Service Manual

SUBGROUP - INDEX
Group

Type

SCR system

040.025.1

R 966 - R 980

Coupling

040.030.1

R 956 - R 980

MKA pump distributor gear

040.045.1

R 956 - R 960
R 966 - R 980

LFR/en/Edition: 09/2014

Section

040.000.1
MJFCIFSS

LFR/en/Edition: 09/2014

Service Manual

040.000.2
MJFCIFSS

Service Manual

SCR system
Design

SCR system
1

Design
The SCR system (Selective Catalytic Reduction) reduces the nitrogen oxides (NOx) content in the
exhaust gases.

LFR/en/Edition: 07/2014

2.1

Function
General diagram and components list

Fig. 1

General diagram - coolant and diesel exhaust fluid

040.025.1
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MJFCIFSS

SCR system

Service Manual

Function
----

Diesel exhaust fluid system (hoses with ____

heating resistance)

Coolant system

A770

Diesel exhaust fluid pump

Y770

Circulation solenoid valve

A772

Level and temperature sensor

Y771

Injector

Fig. 2

General diagram of the exhaust system

----

Diesel exhaust fluid system (hoses with ____

heating resistance)

Coolant system

A770

Diesel exhaust fluid pump

B773

Outside temperature sensor

A772

Level and temperature sensor

D9508 Engine

B726

NOx-sensor / inlet

Y770

Circulation solenoid valve

B727

NOx-sensor / outlet

Y771

Injector

LFR/en/Edition: 07/2014

Hydrolysis: diesel exhaust fluid injected in exhaust gases forms ammonia (NH3) and carbon
dioxide (CO2).
Ammonia synthesis: when ammonia reacts with nitrogen oxides (NOx), it becomes nitrogen (N2)
and water (H2O).

040.025.2
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Service Manual

SCR system
Function

2.2

Arrangement of the components

Fig. 3

2.3

Arrangement of the components

Description of the components

UDL control unit and diesel exhaust fluid pump A770
The UDL control unit monitors the following temperatures: diesel exhaust fluid in the tank, coolant
and outside temperature. It controls the solenoid valve Y771.

Diesel exhaust fluid hoses with heating resistance

The resistances of the hoses are the following:
from the pump to the injector = about 7,2
from the tank to the pump = about 42

LFR/en/Edition: 07/2014

NOx-sensors
B726 is at the inlet of the SCR system. It measures the NOx at the engine outlet and determinates
the diesel exhaust fluid content.
B727 is at the outlet of the SCR system. It measures the NOx content at the exhaust outlet and
checks the efficiency of the reaction in the system.

Circulation solenoid valve Y770

The solenoid valve is active in the following cases:
diesel exhaust fluid temperature is under -10C
outside temperature is under 5C

040.025.3
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SCR system

Service Manual

Maintenance
The solenoid valve is inactive in the following cases:
pump temperature is over 55C
diesel exhaust fluid temperature is over 58C

Diesel exhaust fluid injector Y771

It injects the diesel exhaust fluid at about 8 bar.

2.4

Electrical diagram
(see 110 electrical system)

Maintenance
(see 030 Maintenance)

LFR/en/Edition: 07/2014

(see SCR system menu, in 190.600 Sculi Wizard utility)

040.025.4
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MJFCIFSS

Service Manual

Coupling
Design

Coupling
1

Design

Fig. 1

Design of the coupling

Elastic coupling

Mounting bolt

Disk

Flywheel

Hub

Intermediate housing

Riveted disks

1000 Diesel engine

Pressure spring

The elastic coupling 1 is mounted between the Diesel engine 1000 and the pump assembly.

LFR/en/Edition: 03/2014

The disk 2 is screwed to the flywheel 7 of the Diesel engine 1000. The disks 4 are riveted onto the
hub 3. The hub 3 is driven axially by the riveted disks 4. The pressure springs 5 are inserted into the
disks 2 and 4.

Function
The elastic coupling 1 compensates for misalignment of the crankshaft with the drive shaft and
dampens torque peaks in the event of load variations, imbalance or Diesel engine vibrations. It
prevents premature wearing of the flanged components.
The permanent coupling 1 transfers the torque of the Diesel engine 1000 directly and continuously
to the pump assembly.

040.030.1

R 956 - R 980
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MJFCIFSS

Coupling

Service Manual

Repair
The hub 3 can move radially to the disk 2. The pressure springs 5 ensure an elastic connection
between the disks 4 that are tightly fixed to the hub 3.
The drive shaft of the pump assembly is connected to the hub 3 and the coupling 1 through the spline
mesh.
The power from the Diesel engine 1000 is transmitted to the pump assembly through the flywheel 7,
the mounting bolts 6, the disk 2, the pressure springs 5, the disks 4 with the hub 3 and the drive shaft.
The torque peaks are dampened by the compression and release of the springs 5. The torsional
vibrations transmitted from the Diesel engine 1000 to the pump assembly are greatly reduced.

3.1

Repair
Removing the coupling

Fig. 2

Removing the coupling

Elastic coupling

Intermediate housing

Mounting bolt

1000 Diesel engine

Flywheel

2000 Pump assembly

Remove the pump assembly 2000 from the intermediate housing 8 of the Diesel engine 1000.
(see 040.045 MKA pump distributor gear)
Note the positioning of the coupling 1.

040.030.2

R 956 - R 980
copyright by

MJFCIFSS

LFR/en/Edition: 03/2014

Service Manual

Coupling
Repair
Loosen and remove the mounting bolts 6.
Remove the coupling 1 from the flywheel 7 of the Diesel engine 1000.

3.2

Installing the coupling

LFR/en/Edition: 03/2014

Fig. 3

Cross sectional drawing of a coupling

Disk

Flywheel

Hub

Intermediate housing

Riveted disks

Drive shaft

Pressure spring

1000 Diesel engine

Mounting bolt

Control measure

Machine

Control measure A (in mm)

R956 - R960 SME

about 48

R966 - R970 SME

about 47.5

R976 - R980 SME

about 47.5

Tab. 1

Control measure A for correct positioning

040.030.3

R 956 - R 980
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MJFCIFSS

Coupling

Service Manual

Repair

Caution!
Incorrect installation of the coupling!
Damage to the Diesel engine and pump assembly.
Position the coupling 1 properly on the flywheel 7, see Fig. 3.
If the control measure does not correspond to any position: contact the manufacturer.
Put the coupling 1 in position on the flywheel 7.
Insert two diametrically opposed mounting bolts 6.
Measure the distance between the intermediate housing 8 and the hub 3 and compare it with the
control measure A (see Tab. 1).
If the distance corresponds to the control measure A, the coupling 1 is properly installed.
If the distance does not correspond to the control measure A: turn the coupling 1 around and
check the control measure A again.
Insert the remaining mounting bolts 6 and tighten them with the prescribed torque.
Install the pump assembly 2000. (see 040.045 MKA pump distributor gear)

3.3

Checking concentricity and evenness

Fig. 4

Checking concentricity and evenness

Measure the concentricity E at the outer diameter of the hub 3 with a suitable measuring tool (dial
indicator) (tolerance = 0.1 mm).

LFR/en/Edition: 03/2014

Check the surface of the coupling 1 for evenness F with a suitable measuring tool (dial indicator)
(tolerance = 0.05 mm).

040.030.4

R 956 - R 980
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Service Manual

MKA pump distributor gear

Design

MKA pump distributor gear

1

Design

Fig. 1

MKA pump distributor gear

2000 Pump distributor gear

Drive shaft

Primary output

Intermediate gear

Auxiliary output

The pump distributor gear 2000 is a spur gear unit installed between the Diesel engine and the
hydraulic pumps.
It is directly energized by the Diesel engine through a flexible coupling and transmits the power of the
Diesel engine to the hydraulic pumps.

LFR/en/Edition: 01/2014

The different gear transmission ratios to the primary outputs 2 of working pumps and to the auxiliary
output 3 of swing pump allow an accurate adaptation of the flows for the operating movements.

Technical data
Machine
Pump distributor gear

R 956 - R 960
R 966 - R 980

R956
type

R960

PVG 351 C 398

R966

R970

PVG 351 C 399

R976

R980

PVG 450 C 466

040.045.1
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MKA pump distributor gear

Service Manual

Maintenance
Machine

R956

Weight of pump distributor gear

kg

R960

R966

198

Weight of working pumps

R970
250

Weight of swing pump

60

(2x) 153
28.5

46

73

93

Weight of servo control pump

3.5
type

Swing pump
Gear reduction to the working
pumps

ratio

Gear reduction to the swing

pump

R980
210

(2x) 125

Weight of fan drive pump

Working pumps

R976

LPV165

LPV250

A4VG71

A4VG90

A4VG125

0.83

0.7288

0.9285

0.6037

0.661

0.714

Maintenance
(see Maintenance and inspection schedule, in 030 Maintenance)

Repair

LFR/en/Edition: 01/2014

040.045.2
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MJFCIFSS

R 956 - R 960
R 966 - R 980

Service Manual

MKA pump distributor gear

Repair

Fig. 2

4.1

Removing and installing the pump distributor gear

Fire protection sheets

Diesel engine

Reinforcement

Diesel engines gearing

Shut-off valve

Drive shaft

Hydraulic tank

10

Pump distributor gear

Mounting bolts

11

Air line

Air filter

Removing the pump distributor gear

Remove the air filter 6 (for R956 and R960 only).
Remove the air line 11 (from R966 to R980 only).
Remove the fire protection sheets 1 and the reinforcement 2 (from R966 to R980 only).
Depressurize the hydraulic system. (See chapter 30, Working hydraulics system)
Place the hydraulic tank 4 under negative pressure with the vacuum pump.
Close the shut-off valve 3 on the hydraulic tank 4.
Place a suitable receptacle under the pump distributor gear 10.
Drain the oil out of the pump distributor gear 10. (See chapter 30, Drive group)
Drain the oil out of the suction line: remove the draining screw under the suction line (from R966
to R980 only).
Disconnect all oil lines from the pump distributor gear 10 and from the hydraulic pumps.
Disconnect all electrical connectors from the pump distributor gear 10 and from the hydraulic
pumps.
Attach the pump distributor gear 10 to a suitable slinging device and to a lifting crane.
Loosen and remove the mounting bolts 5 from the pump distributor gear 10.
Remove the pump distributor gear 10 from the Diesel engines gearing 8.

4.2

Repair
(See repair instructions PVG 450C462)

4.3

Installing the pump distributor gear

Make sure the sealing surfaces of the pump distributor gear 10 are clean and in good condition.

LFR/en/Edition: 01/2014

Apply grease on the drive shaft 9.

Move the pump distributor gear 10 closer to the Diesel engine 7 with the lifting crane.
Engage the drive shaft 9 in the Diesel engines gearing 8.
Put the mounting bolts 5 and tighten them to the approved torque.
Remove the slinging device and the lifting crane.
Connect all oil lines to the pump distributor gear 10 and to the hydraulic pumps.
Connect all electrical connectors of the pump distributor gear 10 and of the hydraulic pumps.

R 956 - R 960
R 966 - R 980

040.045.3
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MKA pump distributor gear

Service Manual

Repair
Tighten the draining screw under the suction line (from R966 to R980 only).
Install the fire protection sheets 1 and the reinforcement 2 (from R966 to R980 only).
Install the air line 11 (from R966 to R980 only).
Install the air filter 6 (for R956 and R960 only).
Open the shut-off valve 3 on the hydraulic tank 4.
Pressurize the hydraulic tank 4 with the vacuum pump.
Bleed the air of the hydraulic pumps. (See chapter 30, Working hydraulics system)
Fill the pump distributor gear 10 with oil. (See chapter 30, Drive group)
Run the Diesel engine for some minutes.
Stop the Diesel engine.
Check the oil level in the pump distributor gear 10. (See chapter 30, Drive group)

LFR/en/Edition: 01/2014

Check the hydraulic system for leaks.

040.045.4
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MJFCIFSS

R 956 - R 960
R 966 - R 980