts (1) Tools: screwdriver Fig. 145 Remove sealing cover below, clamping pieces and bushing Motor Grader Repair Manual Page 147...
  • Page 148 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 10 Bearing below: Knock the bolts (1) from below out of the lower bearing using a mandrel (2) and hammer (3). Tools: hammer, mandrel Fig. 146 Knock bolts upward out of bearing from below. Motor Grader Repair Manual Page 148...
  • Page 149 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 11 Push the front part (2) and the rear part (1) of the frame apart Tools: fixture Fig. 147 Push front and rear parts of frame apart Motor Grader Repair Manual Page 149...
  • Page 150 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 12 Bearing below on rear part of frame: Dismantle the cover top (1) and cover bottom (2) by loosening all screws (3) on the cover below (2). Tools: pneumatic wrench + attachment hexagon BG 110 size: 17 BG 130 size: 19...
  • Page 151 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 13 Bearing above on rear part of frame: Dismantle the cover top (1) and cover bottom (2) by loosening all hex screws (3) on the cover below (2). Tools: pneumatic wrench + attachment BG 110 size: 13 BG 130 size: 13...
  • Page 152 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 14 Knock bearing top (1) and bearing bottom (3) with hammer (1) and mandrel (2) from the bore holes in the frame rear part. Tools: hammer, mandrel Fig. 150 Knock bearing from the frame rear part Motor Grader Repair Manual Page 152...

  • Page 153: Mounting Center Pivot Steering

    Assembly change: Center pivot steering assembly: Replacing center pivot steering 5.6.4.2 Mounting center pivot steering Step 1 Prepare frame rear part pivot joint (1): Remove grease and colour from the holes. Knock in bearing top (3) and bearing bottom (4) with hammer and striking mandrel (2) in the bores.
  • Page 154 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 2 Bearing above on rear part of frame: Remove any colour from the cover and the bearing surface of the sealing cap. Secure screws with Loctite 243. Insert the round ring (2) in the upper cover (1). Screw the cover (3) to the cover (1) using hex screws (4) above on the bearing.
  • Page 155 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 3 Bearing below on rear part of frame: Remove any colour from the cover and the bearing surface of the sealing cap. Secure screws with Loctite. Insert the round ring (2) in the upper cover (1). Screw the cover (3) to the cover (1) with 7 screws (4) on the bearing below.
  • Page 156 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 4 Join the front and rear parts of the frame and align with the device. Tools: fixture Fig. 154 Align front and rear part of the frame Step 5 Bearing below on front part of frame: Oil the bolt (1) and bearing hole bottom (3).
  • Page 157 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 6 Bearing below on front part of frame: Push the bushing (3) from below onto the bolt (1). Ensure that the phase (2) is on top. Push the clamping pieces (4 + 5) from below onto the bolt (1).
  • Page 158 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 7 Bearing below on front part of frame: Push the clamping elements (3 + 4) from above on the bolt (5) set into the bearing hole (6). Set the cover (2) on the bolt (5) and secure with 2 cylinder screws (1).
  • Page 159 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 8 Bearing above on front part of frame: Oil the bolt (1) and bearing hole (3). Knock in the bolt (1) and bearing hole (3) from above. Ensure that the long section (2) of the bolt (1) is down! Tools: hammer...
  • Page 160 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 9 Bearing above on front part of frame: Set the cover (2) on the bolt (3) and secure with 2 cylinder screws so that the bolt (2) does not fall through below.
  • Page 161 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 10 Bearing above front part of frame: The bolt (2) is held by secured cover (1) top. Push the clamping pieces (3 + 4 + 5) from below onto the bolt (2). Use 2 cylinder screws (7) to secure the bushing (6) below on the bolt (2).
  • Page 162 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 11 Bearing above on front part of frame: Loosen and remove the 2 cylinder screws (1) on the cover (2). The bolt (3) is held through the cover (4) below. Tools: pneumatic wrench + attachment hexagon socket...
  • Page 163 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 13 Bearing above on front part of frame: Push the clamping pieces (3 + 4) from above onto the bolt (5). Ensure the correct installation position of the clamping piece (3) - slanting downward. Use 2 cylinder screws (1) to secure the cover above (2) on the bolt (5).
  • Page 164 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 14 Bearing below on front part of frame: 2 hex screws (3) without Loctite hold the sealing cover (2) on the bearing below. Tighten 2 other hex screws (4) with Loctite (1) and secure on the sealing cover (2).
  • Page 165 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 15 Bearing below on front part of frame: Unscrew 2 hex screws (2) without Loctite from the sealing cover (2) on the bearing below. Tools: pneumatic wrench + attachment hexagon BG 110 size: 13 BG 130 size: 19...
  • Page 166 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 17 Bearing below - front part of frame: Secure all cylinder screws (3) with Loctite (1) and screw the bushing (2) on the bolt. Tools: pneumatic wrench + attachment hexagon socket BG 110 size: 10 BG 130 size: 12...
  • Page 167 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 18 Bearing below - front part of frame: Use pneumatic wrench (5) to tighten all hex screws (2) on the sealing cover (1). Use a pneumatic wrench (5) to tighten all cylinder screws (4) to the bushing (3) crosswise.
  • Page 168 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 19 Bearing below on front part of frame: Use a torque wrench (5) to retighten all hex screws (2) on the sealing cover (1) crosswise multiple times and check. Use a torque wrench (5) to retighten all cylinder screws (4) on the bushing (3) crosswise multiple times and check.
  • Page 169 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 20 Bearing below on front part of frame, cover above: Two cylinder screws (2) are still attached to the cover (4) on the bolt. Secure two cylinder screws (3) with Loctite (1) and screw in the two open holes in the cover (4).
  • Page 170 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 22 Bearing below on front part of frame, cover above: Use a torque wrench (1) to retighten all cylinder screws (2) on the cover (3) multiple times crosswise and check. The bolt is tightened with the clamping pieces.
  • Page 171 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 23 Bearing above on front part of frame: Two cylinder screws (3) are still attached to the cover (4) on the bolt. Secure two cylinder screws (2) with Loctite (1) and screw in the two open holes on the cover (4).
  • Page 172 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 24 Bearing above on front part of frame: Use pneumatic wrench (1) to tighten all cylinder screws (2) on the cover (3) crosswise. Tools: pneumatic wrench + attachment hexagon socket BG 110 size: 8 BG 130 size: 8 BG 160 size: 8...
  • Page 173 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 26 Bearing above on front part of frame: Two cylinder screws (3) are still attached to the cover (2) on the bolt. Secure two cylinder screws (3) with Loctite (1) and screw in the two open holes on the cover (2).
  • Page 174 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 27 Bearing above on front part of frame: Use pneumatic wrench (3) to tighten all cylinder screws (2) on the cover (1) crosswise. Tools: pneumatic wrench + attachment hexagon socket BG 110 size: 8 BG 130 size: 8 BG 160 size: 8...
  • Page 175 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 28 Bearing above on front part of frame: Use a torque wrench (1) to retighten all cylinder screws (2) on the cover (3) multiple times crosswise and check. The bolt is tightened with the clamping pieces. Tools: torque wrench hexagon socket...
  • Page 176 Assembly change: Center pivot steering assembly: Replacing center pivot steering Step 29 Use grease gun (3) to grease at the grease fitting of frame rear section (1) and at the grease fitting of frame front section (2). Check if grease is leaking out. Tools: grease gun Fig.

  • Page 177: Changing Offset Cylinder

    Assembly change: Center pivot steering assembly: Changing offset cylinder 5.6.5 Changing offset cylinder Fig. 179 Offset cylinder on the pivot steering left side Cylinder Piston rod Cylinder base with hinged bearing Piston rod head with hinged bearing Hydraulic connection An offset cylinder is mounted on each of the two sides of the pivot steering. Motor Grader Repair Manual Page 177...

  • Page 178: Dismounting Center Pivot Steering

    Assembly change: Center pivot steering assembly: Changing offset cylinder 5.6.5.1 Dismounting center pivot steering Step 1 The offset cylinder (2) is located directly behind the step (1). Use a flat wrench to loosen the hex screws (3) on the step (1) and remove the step. Tools: open-end wrench BG 110 size: 19...
  • Page 179 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 3 Piston-shaft head: Lock the banjos (2) on the offset cylinder (1) with closure material (3). Tools: open-end wrench BG 110 size: 27 BG 130 size: 27 BG 160 size: 27 BG 190 size: 27 BG 240 size: 27 Closure material:...
  • Page 180 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 4 Piston-shaft head: Use a flat wrench to loosen the hex screws (1) on the cover (2) of the piston rod head (3). Remove the cover (2). Tools: open-end wrench BG 110 size: 8 BG 130 size: 8 BG 160 size: 8...
  • Page 181 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 6 Piston-shaft head: After removing the guard ring (1), take the spacer ring (2) from the journal pin (3). Fig. 185 Take spacer ring from the journal pin. Motor Grader Repair Manual Page 181...
  • Page 182 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 7 Cylinder bottom: Use a pneumatic wrench to loosen both hex screws (1) on the axle mounting (2) on the cylinder base receptacle (3). Remove the mount plate (2). Tools: pneumatic wrench + attachment hexagon BG 110 size: 17...
  • Page 183 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 9 Cylinder bottom: Use hammer (4) and mandrel (3) to knock out the bolt (1) from the cylinder base bearing (2) half way and pull out. Tools: hammer, mandrel Fig. 188 Remove bolt on cylinder base Motor Grader Repair Manual Page 183...
  • Page 184 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 10 Cylinder bottom: Secure the offset cylinder (3) from slipping. Set hammer shaft (1) in the opening of the cylinder base receptacle (2). Tools: hammer Fig. 189 Use hammer to secure offset cylinder on cylinder base Step 11 Piston-shaft head:...
  • Page 185 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 12 Cylinder bottom: Take the hammer out of the cylinder base receptacle (1) opening. Use both hands to pull the offset cylinder (2) from the cylinder base receptacle (1). Watch when pulling out the spacer ring (3). Fig.
  • Page 186 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 13 Piston-shaft head: Pull out the piston rod head (2) from the journal pin (3) with both hands and set down. Fig. 192 Take piston rod head from the journal pin. NOTE Ensure that the piston rod (1) does not move out.

  • Page 187: Mounting Offset Cylinder

    Assembly change: Center pivot steering assembly: Changing offset cylinder 5.6.5.2 Mounting offset cylinder Step 1 Measure (2) the travel length of the piston rod of the dismantled offset cylinder (1). Use a hammer (4) to make the new offset cylinder (3) have the same travel length, if needed, pull out the piston rod.
  • Page 188 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 2 Use a hex wrench to remove the closure material (2) on the threaded connections (1). Tools: hex wrench BG 110 size: 10 BG 130 size: 10 BG 160 size: 10 BG 190 size: 10 BG 240 size: 10 Fig.
  • Page 189 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 4 Piston-shaft head: Use both hands to safely grab the offset cylinder (1). Set the piston rod head (2) on the journal pin (3), but do not press into fitting position yet Fig.
  • Page 190 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 6 Piston-shaft head: Use crowbar (1) to press the piston rod head (2) on the journal pin (3). Tools: crowbar Fig. 198 Press piston rod head on journal pin Step 7 Piston-shaft head: Place the cover (3) loosely on the piston rod head (2).
  • Page 191 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 8 Piston-shaft head: Remove the cover (1) again from the piston rod head (4). Set the spacer ring (2) on the journal pin (3) in the piston rod head (4). Fig.
  • Page 192 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 9 Piston-shaft head: Use snapring pliers (1) to set the guard ring (2) on the journal pin (4) in the piston rod head (3). Tools: snapring pliers Fig. 201 Set spacer ring on journal pin Motor Grader Repair Manual Page 192...
  • Page 193 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 10 Cylinder bottom: Take the hammer (1) back out from the cylinder base receptacle (2). Use mandrel (4) to align the cylinder base (3) and the cylinder base receptacle (2). Tools: mandrel Fig.
  • Page 194 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 11 Cylinder bottom: Use grease to lubricate the bearing surfaces of the cylinder base receptacle (1) and of the cylinder base (3). Consumables: lubricating grease Fig. 203 Lubricate cylinder base bearing Step 12 Cylinder bottom: Lift the offset cylinder (3) slightly upward and...
  • Page 195 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 13 Cylinder bottom: Use grease (1) to lubricate the axle (2) for the cylinder base bearing (2). Consumables: lubricating grease Fig. 205 Lubricate cylinder base bearing axle Step 14 Cylinder bottom: Insert the axle (2) in the cylinder base receptacle (3) such that the flat side faces the back.
  • Page 196 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 15 Cylinder bottom: Use hex screws (3) to gently secure the axle mounting (4) in order to guide the axle better. Use hammer (1) and mandrel (2) to knock the axle (5) up to the stop in the cylinder base receptacle (2).
  • Page 197 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 16 Cylinder bottom: Reloosen the two securing hex screws (2). Secure both hex screws (2) with Loctite (1) and use a pneumatic wrench to screw the axle mount (4) to secure the axle (5) to the cylinder base receptacle (3).
  • Page 198 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 17 Cylinder bottom: Use hammer to knock the fitting (2) into the axle (3) bore. Tools: hammer Fig. 209 Insert fitting in axle Motor Grader Repair Manual Page 198...
  • Page 199 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 18 Piston-shaft head: Secure three hex screws (2) with Loctite 243 (1). Use flat wrench with hex screws (2) to tighten on the cover (3) on the piston rod head (3). Tools: open-end wrench BG 110 size: 8...
  • Page 200 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 19 Use flat wrench to screw the banjo (3) on the threaded connections (2) on the offset cylinder (1). Use flat wrench to screw the hydraulic hose lines (4) to the banjo (3) Tools: open-end wrench BG 110 sizes: 24, 27...
  • Page 201 Assembly change: Center pivot steering assembly: Changing offset cylinder Step 20 Use grease gun to lubricate at the grease fitting (2) on the piston rod head (1) and on the cylinder base (4). Check if grease is leaking out. Tools: grease gun Fig.

  • Page 202: Front Axle Assembly

    Assembly change: Front axle assembly: Replacing front axle Front axle assembly 5.7.1 Replacing front axle 5.7.1.1 Dismounting front axle Step 1a BG 110 / BG 130 / BG 160 Set the grader on a stable, level surface. Use chocks to secure the grader from rolling away.
  • Page 203 Assembly change: Front axle assembly: Replacing front axle Step 1b BG 190 / BG 240 Set the grader on a stable, level surface. Use chocks to secure the grader from rolling away. Lift up the rear mounted ripper. Use wheel wrench to loosen and remove 2 opposing wheel bolts (3) on the left (2) and right front wheels (1).
  • Page 204 Assembly change: Front axle assembly: Replacing front axle Step 2 Set the dozer blade (5) and the blade (4) crosswise to the direction of travel, lower and thus lift the grader (1) such that the wheels have space from the ground. Place a metal support (3) on the front frame at the front receptacle of the front axle as well as under the pivot joint to secure the grader from dropping...
  • Page 205 Assembly change: Front axle assembly: Replacing front axle Step 3 Secure suitable stopping means on the dozer blade. Disconnect and close all hose lines from the dozer blade cylinder. Use socket wrench to loosen all hex screws (3) on the dozer blade (2). Use crane to remove dozer blade (2) with plate completely from frame front part (1).
  • Page 206 Assembly change: Front axle assembly: Replacing front axle Step 4 Secure front axle with shipping pins: Connect the axle carrier (4) and the coupling rod (3) with pins (1) and secure the hinged pin (2). Material: (1) BG 110 bolt AN 2722954 BG 130 bolt AN 2722954 BG 160 bolt AN 2722954 BG 190 bolt AN 2722954...
  • Page 207 Assembly change: Front axle assembly: Replacing front axle Step 5a BG 110 / BG 130 / BG160 Use pneumatic wrench to unscrew 10x wheel nuts (6) each on the left (4) and right (1) wheels and set down with the lock washers (6). Pull off right (1) and left (4) wheels from the intermediate rings (2+3) and use a crane and cable to set aside.
  • Page 208 Assembly change: Front axle assembly: Replacing front axle Step 5b BG 190 / BG 240 Use a pneumatic wrench to unscrew and set down 8x wheel bolts (7) each on the left (4) and right (1) wheels. Pull off right (1) and left (4) wheels using the loading pin (6) from the intermediate rings (2+3) and use a crane and cable to set aside.
  • Page 209 Assembly change: Front axle assembly: Replacing front axle Step 6 Use socket wrench to loosen and unscrew the hex screws (3) on the supports (2) of both splash boards (1). Remove and set aside splash boards (1). Tools: socket wrench BG 110 size: 19 BG 130 size: 19 BG 160 size: 24...
  • Page 210 Assembly change: Front axle assembly: Replacing front axle Step 7 Use flat wrench to loosen all hex screws (3) on the lamp holder (1). Lift up and secure lamp holder (1). Disconnect the line (2) plug x6.4 (4) from the connection and pull sideways from the front frame.
  • Page 211 Assembly change: Front axle assembly: Replacing front axle Step 8 Use a flat wrench to remove all of the hose lines (2) from the control block (4) and the front frame (1) and close with closure material. Use a flat wrench to remove all of the hose lines (2) from the camber cylinder (3) and the steering cylinder (5) and close both sides with closure material.
  • Page 212 Assembly change: Front axle assembly: Replacing front axle Step 9 Secure suitable hitching gear (1) to the wheel hubs (2) and the axle arms. Carefully use lift apparatus to lift up front axle. Push palettes (3) under the front axle. Use a lift apparatus to carefully set the front axle on the palettes (3).
  • Page 213 Assembly change: Front axle assembly: Replacing front axle Step 10 Use flat wrench to loosen and remove the hex nuts (1) on the axle / bolts (2). Remove the washer (4), the round ring (3) and the grease fitting (5) from the axle (2). BG 110 and BG 130 Hex nut in front direction of travel.
  • Page 214 Assembly change: Front axle assembly: Replacing front axle Step 11 Place the sling (1) on the front frame (3) and lift up slightly until there is no load on the front axle (4). Carefully use a mandrel (5) and hammer to knock the axle / bolts (2) out of the front axle (4).
  • Page 215 Assembly change: Front axle assembly: Replacing front axle Step 12 Line the front axle (3) with wood pieces and use tension belts (4) to secure from accidents. Use forklift (5) or jack lift to lift the palettes slightly. Lower forklift or jack lift and move front axle out of the receptacle.
  • Page 216 Assembly change: Front axle assembly: Replacing front axle Step 13 Use forklift (3) or jack lift to move palette (2) with front axle (1) sideways from the grader and set down. Equipment: forklift truck, Low-lift platform truck Fig. 227 Move palette with front axle from the grader Motor Grader Repair Manual Page 216...
  • Page 217 Assembly change: Front axle assembly: Replacing front axle Step 14 Dismantle all attached parts, hose lines (1) from the front axle (2). Tools: open-end wrench BG 110 size: 19, 22, 27, 30, 32 BG 130 size: 19, 22, 27, 30, 32 BG 160 size: 19, 22, 27, 30, 32 BG 190 size: 19, 22, 27, 30, 32 BG 240 size: 19, 22, 27, 30, 32...

  • Page 218: Mounting Front Axle

    Assembly change: Front axle assembly: Replacing front axle 5.7.1.2 Mounting front axle Step 1 Use lift apparatus to set new front axle (2) on palettes (3) and secure with tension belts (4) to prevent accidents. Mount all attached parts, hose lines (1) to the new front axle.
  • Page 219 Assembly change: Front axle assembly: Replacing front axle Step 2 Secure sling (1) to front frame and lift. Use fork lift (4) or jack lift to move palettes (3) with the front axle (2) sideways in the grader. Equipment: crane, cable, chains forklift truck, low-lift platform truck,...
  • Page 220 Assembly change: Front axle assembly: Replacing front axle Step 3 Check the axle suspension (1) and the bushing and the front axle (2) bushing for damages and lubricate (3). Push round rings (4) in the edge of the bushing (2) from both sides. Equipment: lubricating grease Consumables:...
  • Page 221 Assembly change: Front axle assembly: Replacing front axle Step 4 Lower front frame (2) with sling and lift apparatus. Secure suitable sling (1) to the wheel hubs and the axle arms Align front axle (2) bushing to the front frame (2) bushing.
  • Page 222 Assembly change: Front axle assembly: Replacing front axle Step 5 At the front receptacle, place a metal support (2) under to secure the front axle on the front frame. Lubricate (5) the axle (1). Insert the axle (1) in the bushing of the receptacle and carefully knock in.
  • Page 223 Assembly change: Front axle assembly: Replacing front axle Step 6 Set the washer (3) on the axle (1). Coat the hex nut (1) with Loctite 243 and screw onto the axle / bolts (2). Use flat wrench to tighten. Check to ensure that the axle can still oscillate. Tools: open-end wrench BG 110 size: 65...
  • Page 224 Assembly change: Front axle assembly: Replacing front axle Step 7 Push the round rings (3) over the gap between front frame and axle. Use grease gun (2) on the grease fittings (1) and lubricate until grease leaks out at the round rings (3).
  • Page 225 Assembly change: Front axle assembly: Replacing front axle Step 8 Use a flat wrench to remove the closure material on the hose connections. Use flat wrench to mount all hose lines (2) to control block (3) and front frame (1). Use flat wrench to mount all hose lines (2) to the steering cylinder (4) and camber cylinder.
  • Page 226 Assembly change: Front axle assembly: Replacing front axle Step 9 Place lamp carrier (1) on the front frame and hold. Push line (2) plug x6.4 (4) through lateral hole in the front frame and plug into connection. Insert plug x21 (5) from above to the connection. Place lamp carrier (1) on plug opening in the front frame.
  • Page 227 Assembly change: Front axle assembly: Replacing front axle Step 10 Secure suitable hitching gear on the dozer blade (2). Set dozer blade (2) down on a horizontal surface using crane, place up against front frame (1) and align. Fasten all hex screws (3) with nuts (4) on dozer blade (2) and front frame (1) with socket wrench.
  • Page 228 Assembly change: Front axle assembly: Replacing front axle Weight: BG 110 764 kg BG 130 995 kg BG 160 764 kg BG 190 948 kg BG 240 1112 kg Equipment: crane, hitching gear NOTE Install washer (6) under the screw (3). The recess under the washer (6) must face towards the screw head (3).
  • Page 229 Assembly change: Front axle assembly: Replacing front axle Step 11 Secure the retainer (2) of both splash boards (1) with the hex screws (3) and the spring washer (4) on the front axle and screw tightly. Tools: open-end wrench BG 110 size: 19 BG 130 size: 19 BG 160 size: 24 BG 190 size: 24...
  • Page 230 Assembly change: Front axle assembly: Replacing front axle Step 12a Set the left (1) and right (2) front wheels on the wheel hubs. For BG 190 and BG 240, screw 2x loading pin (4) opposing in the hub. Push front wheels on the loading pins.
  • Page 231 Assembly change: Front axle assembly: Replacing front axle Step 13 Lift up the push blade and the blade. Lower the grader (1). Use a torque wrench to retighten the wheel nuts / wheel bolts (4) of the right and left front wheels. Perform a functional test.
  • Page 232 Assembly change: Front axle assembly: Replacing front axle Step 14 Remove front axle shipping bolts Remove the hinged pin (2) and pull out the pins (1) between the axle carrier (4) and the piston rod (3). Fig. 242 Remove shipping bolts NOTE Put the shipping bolts and hinged pin back in the driver's cab.

  • Page 233: Tandem Axle Assembly

    Assembly change: Tandem axle assembly: Replacing planetary gear Tandem axle assembly 5.8.1 Replacing planetary gear 5.8.1.1 Dismantle the tandem axle Step 1 Set the grader on a stable surface. Secure the grader with shipping clips. On the front axle, connect the axle carrier (3) and the coupling rod (4) with pins (1) and secure the hinged pin (2).
  • Page 234 Assembly change: Tandem axle assembly: Replacing planetary gear Step 2 Use a box wrench or open-ended wrench to loosen the hex screws (4) on the supports (2) of both splash boards (2) on the tandem axle. Remove and set aside both splash boards (2). Tools: Box wrench or open-ended wrench BG 110 size: 19...
  • Page 235 Assembly change: Tandem axle assembly: Replacing planetary gear Step 3 Use flat wrench to remove all brake hose lines (2) on the frame (1) on both sides and close the connections with closure material. Tools: open-end wrench BG 110 size: 22 BG 130 size: 22 BG 160 size: 22 BG 190 size: 22...
  • Page 236 Assembly change: Tandem axle assembly: Replacing planetary gear Step 4 Use an Allen wrench to loosen the hex screws (3) for securing the drive shaft (2) on the differential (1). Remove the drive shaft (2) from the differential gear (1) and secure against falling out. Secure with wire or cable binders on the oil hose.
  • Page 237 Assembly change: Tandem axle assembly: Replacing planetary gear Step 5 Underside of grader: Use a wrench to loosen the hex screws (2) on the axle carrier (1) to the underside of the grader and remove with washer. Tools: Box wrench / bolt / impact wrench or bolt / extension BG 110 size: 30 BG 130 size: 36...
  • Page 238 Assembly change: Tandem axle assembly: Replacing planetary gear Step 6 Slightly lift up the grader on the back of the frame using a crane or sling. Use flat wrench to loosen the connections (3) of the oil fill tube (1) on the tandem axle (2) and then pull out the oil fill tube (1).
  • Page 239 Assembly change: Tandem axle assembly: Replacing planetary gear Step 7 Use flat wrench to loosen the screwed connection (2) of the oil fill hose (1) on the tandem axle (3) and remove oil fill hose (1). Close the connections using closure material. Tools: open-end wrench BG 110 size: 36...
  • Page 240 Assembly change: Tandem axle assembly: Replacing planetary gear Step 8 Variation tandem axle toward back out: Mount suitable sling (1) on the grader. Lift up the grader with lift apparatus until the tandem axle (3) moves freely. Advance the tandem axle forward toward back under the grader.
  • Page 241 Assembly change: Tandem axle assembly: Replacing planetary gear Step 9 Variant tandem axle out sideways: Push metal supports (4) and wood beams under the grader to secure. Dismantle all rear wheels before step 5. Dismantle the rear wheels, see step 11. Put sling (1) on the wheel heads on the tandem axle (2).
  • Page 242 Assembly change: Tandem axle assembly: Replacing planetary gear Step 10 On the right and left (1) axle carrier of the differential gear, screw on 2 ring bolts (2) each in the holes using a washer and a hex nut Suspend 4x hook chains (3) in the front holes. Weight without filling: BG 110: approx.
  • Page 243 Assembly change: Tandem axle assembly: Replacing planetary gear Step 11 Suspend suitable hitching gear (1) from ring bolts. For the BG 190 and BG 240, loosen two opposing wheel screws (3) and mount loading pin (4) at the point of both wheel bolts. Use a pneumatic wrench to unloosen, but not remove, the remaining wheel screws (3) to all rear wheels (2).
  • Page 244 Assembly change: Tandem axle assembly: Replacing planetary gear Step 12 Slightly lift tandem axle (1) with crane. Push metal supports (2) under the tandem axle (1). Place wood beams (5) on the metal supports (2) and set tandem axle (1) on them. Sling cables (3) around each rear wheel (4).

  • Page 245: Dismounting The Wheel Heads

    Assembly change: Tandem axle assembly: Replacing planetary gear 5.8.1.2 Dismounting the wheel heads Step 1 Set oil pan (3) under the tandem axle as the runout points. Use hex wrench to open all lock screws (1) on the tandem axle (4) and drain oil. Do NOT open the lock screws on the planetary gear (2)! Tools:...
  • Page 246 Assembly change: Tandem axle assembly: Replacing planetary gear Step 2 Use box wrench to loosen all hex screws (1). Remove all covers (2) from the tandem axle (3). The contact surface is sealed with Atmosit compact. Tools: box spanner BG 110 size: 13 BG 130 size: 13 BG 160 size: 13 BG 190 size: 13...
  • Page 247 Assembly change: Tandem axle assembly: Replacing planetary gear Step 3 Use hex wrench to loosen all hexagon screws (4). Remove protective plates (1) over the brake line (2) connections on the planetary gear. Tools: Hex wrench + ratchet BG 110 size: 19 BG 130 size: 24, 26 BG 160 size: 24, 26 BG 190 size: 30...
  • Page 248 Assembly change: Tandem axle assembly: Replacing planetary gear Step 4 Use a marking pen (3) to note the position of the brake lines (1) on the tandem housing for the assembly. Use flat wrench to remove all brake lines (1) on the planetary gears (2) and close the connections with closure material.
  • Page 249 Assembly change: Tandem axle assembly: Replacing planetary gear Step 5 Secure chain wheels (3) in the tandem housing from slipping out. Clamp above suitable crowbar (1) or wood between chain and opening (2). Equipment: crowbar, wood Fig. 259 Secure chain wheels from slipping out Motor Grader Repair Manual Page 249...
  • Page 250 Assembly change: Tandem axle assembly: Replacing planetary gear Step 6 Place a cable (1) loop around the wheel heads (3) and secure. Use the crane to slightly tighten the cable (1). Use a box wrench to loosen all of the hex screws (2) on the flange (4) for the tandem housing.
  • Page 251 Assembly change: Tandem axle assembly: Replacing planetary gear Step 7 Evenly screw in 3x hex screws (1) in the flange (3) and thus push the wheel head (2) from the tandem housing (4). Pull the wheel head (2) from the gearing. In the process, ensure that the chain wheel is not pulled out of the tandem housing in the process! Use the crane to set the wheel heads (1) aside.

  • Page 252: Dismounting Planetary Gear From The Flange

    Assembly change: Tandem axle assembly: Replacing planetary gear 5.8.1.3 Dismounting planetary gear from the flange Step 1 Use a torque wrench to loosen all of the hex screws (3) on the intermediate flange (2) to the planetary gear. Use crowbar (4) to lift apart intermediate flange (2) and the planetary gear (1).

  • Page 253: Assemble Planetary Gear On Flange

    Assembly change: Tandem axle assembly: Replacing planetary gear 5.8.1.4 Assemble planetary gear on flange Step 1a BG 110 Clean all contact surfaces on the flange (3) and on the planetary gear (1) with brake cleaner. Knock 2 cotter pins (2) each into the planetary gear (1).
  • Page 254 Assembly change: Tandem axle assembly: Replacing planetary gear Step 1b BG 130 / BG 160 Clean all contact surfaces on the flange (3) and on the planetary gear (1) with brake cleaner. Knock 2 cotter pins (2) each into the planetary gear (1).
  • Page 255 Assembly change: Tandem axle assembly: Replacing planetary gear Step 2 BG 110 / BG 130 / BG 160 Secure all hex screws with Loctite (4). Set the flange (2) on the planetary gear (1). Check the position of the cotter pins and for BG110, also the position of the washer! Secure the intermediate flange (2) with hex screws (3).

  • Page 256: Mounting Wheel Heads On The Tandem Axle

    Assembly change: Tandem axle assembly: Replacing planetary gear 5.8.1.5 Mounting wheel heads on the tandem axle Step 1 Apply sealant on all contact surfaces on the intermediate flange (3) of the wheel head and on the tandem housing (1). Use grease (4) to stick the washer (2) to the sealing surface of the intermediate flange (3) for tandem housing (1).
  • Page 257 Assembly change: Tandem axle assembly: Replacing planetary gear Step 2 Place a cable (1) loop around the wheel head (3) and secure. Lift the wheel head (3) with the cable and align with the tandem housing (2). Watch the position of the connections from the brake line - mark on tandem housing (4)! Coat the gearing of the drive shaft (6) with grease (7).
  • Page 258 Assembly change: Tandem axle assembly: Replacing planetary gear Step 3 Use 2 hex screws (1) with mounted nuts (4) to screw the wheel head (2) on the tandem housing (3). Use a flat wrench (5) to tighten the wheel head (2) by tightening the nuts (4) up to the sealing surface of the tandem housing (3).
  • Page 259 Assembly change: Tandem axle assembly: Replacing planetary gear Step 4 Secure all hex screws (1) with Loctite 243 (4) and tightly screw the wheel head (2) to the tandem housing (3). Unscrew the 2 hex screws M12x70 and hex nuts again and replace with 2 original hex screws (1).
  • Page 260 Assembly change: Tandem axle assembly: Replacing planetary gear Step 5 Remove safety (1) (wood, crowbar) to prevent the chain wheels (3) from slipping out in the tandem housing and pull out of the opening (2). Equipment: crowbar, wood Fig. 270 Remove safety to prevent slipping out of chain wheels Motor Grader Repair Manual Page 260...

  • Page 261: Mounting The Tandem Axle

    Assembly change: Tandem axle assembly: Replacing planetary gear 5.8.1.6 Mounting the tandem axle Step 1 Seal contact surfaces on the tandem housing with Atmosit compact. Secure all hex screws (1) with Loctite 243 (4). Use box wrench to screw in all hex screws (1) and secure the cover (2) to the tandem housing (3).
  • Page 262 Assembly change: Tandem axle assembly: Replacing planetary gear Step 2 Place a funnel (1) on the fill openings (2) and fill the oil levels. Only check the oil level on the planetary gears (3), do not fill with oil! Close all fill openings (2). Oil quantities: See the following tables.
  • Page 263 Assembly change: Tandem axle assembly: Replacing planetary gear Lubricants, operating materials, fill volumes BG 110 Lubricants, Fill volume in litres Lubricants, Temperature limits Viscosity classes Fuels and lubricants, (USgal) Operating Filling quantities materials (international specification) * Working hydraulic approx. 140 H-LP 46 10°...
  • Page 264 Assembly change: Tandem axle assembly: Replacing planetary gear Lubricants, operating materials, fill volumes BG 130 Lubricants, Fill volume in litres Lubricants, Temperature limits Viscosity classes Fuels and lubricants, (USgal) Operating materials Filling quantities (international specification) * Working hydraulic approx. 160 H-LP 46 10°...
  • Page 265 Assembly change: Tandem axle assembly: Replacing planetary gear Lubricants, Fill volume in litres Lubricants, Temperature limits in °C (°F) Viscosity classes Fuels and lubricants, (USgal) Operating materials Filling quantities (international specification) * Working hydraulic approx. 170 H-LP 46 10° to 50 °C ( 50° to 122 °F) ISO VG 100 Hydraulic steering (44.9)
  • Page 266 Assembly change: Tandem axle assembly: Replacing planetary gear Lubricants, operating materials, fill volumes BG 190 Lubricants, Fill volume in litres Lubricants, Temperature limits in °C (°F) Viscosity classes Fuels and lubricants, (USgal) Operating Filling quantities materials (international specification) * Working hydraulic approx.
  • Page 267 Assembly change: Tandem axle assembly: Replacing planetary gear Lubricants, operating materials, fill volumes BG 240 Lubricants, Fill volume in litres Lubricants, Temperature limits in °C (°F) Viscosity classes Fuels and lubricants, (USgal) Operating materials Filling quantities (international specification) * Working hydraulic approx.
  • Page 268 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Rear axle When performing welding tasks on the machine, the (-) pole must not be connected to the rear axle. Welding tasks are not permitted on the rear axle! Check oil level Check oil level in the axle gear Fig.
  • Page 269 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Oil change on the rear axle Prior to changing the oil, clean dirt from the areas around the check, fill and drain screws. Generally only change oil in warm conditions. To do this, place machine so that it is level.
  • Page 270 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Tandem oil change Screw off the cover of the fill opening (E) and unscrew the oil drain screw (A). Let oil drain out into container. Close drain opening (A) and fill with oil until the level is halfway up the check window (K).
  • Page 271 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Oil change wheel hubs (planetary gear) and axle funnel (multi-disc brakes) Fig. 280 and Fig. 281 To drain the oil, set the machine such that the lock screws (50 and 52) of the respective wheel are down (lowest point).
  • Page 272 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 40, 41 - Oil fill and oil check screw 42 - Oil drain screw for differential Fig. 282 Oil change differential gear BG 110 - drawing 1 Motor Grader Repair Manual Page 272...
  • Page 273 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Fig. 283 Oil change differential gear BG 110 - drawing 2 Motor Grader Repair Manual Page 273...
  • Page 274 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 110 Fig. 284 Oil change differential gear BG 110 - drawing 3 Motor Grader Repair Manual Page 274...
  • Page 275 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 130 / BG 160 rear axle When performing welding tasks on the machine, the (-) pole must not be connected to the rear axle. Welding tasks are not permitted on the rear axle! Check oil level Check oil level in the axle gear...
  • Page 276 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 130 / BG 160 Oil change on the rear axle Generally only change oil in warm conditions. To do this, place machine so that it is level. Do not allow any oil to drain into the soil. Always use oil pan.
  • Page 277 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 130 / BG 160 Tandem oil change Fig. 290, Fig. 291, Fig. 292 Screw off the cover of the oil fill opening (E) and unscrew both oil drain screws (A). Let oil drain out into container.
  • Page 278 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 130 / BG 160 Oil change wheel hubs (planetary gearing) Fig. 293, Fig. 294, Fig. 295 Set the machine to drain the oil such that the oil drain screw (A) of the respective wheel is down (lowest position).
  • Page 279 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 190 Rear axle When performing welding tasks on the machine, the (-) pole must not be connected to the rear axle. Welding tasks are not permitted on the rear axle Check oil level Check oil level in the axle gear Fig.
  • Page 280 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 190 Oil change on the rear axle Generally only change oil in warm conditions. To do this, place machine so that it is level. Do not allow any oil to drain into the soil. Always use oil pan.
  • Page 281 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 190 Lubricate slewing ring Fig. 301 and Fig. 302 Notice! The slewing ring has 2 separate chambers to lubricate. Chamber 1 as ball groove and chamber 2 as anteroom with protective grease fill. The ball groove (chamber 1) is already filled with grease.
  • Page 282 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 190 Tandem oil change Screw off the cover of the oil fill opening (E) and unscrew both oil drain screws (A). Let oil drain out into container. Close drain screws (A) fill with oil until the level is halfway up the check window (K).
  • Page 283 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 190 Oil change in the axle gear Drain screw (A) and fill screw (E) oil change wheel hubs (planetary gear) Unscrew the drain screws (7). Let oil drain out into container. Close oil drain openings. Top up oil.
  • Page 284 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 240 Rear axle When performing welding tasks on the machine, the (-) pol must not be connected to the rear axle. Fig. 307 Welding tasks are not permitted on the rear axle! Check oil level Check oil level in the axle gear...
  • Page 285 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 240 Oil change and lubrication on the rear axle Generally only change oil in warm conditions. To do this, place machine so that it is level. Do not allow any oil to drain into the soil. Always use oil pan.
  • Page 286 Assembly change: Tandem axle assembly: Replacing planetary gear Maintenance BG 240 Oil change wheel hubs (planetary gearing) Fig. 313 Unscrew the drain screws (7). Let oil drain out into container. Close oil drain openings. Top up oil. Check oil level with oil dipstick (3). Clean any dirt from the area of the lock screws before unscrewing.
  • Page 287 Assembly change: Tandem axle assembly: Replacing planetary gear Step 3 Remove the closure material on the planetary gears (2). Use a flat wrench to screw all brake lines (1) on the planetary gears (2). Check the marking (3) of the setting of the brake lines (1) on the tandem housing.
  • Page 288 Assembly change: Tandem axle assembly: Replacing planetary gear Step 4 Secure all hex screws (4) with Loctite (243). Use a hex wrench (4) to screw on all protective plates (1) over the brake hose (2) connections on the planetary gear. Tools: hex wrench BG 110 size: 19...
  • Page 289 Assembly change: Tandem axle assembly: Replacing planetary gear Step 5 Screw on 2 ring bolts (2) each to the axle carriers (3) in the back holes with washers and hex nuts or hand 4x hook chains (1) in the front holes. BG 110, BG 130 and BG 160: Sling cables (4) around each rear wheel (5) and lift to the height of the planetary gear / wheel head (6).
  • Page 290 Assembly change: Tandem axle assembly: Replacing planetary gear Step 6 Use the crane and chains (1) to lift the tandem axle from the metal supports and set on the ground. BG 110, BG 130 and BG 160: Use torque wrench to retighten crosswise the wheel nuts (5) with washers (4) on the wheel bolts (3) on all rear wheels (2).
  • Page 291 Assembly change: Tandem axle assembly: Replacing planetary gear Step 7 Variant tandem axle from back under grader: Align and set down tandem axle (3) behind the grader (1). Coat contact surfaces (5) with Loctite (4). Use the lifting apparatus (1) to lift up the grader (1) so that the differential gear (3) fits under the diesel tank.
  • Page 292 Assembly change: Tandem axle assembly: Replacing planetary gear Step 8 Variant tandem axle sideway under grader: Begin according to step 4 - without rear wheels. Coat contact surfaces (5) with Loctite (4). Put sling (2) on the wheel heads on the tandem axle (3).
  • Page 293 Assembly change: Tandem axle assembly: Replacing planetary gear Step 9 Underside of grader: Secure all hex screws (2) with Loctite (243). Carefully let the grader off. Screw in the hex screws (2) on the axle carriers (1) for the grader underside with washer (3). Tools: box wrench, impact wrench + attachment, extension...
  • Page 294 Assembly change: Tandem axle assembly: Replacing planetary gear Step 10 Remove the closure material on the differential (3). Assemble the screwed connections (2) and oil fill hoses (1) on the differential axle (differential gear, planetary rigid axle). Tools: open-end wrench BG 110 size: 36 BG 130 size: 36 BG 160 size: 36...
  • Page 295 Assembly change: Tandem axle assembly: Replacing planetary gear Step 11 Remove the closure material on the axle carriers (2). Insert oil fill pipes (1) from above and screw them down on the axle carriers (2) with screw in socket (3). Also fasten the differential oil fill hose in the engine compartment.
  • Page 296 Assembly change: Tandem axle assembly: Replacing planetary gear Step 12 Secure all hex screws (3) with Loctite (4). Attach the universal drive shaft (2) to the differential gear (1). Screw in the hex screws (3) with a hex wrench and tighten using a torque wrench. Tools: Hex wrench with extension and tensile force increase,...
  • Page 297 Assembly change: Tandem axle assembly: Replacing planetary gear Step 13 Remove the closure material on the connections (1) on the grader and the brake hoses (2). Use flat wrench to screw all brake lines (2) to the connections (1). Bleed all brakes. Tools: open-end wrench BG 110 size: 22...
  • Page 298 Assembly change: Tandem axle assembly: Replacing planetary gear Step 14 Secure all hex screws (4) with Loctite (5). Use box wrench or open-ended wrench to screw the hex screws (4) on the supports (2) of both splash boards (2) on the tandem axle. Tools: Box wrench or flat wrench BG 110 size: 19...

  • Page 299: Changing Differential Gear

    Assembly change: Tandem axle assembly: Changing differential gear 5.8.2 Changing differential gear 5.8.2.1 Dismounting differential gear from axle carriers Step 1 Mark the position of the axle carrier to the differential. Use torque wrench to loosen and remove hex screws (3) on the left (1) and right (4) flange of the axle carrier to the differential (2).
  • Page 300 Assembly change: Tandem axle assembly: Changing differential gear Step 2 Suspend suitable slinging equipment (1) from ring bolts. Using the crane, lift the tandem axle (3) and set on the floor. Lay wooden beam (2) underneath. Weight BG 110: approx. 850 kg BG 130: approx.
  • Page 301 Assembly change: Tandem axle assembly: Changing differential gear Step 3 Suspend suitable slinging equipment (1) from eyelets on right tandem housing (2). Use hex wrench to remove the last hex screws (3) from the right flange (4) of the axle carrier to the differential (5).
  • Page 302 Assembly change: Tandem axle assembly: Changing differential gear Step 4 Gently lift right tandem housing (1) with axle carrier (2). By pressing on a crowbar or similar, lever the two parts apart from one another until the knockout spindle (4) is removed from the differential (3). If necessary, support by hitting with the hammer and wood against the tandem housing (1).
  • Page 303 Assembly change: Tandem axle assembly: Changing differential gear Step 5 Make and secure a loop around the differential (2) with the cable (1). Use the crane to slightly tighten the cable (1). Use hex wrench to remove the last hex screws (3) from the left flange (4) of the axle carrier to the differential (2).
  • Page 304 Assembly change: Tandem axle assembly: Changing differential gear Step 6 Press with a crowbar or similar to lever the differential (2) and the left tandem housing with axle carrier (3) apart from one another. Pull the differential (2) completely out of the knockout spindle (4).

  • Page 305: Mounting Differential Gear Onto Axle Carriers

    Assembly change: Tandem axle assembly: Changing differential gear 5.8.2.2 Mounting differential gear onto axle carriers Step 1 Make and secure a loop around the new differential (2) with the cable (1). Use the crane to slightly tighten the cable (1). Lay a wooden beam under the left axle carrier (4) and differential (2).
  • Page 306 Assembly change: Tandem axle assembly: Changing differential gear Step 2 Use crane and cable (1) to raise the differential (2) gently and move to the axle carrier (3). Insert the differential (2) carefully into the insert shaft (4) of the left axle carrier (3). Watch cotter pins and the position of the round ring on the differential (2)! Do not apply any additional sealant!
  • Page 307 Assembly change: Tandem axle assembly: Changing differential gear Step 3 Use hex wrench to screw in all hex screws (3) on the flange (4) of the left axle carrier to the differential (2), thus joining the two parts (2+4). Use torque wrench to tighten all hex screws (3). Do not glue screws in place! Tools: Hex wrench + ratchet...
  • Page 308 Assembly change: Tandem axle assembly: Changing differential gear Step 4 Sling suitable slinging equipment in eyelets on right tandem housing (1). Clean the surfaces of right axle carrier (2) and differential (3). Affix the round ring (5) on the differential (2) with lubricating grease.
  • Page 309 Assembly change: Tandem axle assembly: Changing differential gear Step 5 Use socket wrench to screw in all hex screws (1) on the flange (2) of the right axle carrier to the differential (3), thus joining the two parts (2+3). Use torque wrench to tighten all hex screws (1). Do not glue screws in place! Tools: Hex wrench + ratchet...
  • Page 310 Assembly change: Tandem axle assembly: Changing differential gear Step 6 Suspend hook chains (2) from the eyelets (2). Using a crane, lift the tandem axle (1) and set on metal supports (4). Equipment: crane, hook chains, metal supports Weight BG 110: approx. 850 kg BG 130: approx.

  • Page 311: Replacing Tandem Chain

    Assembly change: Tandem axle assembly: Replacing tandem chain 5.8.3 Replacing tandem chain NOTE For each grader type, the left and right tandem housings are the same. In this way, the arrangement of the front and rear chains and that of the left and right cover are set against one another.
  • Page 312 Assembly change: Tandem axle assembly: Replacing tandem chain BG 110 Inside chain (1) Outside chain (2) Fig. 339 Tandem chain BG 110 Motor Grader Repair Manual Page 312...
  • Page 313 Assembly change: Tandem axle assembly: Replacing tandem chain BG 160 Inside chain (2) Outside chain (1) Fig. 340 Tandem chain BG 160 Motor Grader Repair Manual Page 313...
  • Page 314 Assembly change: Tandem axle assembly: Replacing tandem chain BG 190 / BG 240 Inside chain (2) Outside chain (1) Fig. 341 Tandem chain BG 190 / 240 Motor Grader Repair Manual Page 314...

  • Page 315: Dismounting Chain

    Assembly change: Tandem axle assembly: Replacing tandem chain 5.8.3.1 Dismounting chain Step 1 Open the cover. Chain lock installation and deinstallation. Use a ring wrench to loosen all hex screws. Remove all covers from tandem housing. Equipment: crane, hitching gear, crowbar, hammer, wood...
  • Page 316 Assembly change: Tandem axle assembly: Replacing tandem chain Step 2 Use box wrench to loosen all hex screws (1). Remove all covers (2) from the tandem axle (3). The contact surface is sealed with Atmosit compact. Tools: box spanner BG 110 size: 13 BG 130 size: 13 BG 160 size: 13 BG 190 size: 13...
  • Page 317 Assembly change: Tandem axle assembly: Replacing tandem chain Step 3 Use box wrench to loosen all hex screws (5). Remove all covers (4) from the tandem axle. The contact surface is sealed with Atmosit compact. Move rear axle so that the chain lock is positioned by the assembly opening (3).
  • Page 318 Assembly change: Tandem axle assembly: Replacing tandem chain Step 3 Set the chain tensioner (1) on the chain (4) through the top opening (2). Set the chain tensioner to tighten. Remove the keys (5) from the chain lock (4) and disassemble the chain lock.

  • Page 319: Mounting The Chain

    Assembly change: Tandem axle assembly: Replacing tandem chain 5.8.3.2 Mounting the chain Step 1 Feed the chain (1) through the upper opening (2). First always mount the internal chain in the chain carrier! Lay the chain on the double chain wheel and the chain wheel (3) so that the separating points of the chain are located at the opening (4) for the installation of the chain lock.
  • Page 320 Assembly change: Tandem axle assembly: Replacing tandem chain Step 2 Set the chain tensioner (1) on the chain ends (3) through the top opening (2). Place ratchet (4) on chain tensioner (1) and pull the chain together. Equipment: chain tensioner 9080135 ratchet with adapter, 2x mandrel Fig.
  • Page 321 Assembly change: Tandem axle assembly: Replacing tandem chain Step 3 Use the chain tensioner (1) to pull the chain ends (2) together until the chain lock (5) fits. Insert chain lock (5) from inside to outside. Secure the chain lock with keys (4). Equipment: chain tensioner 9080135 ratchet with adapter,...
  • Page 322 Assembly change: Tandem axle assembly: Replacing tandem chain Step 4 Secure all screws with Loctite 243 (4). Seal the contact surface using Atmosit compact. Screw cover (2) to tandem axle with hex screws (3) using ring wrench. Tools: box spanner BG 110 size: 13 BG 130 size: 13 BG 160 size: 13...
  • Page 323 Assembly change: Tandem axle assembly: Replacing tandem chain Step 5 Secure all screws with Loctite 243 (4). Seal the contact surface using Atmosit compact. Screw cover (2) to tandem axle with hex screws (3) using ring wrench. Tools: box spanner BG 110 size: 13 BG 130 size: 13 BG 160 size: 13...

This manual is also suitable for:

Gp gunter papenburg bg 130Gp gunter papenburg bg 160Gp gunter papenburg bg 190Gp gunter papenburg bg 240

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