BW 120-4 English Service Training

Service Training
BW 100 AD/AC Series 4 BW 120 AD/AC Series 4

P/N 008 099 86 STATUS: 03/2004
Service Training
Table of contents
Foreword List of additional documentation General Maintenance List of components Kubota diesel engine View of engine Pump installation on diesel engine View of diesel engine, flywheel side Tests and adjustments Adjusting the valve clearance Trouble Shooting Travel system Travel pump Travel pump control Charge pressure relief valve High pressure relief valves Drum drive motor Wheel drive motors on AC-machines Trouble shooting travel system Insufficient travel power The machine moves with the travel lever in Neutral Vibration Vibration pump Vibration control valve Vibration motor Trouble shooting vibration Steering Steering valve Trouble shooting steering Electric circuit diagrams Table of contents Function groups Reference lines, frames Potential cross references Relay cross references List of components Electric system A1 A2 A3 A4 B1 C1 C2 C3 C4 C5 C6 C8 D1 D3 D7 D9 D 10 D 12 D 16 D 17 D 28 D 30 E1 E3 E4 E5 E6 F1 F3 F5 G1 G1 G2 G3 G4 G5 G5 G6
________________________________________________________________________________________ BW 100/120 AD-3 1 BW 100/120 AC-3
Service Training
Foreword
In 2004 the tandem vibratory rollers of product range BW 100 AD/AC4 and BW 120 AD/AC4 were launched in the market for the first time. They are a further development of the old BW 100/120AD/AC of generation 3, which already were a great sales success. The contents of this training shall enable the service engineer to perform adjustments and trouble shooting as well as all necessary repair work in a professional manner. The owner of the machine should recognize that the service engineer is fully familiar with the machine. He should realize that the service engineer applies the correct measures to detect a possible fault on a machine and that all repair measures are performed with skill and knowledge. Persons participating on this training course should be confident when having to work on this machine.
Documentation
For the BOMAG machines described in this training manual the following documentation is additionally available: Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine. 1. 2. 3. 4. 5. 6. Operating and maintenance instructions Spare parts catalogue Wiring diagram* Hydraulic diagram* Repair instructions Service Information
* The document versions valid at the date of printing are part of this training manual.
________________________________________________________________________________________ BW 100/120 AD-4 A1 BW 100/120 AC-4
Service Training
General
Machines of product range BW 100/120 AD/AC-4 are tandem vibratory rollers or combination rollers for compaction work in road construction. They are most suitable for the compaction of bituminous materials as well as light compaction tasks in earthwork. Compaction is achieved by the vibration of both drums or the vibration of the drum and the static load of the rubber tires. The power output from the water cooled Kubota diesel engine is transferred to drums or wheels (travel and vibration systems) and to the steering via the hydrostatic drive systems of the machine. This type of power transmission ensures lowest possible efficiency losses. Both drums of the BW 100/120 AD-4 are fitted with both travel motors as well as vibration motors. The motors for the respective drive systems are always arranged on one side of the machine. Since it is beneficial for many applications (e.g. when laying asphalt layers) to work with one vibrating and one static drum, the machine is equipped with a vibration shut-off valve for the rear drum. On machines of type BW 100/120 AC-4 the wheel set is driven by two travel motors. This roller combines the high compaction power of a vibration drum with the excellent surface sealing effect of rubber tires in one machine. This machine obviously achieves considerable savings in costs when compared with a pure vibratory or pneumatic tired roller. The standard equipment of the machine includes a gravity sprinkler system. A pressure sprinkler system is optionally available on request. In connection with the scrapers the water sprinkler system avoids picking up of material by the drums. On the AC-machines a pressure sprinkler system prevents sticking of dirt and bitumen to the rubber tires. For this purpose the tires are sprayed with emulsion. Front and rear frames of the machine are joined by an oscillating articulated joint. The amply dimensioned oscillation angle makes sure that the drums always have ground contact over the entire width. Both travel motors are fitted with integrated brakes working as parking brakes. Depending on the position of the brake solenoid valve these brakes are released by charge pressure when starting the engine and applied when shutting the engine down.
________________________________________________________________________________________ BW 100/120 AD-4 A2 BW 100/120 AC-4
Service Training
Maintenance
The tandem/combination rollers of series BW 100/120 AD/AC-4 are high performance machines for the extremely difficult use in asphalt compaction and earth work. To be able to meet these demands the machine must always be ready to be loaded up to its limits. Apart from that, all safety installations must always be fully functional when working under the partly very dangerous conditions on a construction site. Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed. The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hour interval you must also perform the maintenance work for the 500 and 1000 hour intervals. It should also be clear, that with the 2500 hours interval only the work for the 10 and 500 hour intervals must be performed. For maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).
________________________________________________________________________________________ BW 100/120 AD-4 A3 BW 100/120 AC-4
Service Training
List of components BW 100/120 AD/AC-4 Engine Manufacturer Type Cooling Working cycles Number of cylinders Power DIN 6271 IFN/SAE at 2700 rpm Fixed engine speed Stage 1 Fixed engine speed Stage 2 Valve clearance I/E Travel pump Manufacturer Type System Displacement High pressure limitation Charge pressure Speed Max. flow capacity cm/rev. bar bar rpm l/min Hydromatik A10 VG 28 Axial piston 28 380 24 2700 73 kW rpm rpm mm Kubota D 1703 MDI Water 4 3 25,2 2250 2700 0,20/0,20
________________________________________________________________________________________ BW 100/120 AD Series 4 B1 BW 100/120 AC Series 4
Service Training
BW 100/120 AD/AC-4 Travel motor (drums) Manufacturer Type Number System Displacement Brake cm/rev. Poclain MK 04 2 Radial piston motor 408 yes BW 100/120 AC-4 Travel motor (wheels) Manufacturer Type Number System Displacement Brake cm/rev. Poclain MSE 02 2 Radial piston motor 255 yes BW 100/120 AD/AC-4 Vibration pump Manufacturer Type System Displacement Starting pressure Operating pressure cm/rev. bar bar Bosch HYZ 11 Gear 11 210 100 +/-60 bar (soil dependent)
Service Training
Vibration motor Manufacturer Type System Displacement Frequency stage 1 Frequency stage 2 Amplitude cm/rev. Hz Hz mm Bosch HYZ 8 Gear 8 55 70 0.5
Steering pump Manufacturer Type System Displacement max. steering pressure Steering valve Manufacturer Type System Danfoss OSPC 80 ON Rotary valve cm/rev. bar Bosch HYZ 8 Gear 8 140 +/-30 bar
Service Training
Kubota diesel engine 1703 MDI
The tandem vibratory rollers of series BW 100/120 AD/AC-4 are powered by a water cooled 3-cylinder Kubota diesel engine type 1703 MDI. The engine is an upright water-cooled four-stroke diesel engine.
Cross-section of diesel engine
________________________________________________________________________________________ BW 100/120 AD Series 4 C1 BW 100/120 AC Series 4
Service Training
View of engine:
Pos. 1 Pos. 2 Pos. 3 Pos. 4
Engine temperature switch Connection glow plug Oil dipstick Injection nozzles
Service Training
Pump installation on diesel engine
Pos. 1 Pos. 2 Pos. 3
Charge pump Vibration pump Oil pressure switch
0.6 bar
Service Training
View of diesel engine, flywheel side
Pos. 1 Pos. 2 Pos. 3 Pos. 4
Travel pump Pressure test port A high pressure forward Pressure test port B high pressure reverse High pressure relief valves
380 bar
Service Training
Tests and adjustments Measuring the compression
Fig. 5: Compression pressure: 1. Run the engine warm and shut it down. Disassemble the nozzle holders. 2. Install the diesel engine compression tester to the nozzle holder opening. 3. Make sure that the throttle lever is in top position (no injection) and start the engine with the starter motor. 4. Read the max. pressure. Repeat the measurement at least two times. 5. If the measurement is below the permissible limit value check cylinder, piston, valve and cylinder head.
Adjustment values:
Compression pressure Factory settings 29.4 -32.4 bar Permissible limit value min. 23.5 bar
Service Training
Checking the valve clearance
IMPORTANT: The valve clearance must only be checked and adjusted when the engine is cold. The cylinders are counted from the flywheel end, i.e. cylinder 1 is on the flywheel side. 1. Remove the cylinder head cover. 2. Align the mark 1TC on the flywheel and the notched part (1) on the plate so that piston no. 1 is in compression stroke or overlaps top dead centre (TDC). 3. Measure the valve clearance marked "1" with a feeler gauge. 4. Correct the clearance by the setscrew if it is not within the limits of the specified factory data. Valve clearance (cold) Factory settings 0,20 mm
(The values apply for intake and exhaust valves)

Service Training
Please note that the TC-mark is only valid for cylinder 1. There is no mark for the other cylinder. Cylinder 1 is in compression stroke when the TC-mark is visible in the window (2) Now turn the flywheel further, until the other valves overlap top dead centre and adjust the valve clearance accordingly. Note: The "TC"-mark on the flywheel applies only for cylinder no. 1. The other cylinder has no "TC"-mark. When the TC-mark is aligned with the punched mark on the rear disc, piston no. 1 is in top dead centre position. Now turn the flywheel bz 15 clockwise or anticlockwise to check whether the pistons are in TDC-position (compression position). (The piston is in TDC when intake and exhaust valves do not move. When both valves are moving, the piston is in overlapping position.) Finally turn the flywheel by 360 to ensure that TC-mark and punched mark match exactly. All valve clearances must be set to the nominal value. Turn the flywheel two to three times in anti-clockwise direction to check the valve clearance. After adjusting the valve clearance retighten the locking nut of the setscrew.
Service Training
Troble Shooting Fault
Engine does not start
Possible cause
No fuel Air in the fuel system Water in the fuel system
Remedy
Fill in fuel Bleed Replace fuel and clean or replace the fuel system Clean Replace Use specified fuel Use specified fuel Tighten nuts Adjust Replace Clean Repair or replace Repair or replace Replace cylinder head gasket, tighten cylinder head screws, glow plug and nozzle holder Repair or replace Adjust Replace Adjust Charge Repair or replace Repair or replace Connect
Fuel line clogged Fuel filter clogged Too high viscosity of fuel or engine oil at low temperatures Fuel with low Ceten-number Fuel loss caused by loose locking but on injection line Incorrect adjustment of injection Fuel camshaft worn Injection nozzle clogged Malfunction of fuel lift pump Crankshaft, camshaft, piston or bearings seized Loss of compression on a cylinder
Incorrect valve seat alignment, valve spring broken, valve seized Insufficient valve control Piston rings worn Excessive valve clearance Battery discharged Starter does not work Malfunction of starter Malfunction of ignition switch Wiring has come loose
Service Training
Fault
Engine does not turn regularly
Possible cause
Fuel filter clogged or soiled Air filter clogged Fuel loss caused by loose locking but on injection line Faulty function of injection pump Incorrect injection valve opening pressure Injection nozzle sticking or clogged Fuel overflow line clogged Malfunction of regulator Too high engine oil level Piston ring worn or sticking Incorrect injection setting Insufficient compression Cylinder head gasket defective Overload Poor fuel quality Fuel filter clogged Air filter clogged Incorrect injection setting Moving engine parts possibly seized Uneven fuel injection Insufficient nozzle injection Loss of compression
Remedy
Replace Clean or replace Tighten nuts Repair or replace Adjust Repair or replace Clean Repair Correct the oil level Replace Adjust Check compression pressure Repair Reduce the load Use specified fuel Replace Clean or replace Adjust Repair or replace Repair or replace the injection pump Repair or replace the nozzle Replace cylinder head gasket, tighten cylinder head screws, glow plug and nozzle holder Replace Replace piston Replace Replace Replace pump elements or pump Replace Replace
White or blue exhaust gas
Black or dark grey exhaust fumes
Insufficient power
Excessive lubrication oil consumption
Fuel mixed with lubrication oil Water mixed with lubrication oil
Oil scraper ring worn or sticking Piston ring groove worn Valve stem and guide worn Crankshaft bearing and crank journal bearing worn Injection pump plunger worn Cylinder head gasket defective Cracks in crankcase or cylinder head
Lubrication oil in coolant Cylinder head gasket defective
Replace
Service Training
Fault
Too low oil pressure
Possible cause
Engine oil level too low Oil strainer clogged Oil filter cartridge clogged Pressure relief valve clogged with dust Pressure relief valve spring fatigued or broken Excessive clearance of crankshaft bearing Excessive clearance of Rocker arm shaft Oil passage clogged Different type of oil Oil pump defective Different type of oil Pressure relief valve defective Engine oil level too low Fan drive belt broken or not correctly tightened Coolant level too low Radiator and cooling fins clogged by dust Radiator internally corroded Coolant line corroded Radiator cap defective Water pipe damaged Thermostat defective Water pump defective Overload Battery fluid level too low
Remedy
Top up Clean Replace Clean Replace Replace Replace Clean Use specified oil quality Repair or replace Use specified oil quality Replace Top up Replace or adjust Top up Clean Clean or replace Clean or replace Replace Replace Replace Replace Reduce the load Top up distilled water and recharge Adjust the tension or replace the belt Connect Replace Replace Replace
Excessive oil pressure Engine overheating
Rapid discharging of battery
Fan drive belt slipping Wiring has come loose Regulator defective Generator defective Battery defective
________________________________________________________________________________________ BW 100/120 AD Series 4 C 10 BW 100/120 AC Series 4
Service Training
Engine solenoid: The machine is equipped with a solenoid which works according to the principle ENERGIZED TO RUN. This solenoid has the benefit that the engine will be immediately shut down in case of a fault in the electric system. A disadvantage is the quite costly design of the solenoid with two coils. Nominal currents of windings: Pickup winding (PW) Holding winding (HW) 51 A 0.7 A
Solenoid
Fig. 14: Function of the engine solenoid: The pickup winding (PW) is directly triggered via potential 30. Once the engine has started and oil pressure is available the voltage to the pickup winding is interrupted and voltage is only applied to the holding winding.
________________________________________________________________________________________ BW 100/120 AD Series 4 C 11 BW 100/120 AC Series 4
Service Training
Travel system:
On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of the travel pump with the integrated safety elements, two travel motors, the hydraulic oil filter and the hydraulic oil cooler.
Charge pressure from brake valve
Charge pressure from brake valve
High pressure test ports MA and MB
Charge pressure after hydraulic filter
Leak oil port to tank
The installation of a hydraulic pump with variable displacement into a closed hydraulic circuit is a perfect solution for a hydrostatic travel system, because with this design the travel direction can be reversed without any problems. The travel pump is flanged to the flywheel side of the diesel engine. It is directly driven by the engine with constant speed. The tandem gear pump driven by the auxiliary output of the diesel engine consists of a steering/charge pump and a vibration pump. The return flow from the steering valve is fed through the charge oil port into the travel pump.
________________________________________________________________________________________ BW 100/120 AD Series 4 D1 BW 100/120 AC Series 4
Service Training
Besides its function of supplying the closed circuit with cool and filtered oil as replacement for leakage and flushing losses, the oil from the charge circuit is also used to release the travel motor integrated brakes: All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in the travel pump. These are: High pressure relief valves (380 bar) with integrated boost check valves Charge pressure relief valve (24 bar) Servo control The travel motors (on AD-machines) are hydraulically connected parallel to each other. On AC-machines all three motors are arranged parallel to each other.
Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch Rexroth-Hydromatik, type A 10 VG 28.
2 1
380 bar 5
To the travel motors
380 bar
24 bar
Leak oil to tank
Charge pressure
Hydraulic diagram for travel pump 1 2 3 4 5 Pump drive Control piston 4/3-way servo valve Charge pressure relief valve High pressure relief valves
The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit. These are:
Service Training
Servo control High pressure relief valves with integrated boost check valves Charge pressure relief valve
The travel pump unit is directly driven by the flywheel side of the engine via an elastic coupling. The pump speed is therefore identical with the engine speed.
6 8 5
1 3
Travel pump, cross-section 1 2 3 4 5 6 7 8 Drive shaft Swashing cradle with swashing lever Cylinder block Working pistons Control piston Control unit with feedback lever Slipper pad Valve plate
Service Training
Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction (direction of oil flow). A manually operated 4/3-way valve directs the pilot oil flow (from the charge circuit) to the corresponding control piston side in the servo control. The 4/3-way valve is controlled by the travel lever and the travel cable. In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control piston to the corresponding direction. The swashing lever between the control piston and the swash plate transfers the control piston movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction. This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil into the pump and presses it to the travel motors. All working pistons are drilled through their entire length. Pressure fluid flows through these bores into the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically balanced field, on which the slipper pads can slide without any metal to metal contact between swash plate and slipper pads. The feedback lever on the control piston detects when the swash plate has reached a position that corresponds with the displacement of the travel lever. This feedback lever controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of the working pistons (oil flow rate) remain constant, until a new control command requires a different swashing angle. When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the travel motors will change. The spherical valve plate centres cylinder block, which is mounted on the splines of the drive shaft. This avoids the appearance of undesired transverse forces. The complete drive consisting of valve plate cylinder block with working pistons and swash plate is held together and preloaded by Belleville springs. This immediately eliminates any appearing wear, increases the efficiency of the pump and prolongs the lifetime considerably. When controlling the travel pump pressure will build up in the line between pump outlet and motor inlet. This pressure depends on the load acting on the travel motors. This pressure keeps the boost check valve inside the high pressure relief valve for this particular side of the closed hydraulic circuit closed. Cool and filtered oil can now only enter into the closed circuit on the opposite side (low pressure side). The high pressure relief valve limits possibly occurring extreme pressure peaks to the adjusted value. If one of these valves responds, hydraulic oil will flow out of the high pressure side and enter the low pressure side through the corresponding boost check valve.
Service Training
Control The servo control of the pump is an integral part of the pump housing and consists mainly of: the manually controlled 4/3-way valve (1) the control piston (2) the feedback lever (3) the swashing lever with the swashing cradle (see Fig. 3).
Service Training
Travel pump control
When actuating the travel lever the 4/3-way valve moves out of neutral position to the desired direction and guides the pilot oil flow through the pilot oil portioning valve to the corresponding control piston side. The control piston moves to the corresponding direction and operates the swash plate via the swashing lever accordingly. The feedback lever, which is mounted with its ball head in the pump control shaft, follows the control piston and interrupts the pilot oil flow when the control piston has reached a position corresponding with the displacement of the travel lever. The pump can now deliver oil to the travel motors. The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing. The supply bores to both control chamber sides are fitted with nozzles (swashing time nozzles). These nozzles restrict the pilot oil flow and enable a very sensitive control of the pump.
Control in neutral position
Service Training
The feedback lever controls the pilot oil portioning valve so that the swashing angle remains unchanged, until the introduction of a new control command.
Control actuated When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical (case pressure = max. 3 bar).
Service Training
Charge pressure relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value.
Charge pressure relief valve The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed hydraulic circuit. Charge oil is also required to control the pumps and to release the parking brake. Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure in both sides of the closed circuit is identical with charge pressure.
Service Training
High pressure relief valves
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
Hydraulic diagram 1 2 3 4 Travel pump Control piston (actuated) 4/3-way valve (actuated) High pressure relief valves, fixed adjustment (380 bar)
________________________________________________________________________________________ BW 100/120 AD Series 4 D 10 BW 100/120 AC Series 4
Service Training
High pressure relief valves 1
1 2
High pressure relief valves Charge pressure relief valve
The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the diesel engine and all other machine components against overloads. The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and flushing quantities. High pressure relief valve 380 bar
Service Training
Drum drive motor:
Poclain travel motor type MK04 Both drums are driven by Poclain travel motors type MK04. These are radial piston motors. These drive motors consist of the outer housing, the flat distributor, the cylinder block with the working pistons, the output shaft and the brake. The brake is designed as a Hirthtoothing. The housing consists of bearing section (bearings for output shaft) torque module (cam race) oil distributor and Hirth brake
The function of the radial piston motor is described hereunder. The piston positions mentioned in the description are shown in the corresponding illustration.
The movement of a piston along the cam race must be examined during various phases of the rotation.
Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. This is the start of a rotation. Due to the pressure on the back of the piston the roller will move along the cam, thereby causing a rotary movement of the cylinder block.
Piston position 2:
At this point the oil flow to the piston has reached its largest cross section. The piston continues its travel along the cam race towards the valley between two cams. The opening cross section decreases with continuing rotary movement.
Piston position 3:
Once the piston has reached the deepest point the oil flow to the piston is cut off. The piston is no longer driven. It has reached its dead centre. Another piston must now be driven to move the previous piston out of dead centre position.
Piston position 4:
By driving other pistons the previous piston is moved out of dead centre position. The oil behind the piston is connected with the low pressure side and the retracting piston presses it back to the pump.
Piston position 5:
The oil supply back to the pump comes close to an end, the connecting bore between cylinder and low pressure side closes slowly. The piston will now reach its second dead centre position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
Service Training
Brake actuation MK04 motor (drum drive motor) The travel system is equipped with a Hirth-type brake in the travel motors. This brake serves as parking brake to park the machine. (to secure the machine when the engine is running or to park the machine with the engine shut down) and as emergency brake. The brake control is accomplished via a 3/2 way valve which is located at the front in the engine compartment. If the solenoid valve is supplied with electric current when the engine is started, the valve will switch over and guide charge pressure into the brake housings. This releases the brakes. If the solenoid valve is de-energized while the engine is running (e.g. when actuating the emergency stop switch), the oil pressure in the brake housings is relieved to the tank and the brakes will close.
Hirth gearing
Service Training
During travel operation the machine is braked by the closed hydraulic circuit. When moving the travel lever to neutral position the supply from the pump is interrupted. The machine will stop. However, both travel motors are additionally fitted with brakes. These brakes work only as parking brakes. The brakes are automatically relieved by the charge pressure building up when starting the engine. Should the charge pressure drop considerably (failure or shutdown of the engine, damage in the hydraulic system), the brakes close automatically. When shifting the travel lever to neutral position the brake closes after a short while. The brake closes also when the seat contact switch is open. The brakes can be relieved mechanically with screws.
The mechanical releasing of the brakes works as follows :
Unscrew the 2 plugs (191) Press the screws (192) against the springs (193) Tighten both screws (192) alternately and in steps until they bottom (approx. 2 revolutions) (max. 35 Nm)
To close the brake, proceed in reverse order.
Service Training
Wheel drive motors on AC-machines The rubber tires of the BW 100/120 AC-4 are driven by two radial piston motors Poclain MSE 02 which are joined parallel to each other and also parallel to the drum drive motor. The function of the motor is identical with the previously described Poclain motor MK04. However, the main difference is the design of the integrated brake. The MSE02 is fitted with a multi-disc brake. This consists of inner and outer discs which run permanently in an oil bath. Since the brake is normally only applied in events of emergency, it is almost wear free. If needed, the brakes can be released with the help of a brake releasing device. For this purpose a ball valve is installed in the engine compartment. By operating this valve oil can be directly guided to the motors (drum as well as wheel drive motors). For this purpose the steering wheel must be slowly turned for approx. two turns in clockwise direction. In this case the steering wheel or Orbitrol has the effect of a pump and delivers oil to the brakes (to the drum as well as the wheel drive motors). The brakes are thereby is released.
Service Training
Trouble shooting travel system Machine does not drive Checking the function of the brake valve > Switch the ignition on > Release the parking brake by shifting the travel lever out of neutral position > Measure the voltage supply on the solenoid valve Nominal value: 12 V If the voltage supply is not correct perform trouble shooting in the electric system. If the voltage supply is correct the current consumption of the brake valve must be checked next: > For this purpose the meter must be connected in line with the solenoid of the brake valve > Switch the ignition on Nominal value: max. 2.7 A If no current consumption can be detected, change the solenoid coil
Brake valve
Fig. 1
Service Training
If the solenoid coil is o.k., check the solenoid valve. > Connect a 60 bar pressure gauge to the pressure test port > Start the engine and move the travel lever out of neutral. > Read the pressure gauges. Nominal value: approx. charge pressure 24 bar
Pressure test port M3
Fig. 2
Service Training
If the charge pressure value is not reached check the brakes in the motors. > Connect a 600 bar pressure gauge to pressure test port (M1). > Close the brake (travel lever in neutral) > Start the engine > Turn the steering against an end stop and read the pressure gauge Nominal value approx.: 170 bar
Test port M1
Fig 3: If the steering pressure value is not reached replace the steering/charge pump.
Service Training
If the steering pressure is correct check the charge pressure relief valve of the travel pump. > Unscrew the plug. > Take the valve insert out. > Check the valve visually. Replace the valve immediately if damaged.
Charge pressure relief valve
Fig 4:
Service Training
If the valve is o.k., check the brakes. > Disconnect the brake hoses from front and rear travel motor, one after the other, and close them with plugs. > Perform a pressure test on the pressure test port (near hydraulic oil filter M 3) after each disconnection of a brake hose If the charge pressure value is not reached replace the corresponding motor.
Disconnect the brake line and close it with a plug (line in the back)
Fig 5:
Service Training
If the charge pressure is correct check the high pressure of the travel pump. Attention! The following test must not exceed 5 seconds ! > Close high pressure ports A and B. > Connect 600 bar pressure gauges to the high pressure test ports > Run the engine in idle speed and actuate the travel pump quickly to both directions. > Read the pressure gauges. Nominal value: approx. 400 bar
Close the ports
Install 600 bar pressure gauges
Fig 6:
Service Training
If the high pressure value is not reached replace the high pressure relief valves. If the problem still exists after replacing the high pressure relief valves, replace or repair the travel pump.
High pressure relief valves
Fig 7:
Service Training
If the high pressure value is reached, the travel motors must be checked individually. > Reconnect the high pressure hoses from the front travel motor to the travel pump. > Repeat the pressure test If the high pressure value is not reached replace the front travel motor. If the high pressure value is reached replace the rear travel motor.
Connect hoses from front travel motor or close ports to rear travel motor
Connect 600 bar pressure gauges
Fig 8:
Service Training
If the charge pressure is reached in the test described under Fig. 2, charge pressure must be checked together with high pressure. > Connect 600 bar pressure gauges to the pressure test ports MA and MB. (Travel pump) > Run the engine with max. speed > Block the drum or disconnect the cable from the brake valve. > Actuate the travel lever for a moment and read the pressure gauge Nominal value: charge pressure approx. 22 to 24 bar high pressure approx. 380 bar
Connect 600 bar pressure gauges
Charge pressure test port M3
Fig 9:
Service Training
If the charge pressure is reached check the control chamber pressure. > Connect pressure test ports to the control chambers (X1 and X2). > Connect a 60 bar pressure gauge to the pressure test ports > Block the drum or disconnect the cable from the brake valve. > Actuate the travel pump to full displacement and read the pressure gauge. Nominal value: approx. 24 bar
If the control chamber pressure value is not reached replace or repair the travel pump.
Control chamber pressure test port
Fig 10:
Service Training
If the control chamber pressure is reached and the high pressure value is correct, release the brakes in both travel motors mechanically > Check whether the machine is able to drive If the machine drives replace or repair the travel motor with the defective brake. Mechanical releasing of brake (AD-machines only) is accomplished as follows: - Unscrew the 2 plugs (191) - Press the screws (192) against the springs (193) - Tighten both screws (192) alternately and in steps until they bottom (approx. 2 revolutions) (max. 35 Nm)
Fig 11:
Service Training
Insufficient travel power With this fault the engine speed must be checked first. Nominal value: Stage 1 = 2250 rpm Stage 2 = 2700 rpm
If the nominal speeds are not reached perform trouble shooting on the engine.
If the speed values are correct check the travel control. > Detach the control cable > Shift the pump control lever forward and reverse and check whether the pump swashes to maximum displacement. > Check whether the travel cable is worn.
Detach the control cable
Fig 12:
Service Training
If the end stops are not reached adjust the end stops. Adjust the end stops for the speed on the setscrews > Check the travel cable for wear.
End stop for travel speed in reverse
End stop for travel speed in forward
Fig 13:
Service Training
The machine moves with the travel lever in Neutral With this fault the neutral position of the pump must be checked first. > Shift the travel lever to Neutral position > Disconnect the travel cable from the pump Check, whether bores in ball socket and pump control lever are in line.
Detach the control cable
Fig 14:
Service Training
If the bores are not in line adjust the travel cable. > Slacken the counter nut on the back stop. > Adjust the nuts until the travel cable corresponds with the neutral setting of the pump. > Tighten the counter nut again
Fig 15:
Service Training
If the bores are in line check the mechanical neutral position. > Join both control chambers of the travel pump (X1 and X2) Note: The resulting condition of equilibrium must bring the machine to standstill. If the neutral position is reached by this measure replace or repair the servo control on the machine.
Connect ports X1 and X2 with a hose
Fig 16:
Service Training
If the neutral position is not reached it is necessary to adjust the mechanical neutral position. > Connect 600 bar pressure gauges to MA and MB. > Block the drum or disconnect the cable from the brake valve. > Run the engine with max. speed. > Read the pressure gauges. > Adjust the mechanical 0-position until the pressure readings are identical on both sides If the neutral position is not reached, replace or repair the travel pump.
Setscrew underneath the servo control
Fig 17:
Service Training
Vibration
The vibration drive is an open hydraulic circuit and consists mainly of the vibration pump, the control valve and the vibration motors.
Circuit diagram AD-machine
8 cm
8 cm
110+10 bar
210+10 bar
11 cm
Fig. 20:
________________________________________________________________________________________ BW 100/120 AD Series 4 E1 BW 100/120 AC Series 4
Service Training
The vibration pump is directly driven by the timing gear side of the diesel engine. Vibration pump and steering/charge pump are joined together to a tandem pump unit. The gear pump delivers the hydraulic oil out of the hydraulic oil tank to the vibration control valve. If the vibration is switched off the hydraulic oil flows directly back to the tank. When the vibration is switched on, the control valve directs the oil flow to the in line connected vibration motors (BW 100/120 AD-4), or to the vibration motor on the drum (BW 100/120 AC-4). The vibration motors (gear motors) drive the vibrator shafts in the drums with constant speed via Bowex couplings. The rotation of the exciter shafts with the attached eccentric masses generates the vibration of the drums, which are suspended in rubber elements. From the second vibration motor the oil flows back through the control valve block to the tank (open circuit). The standard equipment of the AD-machine includes a shut-off valve for the rear drum vibration. When operating a ball valve the oil flow is directly returned to the tank after the first motor (front drum) via the control valve block
Service Training
Vibration pump
The vibration pump is a directly driven gear pump.
Fig 21:
The drive gear is connected with the auxiliary drive of the diesel engine via a pinion. Drive gear and driven gear are positioned by a bearing plate in such a way, that the gears mesh with minimum clearance when rotating. The displacement chambers are created between the tooth flanks, the inside wall of the housing and the faces of the bearing plates. During operation of the pump the hydraulic oil is transported in these chambers from the suction side to the pressure side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. These tooth chambers convey the fluid to the pump outlet from where it is pressed to the consumer. To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the suction side to the pressure side without any losses. Outer gear pumps are fitted with gap seals. In dependence on the operating pressure there will be losses from the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side against the front face of the gears, making sure that only a very little quantity of oil will leak from the pressure side to the suction side when the pressure increases. The pressure field is always under the actual system pressure. The vibration pump delivers the hydraulic oil from the tank to the vibration motors and from there back to the tank.
Service Training
Vibration control valve
With the vibration control valve the vibration is electrically switched on and off. The valve consists of the solenoid operated valve piston, the pressure relief valve for the vibration circuit and the brake valve to brake the exciter shafts when switching the vibration off. When switching the vibration on the direct return flow to the hydraulic oil tank is interrupted and the hydraulic oil is guided to the vibration motors. The high pressure (starting pressure) in the vibration circuit generated by the resistance of the resting exciter shafts is limited to 210 bar by a pressure relief valve inside the control valve block. When operating the control valve the valve spool opens also a direct connection between the outlet of the second vibration motor and the oil tank. When switching the vibration off this direct connection is interrupted. The hydraulic oil, which is now displaced to the control valve by the still rotating vibration motors is applied to 110 bar pressure relief valve (brake valve). This valve brakes the rotation of the exciter shafts within the shortest possible time.
Service Training
Vibration motor
On the machines of series BW 100/120 AD-4 and BW 100/120 AC-4 the exciter shafts inside the drums are directly driven by vibration motors. These vibration motors are gear motors which are directly connected with the exciter shafts via Bowex couplings. The design of these vibration motors is almost identical with the design of the vibration pump. A more detailed description of the design is therefore not required. On the BW 100/120 AD-4 the vibration motors are connected in series. The standard equipment of the machine includes a shut-off valve for the rear drum vibration. When operating a ball valve the oil flow is directly returned via the control valve block to the tank after the first motor.
Service Training
Trouble shooting vibration Vibration frequency too low
If the specified exciter shaft speed is not reached, the engine speed must be checked first. Check the engine speed with a vibration reed frequency meter.
Nominal value:
2700 rpm (with throttle control in stage II)
If the nominal speed is not reached perform trouble shooting on the engine. Various instruments or methods may be used to check the engine speed. (e.g. vibration reed frequency meter, optical speedometer etc.)
Service Training
If the engine speed is correct, check the pressures in the vibration circuit. > Stand both drums on an elastic base (rubber tires). > Connect a 600 bar pressure gauge to vibration pressure test port. > Run the engine with full speed and switch the vibration on. Nominal value : Starting pressure approx. 210 bar (for approx. 3 - 6 seconds) Operating pressure (one vibrating drum): approx. 60 bar Operating pressure (two vibrating drums): approx.: 100 bar
Test port
Fig 22:
Service Training
If the starting pressure is not reached check the control valve block. > Disconnect the high pressure hoses from the valve block (A and B). > Close ports A and B on the valve block. > Switch the vibration on. Nominal value : approx. 210 bar
Service Training
If the pressure value is not reached subject the vibration pump to a high pressure check. > Install a 200 bar pressure relief valve with a 600 bar pressure gauge between vibration pump and vibration valve. > Start the engine and switch on the vibration Nominal value : approx. 200 bar
If the pressure is reached replace the vibration valve block. If the pressure value is not reached replace the vibration pump.
Service Training
If the pressure is reached during the pressure test described in Fig. 5, check the leak oil rate of the vibration motors. For this purpose stand the machine on rubber tires. > Disconnect the leak oil line and hold it into a measuring vessel. > Switch the vibration on. Nominal value: max. 1.0 l/min Replace the motor with too high leak oil rate.
Fig 23: If the starting pressure is reached, but the operating pressure is too low, you must also check the leak oil rate of the vibration motors.
________________________________________________________________________________________ BW 100/120 AD Series 4 E 10 BW 100/120 AC Series 4
Service Training
If the operating pressure is too high, the bearings for both vibrator shafts must be checked. > Check end float and moveability of the exciter shafts (front and rear). Nominal values: min 0.5 mm max. 2.00 mm
Fig 24:
Service Training
No vibration
If the vibration does not work at all you should first check the voltage supply for the vibration control valve. > Switch the vibration on and check whether voltage is applied to the plug. Nominal value: 12 Volt
If no voltage is applied, perform trouble shooting in the electric system.
Vibration solenoid valve
Fig 25:
If voltage is applied check the magnetic coil of the control valve. > Measure the current consumption with a meter. (For this purpose the meter must be connected in line with the magnet) Nominal value : approx. 3.5 A
If the current consumption is not correct replace the magnetic coil. If the current consumption is correct continue trouble shooting with Fig. 22.
Service Training
Steering
The steering system is an open hydraulic circuit and consists mainly of the steering/charge pump, the steering valve, the steering cylinder and the connecting pressure resistant hoses.
________________________________________________________________________________________ BW 100/120 AD Series 4 F1 BW 100/120 AC Series 4
Service Training
The steering pump delivers the hydraulic oil from the tank to the steering valve and the connected steering cylinder. When the steering is not operated the complete oil flow is guided through the fine filter to the charge ports on the travel pump and further via the cooler to the tank. When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side of the steering cylinder. A measuring pump in the steering unit measures the exact oil quantity corresponding to the turning angle of the steering wheel and delivers this oil to the steering cylinder. The steering cylinder extends or retracts and articulates the machine. The steering unit is fitted with an integrated pressure relief valve. This valve limits the steering pressure to 140 bar. Since the hydraulic oil flowing out of the steering system is used as charge oil for the closed travel circuit, the charge pressure value must be added. When testing the pressure a value of 160 bar would therefore be measured.
Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, steering pressure relief valve and the shock valves. When turning the steering wheel the oil flow from the pump is directed through the distributor valve to the measuring pump. The measuring pump, in turn, directs the oil flow through the distributor valve to the corresponding side of the steering cylinder. The machine is fitted with a so-called Open Centre steering valve, i.e. in neutral position of the valve the incoming oil flows through the tank return bore directly to the charge ports for the closed travel circuit.
1 2 9 3
. Fig. 3: 1 3 5 7 9 Neutral setting springs Inner spool Universal shaft Gear Pressure relief valve 2 4 6 8 Housing Outer spool Gear ring Check valve
Service Training
The rating pump determines the exact oil quantity in dependence on the turning angle of the steering wheel. The oil quantity directed to the steering cylinder articulates and steers the machine. The high pressure relief valve in the steering unit limits the pressure in the steering system to 140 bar. Since the oil leaving the steering system is used to charge the closed travel circuit, this charge pressure value must obviously be added when checking the steering pressure. The steering unit is fitted with so-called shock valves in each pressure side to the steering cylinder. These valves are adjusted to an opening pressure of 200 bar. The valves compensate extreme pressure peaks which may occur, e.g. when driving over obstructions, and protect the system against overloads. Each of these shock valves has its additional anti-cavitation valve. This anti-cavitation valves prevent the appearance of cavitation, which may be caused by the response of the shock valves. A check valve near the inlet port of the steering unit makes sure that no hydraulic oil will flow back to the steering pump if the machine is articulated by sudden external forces. In such a case the steering cylinders would act as pumps and press the oil back to the pump.
Service Training
Trouble shooting steering
Steering function faulty Note: The steering pump works also as charge pump. In case of a fault in the steering system the steering/charge pump must be checked first. > Connect a 600 bar pressure gauge to steering pressure test port (M1). > Turn the steering against an end stop. > Read the pressure gauge. Nominal value: approx. 170 bar
If the steering pressure is reached check the moveability of articulated joint and steering cylinder.
Pressure test port M1
Fig. 26:
Service Training
If the nominal value is not reached check the steering cylinder.
Disconnect the hydraulic hoses from ports L and R on the steering orbitrol and close the orbitol with plugs. Due to the installation position the test is conducted on the orbitrol valve and not directly on the steering cylinder.
> Run the engine and turn the steering wheel. Nominal value: approx. 160 to 190 bar
If the nominal value is reached replace the steering cylinder.
If the nominal value is not reached check the steering/charge pump. > Close the pump outlet with a 200 bar pressure relief valve. > Repeat the pressure test. Nominal value: approx. 200 bar
If the nominal value is not reached replace the steering/charge pump. If the nominal value is reached replace the steering valve (Orbitrol).
Pressure test port

Fig. 6:
Service Training
Electric circuit diagrams
Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics. Circuit diagrams are of help when performing trouble shooting and enable the fault free connection during modifications or changes to the electric equipment of the machine.
Structure:
1. Table of contents 2. Function groups 3. List of components
1.
Table of contents
The table of contents lists all function groups and component lists of the machine. The arrangement of all sheets in a sequence results in the total wiring diagram.
Example:
Function group brake, drawing number 880,100 51 is found on sheet 4 Components list on sheet 101
________________________________________________________________________________________ BW 100/120 AD Series 4 G1 BW 100/120 AC Series 4
Service Training
2. Function groups
Electric circuits with a function oriented interrelationship are combined on individual sheets (sheet-no.: 1, 2, ...) in function groups (brake, warning systems ...) and subdivided into 20 current paths (along the bottom end of the page). This allows easy tracking of functional interrelationships of the electric circuits. Arrangement of current paths The individual current paths must be read as follows: > from top (plus potential) to bottom (minus potential) > from left to right (current path 1 to 20, along the bottom of the page, Fig.1)
Fig.: 1: > from function group (sheet-no.) to function group (sheet-no.) > via cross references for potentials and relays
Service Training
Reference lines, frames
Components and connections that apply only for special versions of machines (accessories, retrofit kits or optional designs, Fig. 3) are drawn with thin dash dot line and specially marked with bilingual text.
Fig. 3:
Service Training
Potential cross references
Example potential 15: 5:1 ---------> direction arrow (cross reference to sheet 5 current path 1) Potentials stretching over a longer distance in the circuit diagram may be interrupted for the reason of clarity. In this case only the beginning and end of the potential is shown. The interrelationship of these cut-off points is represented by cross-references. Potential crossreferences therefore enable tracking of signals transferred from one function group (sheetno.) to another function group (sheet-no).
Example 1 (Fig. 4):

Potential 15" on sheet no. 6 continues to the left on sheet-no. 4 in current path 10" and to the right on sheet-no 8 in current path 1". To the right it ends at the nodal point (without arrow) on sheet-no. 8 in current path 3".
Fig. 4:
Service Training
Relay cross reference in developed presentation
Switching symbols of parts of electric components (relays, switches ...) are drawn separately and arranged in such a way, that every current path can be easily tracked. The spatial relationship of individual contacts is of no importance. A straight and clear presentation without any crossing of the individual current paths is of highest importance. Relay cross references can therefore be used to trace signals which have to be followed on components with dependent contacts. Apart from this there is a contact plan under each relay coil providing information about the contact types of a relay and where these appear in the wiring diagram. Example 2 (Fig. 4): On sheet no. 8 the coil of relay (K99) is located in current path 6". The contact sketch under the relay informs that a throw-over contact with the contact types 30, 87 and 87a is triggered. On sheet no. 8 this double-throw contact is located in current path 3".
3.
List of components
This list contains all components used in alphabetical order, related to their component abbreviation (A01, A02....).
Fig. 5:
Component cross references Example (Fig.5): in current path 3. In the circuit diagram the warning horn B 11" is located on sheet no. 8
Service Training
Electric system
Table of potentials
Potentials 30 31 M15
Meaning Battery positive Vehicle ground battery negative control elements Battery minus is supplied when ignition is ON
Explanations to the electric circuit diagram: Start the engine: To start the diesel engine the following conditions must be fulfilled: - Emergency stop switch not operated - Travel lever in neutral position (switch B08) B08 triggers relay K05 - Voltage on ignition switch output 50a Driving the machine: - The machine can only be driven when the seat contact switch (S06) is closed and K22 has switched. (OPTION !!!) Attention! Standard on machines with CE conformity ! Switching the vibration on (standard version) Push button S13 switches ground potential to the module A03 Pin 13. A03 then switches the solenoid valve Y71 accordingly. When moving the travel lever fully to forward or reverse vibration is switched off in dependence on the position of angle sensor B 39 when a speed of 6 km/h is exceeded. If the speed is fallen short of (< 6 km/h) the vibration switches on again. Switching the pressure sprinkler system on: Interval switch A01 switches + potential to module A03 on PIN 1. The module switched relay K79 (terminal 86) via Pin 4. This requires that the travel lever is moved out of 0-position. The module now switches relay K79 in dependence on the set interval. The contact of relay K79 then activates the water pump. To check the water sprinkler system without deflecting the travel lever is possible when the interval switch is to the highest stage.
Service Training
Description of the modules
The machine is equipped with two control/monitoring modules. These modules are fitted with control lamps on the inputs/outputs, which are used to monitor the applied signals. Module travel lever monitoring (part number 880 255 02)
a bc
LED 1 LED 2 LED 3
The following applies when measuring the signal level: PIN digit. inputs (HIGH-active) digit. input (LOW-active) digit. output Analogue input (PIN 8) Analogue input (PIN 7) Potential with LED on Potential with LED off Operating voltage +12V Voltage < 1V Ground Input open/no ground Operating voltage (UB - 0,7V) < 1V Current on PIN 8 = 3,5mA to 20,5mA (depending on angle sensor) Voltage on PIN 7 against ground = 0,6V to 7,65V (depending on interval switch)
Service Training
Description of hardware:
The inputs are designed in such a way, that the following table is valid: Input Input PIN12 Input PIN13 Input PIN14 Input PIN15 Input PIN16 Performance Remark HIGH-active LOW-active HIGH-active HIGH-active HIGH-active LED lights when applying positive voltage! LED lights when applying ground potential! LED lights when applying positive voltage! LED lights when applying positive voltage! LED lights when applying positive voltage!
Pin assignment digital inputs Signal Name Initiator for brake Button vibration on Switch position vibration auto / manual Start signal Bridge option America Module Pin 12 13 14 15 16 Description Active-HIGH = Travel lever in braking position LED on LOW =Travel lever not in brake position LED off Active-LOW = Momentary contact function LED on HIGH = Normal status LED off Active-HIGH = autom. vibr. nominal on, LED on LOW = manual vibr. nominal on LED off Active-HIGH = Vibration may not switch on LED on LOW = Vibration may switch on LED off Active-HIGH = Vibration shut down at >6km/h LED on LOW = No vibration shut down at >6km/h LED off
Pin assignment analog inputs Signal Name 8,5 Volt Voltage output Analog input 1 Analog input 2 Pin assignment outputs Signal Name Brake Water sprinkling system Vibration Backup alarm Module Pin 3 4 5 6 Description HIGH = Brake valve picked up LED on LOW = Brake valve not picked up LED off HIGH = Sprinkling on LED on LOW = Sprinkling off LED off HIGH = Vibration on, LED on LOW = Vibration off LED off HIGH = Buzzer on, LED on LOW = Vibration off LED off Module Pin 9 8 7 Description Output 8,5 V for voltage supply of angle sensor. Function o.k. LED on Input for signal 4-20mA Connection for travel lever angle sensor Input for signal 0-8,5V 12-stage switch (stage 1 = off)
Signal level:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 LED 2 LED 3 LED 1
Versorgungsspannung (+U B) 1)Power Supply (+UB) 2)Power Supply (+UB) Versorgungsspannung (+UB ) 3)Brake Bremse
4) Output Sprinkler system Ausgang Berieselung

Vibration ein 5) Vibration ON Rckfahrwarnsummer 6) Backup alarm 7)IntervalIntervallschalter switch Sprinkler system Berieselung Winkelsensor Fahrhebel 8) Angle Sensor Travel lever 9) Output 8,5 Volt Ausgang 8,5 Volt
10)Ground potential Masseanschlu 11)Ground potential Masseanschlu 12) Proximity switch Brake Initiator Bremse 13) Button Vibration Taster Vibration 14) Switch Vibtation Auto/Manual Schalter Vibration Auto / Manuell 15) Startsignal Brcke Option Amerika 16) Bridge Option America
Service Training
a bc
Service Training
Description of function Switching off
If operating voltage is applied to the module (PIN1/2 UB, PIN10/11 ground), LED1 will light as a control light. LED 2 flashes as Stay-Alive-Indicator (Live Sign of Module), but with a flashing frequency which depends on the current on input PIN 8 (analogue input 1).
Angle sensor:
The machine is equipped with an angle sensor under the drivers seat, mounted to the switch guide plate of the travel lever. The angle sensor reports the travel lever position back to the module. The sensor works with an output current of 4-20 mA.
Angle sensor
When replacing the sensor, a zero adjustment will be automatically performed as followed.
________________________________________________________________________________________ BW 100/120 AD Series 4 G 10 BW 100/120 AC Series 4
Service Training
Neutral position of angle sensor The zero point of the angle sensor is automatically adjusted via the module. Once the travel lever is in neutral position the brake initiator (on the travel lever) (Pin 12) is actuated. The zero position is thereby recognized. Should the brake initiator be defective or a cable is broken the last value is set as default for the zero point. If LED2 (on the module) flashes in intervals of one second and LED3 lights permanently, the zero point is reached.
In it iator fo r Brake
LED lights with trav el lev er in zero posit ion
Service Training
Defect on angle sensor The current of the functional angle sensor is in the range from 4mA to 20mA. A current flow of <2mA or >22mA on Pin 8 of the module indicates a sensor fault (sensor defective, short circuit, or sensor not connected, etc.). LED2 and LED3 are then used as indicators. LED2 flashes fast (with 80 Hz), LED3 shows permanent light. Constant voltage monitoring The flashing frequency of LED 2 indicates whether the output voltage of 8.5 V on Pin 9 is outside the permissible tolerance. If this voltage is not high enough, the angle sensor will not work correctly and the output signal of the sensor is undefined. For this reason the flashing frequency of LED2 is set to 80 Hz, if the voltage is too low. This always takes place in case of a low voltage level on Pin 9. This may be caused by a too low supply voltage for the module (with UB < 9,5V the voltage of 8,5V can no longer be maintained on PIN 9) or by a defect of the module. The complete module works from a minimum voltage of UB = 6,5V. However, the analogue inputs only work from a supply voltage of 9,5 Volt, since the sensor supply voltage of 8,5V can only be generated if this input voltage is available.
The following functions are influenced by the angle sensor: Automatic vibration ON/OFF Sprinkler system water off after 30 sec. If travel lever is in 0-position Backup protection Checking of neutral position
Service Training
Vibration control
Manual vibration If no voltage is applied to PIN 14 (manual vibration on), vibration can be switched on via button input (vibration on) on PIN 13. Vibration is always switched on or off when a clear ground potential is detected on Pin 13. If vibration is switched on, the LED on Pin 5 lights up. If the vibration button is actuated again, vibration is switched off. In case of a bridge (Active-HIGH-Signal) on PIN 16 vibration switched off at a speed higher than 6 km/h and on again at a speed below 6 km/h. Without a bridge on PIN 16 the vibration is not switched off above 6 km/h.
Auto Vibration ON
Manuell Vibration
Travel lever
Push button Vibration
Vibration
Fig. 1: Manual vibration control with HIGH-Signal on PIN 16
Service Training
Automatic vibration control (optional) If a positive voltage is applied to PIN 14 (automatic vibration on) the LED on PIN 14 lights up and the vibration (PIN 5) is switched on and off in dependence on the travel lever position. With a bridge (Active-HIGH-Signal) on PIN 16 the vibration (output, PIN 5) is switched off with the travel lever in a position <1 km/h and >6 km/h. Without the bridge (LOW-Signal) on PIN 16 the vibration (output, PIN 5) is only switched off at a speed < 1 km/h.
Auto Vibration ON
Travel lever
Push button Vibration
Fig.: Automatic vibration control with Active-HIGH-Signal on PIN 16 (Active High means + 12 V)
Service Training
Water sprinkling control The sprinkler intervals are controlled by connection of a 12-stage switch to PIN 7. This switch switches resistors in 500 -steps from 500 to 6 k . Sprinkling stages for pressurized sprinkler system
Stufe 12 Stufe 11 Stufe 9 Stufe 8 Stufe 10
Stufe 12 Stufe 11 Stufe 10
12-Step switch
Stufe 5 Stufe 4 Stufe 2 Stufe 1 Stufe 3
Stufe 7 Stufe 6
Travel lever
Sprinkler system
The total cycle (time for activation and deactivation phase) takes 15 seconds. The sprinkling intervals are set according to the following table: Stage Activation time Deactivation time 1 0,0 s 15,0 s 2 1,0 s 14,0 s 3 2,0 s 13,0 s 4 3,0 s 12,0 s 5 4,0 s 11,0 s 6 5,0 s 10,0 s 7 6,0 s 9,0 s 8 7,0 s 8,0 s 9 8,0 s 7,0 s 10 10,0 s 5,0 s 11 12,5 s 2,5 s 12 15,0 s 0,0 s Cycle time 15s 15s 15s 15s 15s 15s 15s 15s 15s 15s 15s 15s
Service Training
After stopping the machine (travel lever in neutral, evaluation of analogue signal on PIN 8) sprinkling continues with the set interval for another 30 seconds (pressure sprinkling). After this time sprinkling will only be resumed after moving the travel lever out of neutral. If the switch is in stage 12 (permanent sprinkling), sprinkling will continue after the 30 seconds, without any temporal limitation! Should be used for inspection with the machine stopped to check nozzles, pump etc. Gravity feed sprinkler system If no 12-stage switch is connected, but the gravity sprinkler switch (S05 on output PIN 4) instead, the output will permanently switch a High signal. The sprinkling system is triggered via this switch. With the machine stopped (travel lever in neutral position, evaluation of analogue signal on PIN 8) the HIGH-signal will still be emitted at PIN4 for another 30 seconds, after this it will be set to LOW-signal, until the travel lever is moved out of neutral again.
12-Step switch
12 step switch not connected
Travel lever
30 seconds
Output sprinkler system
Fig. 2: Gravity feed sprinkler system With both sprinkling systems the sprinkling cycle time is independent from the displacement of the travel lever, i.e. from the travel speed of the machine. Only the neutral position is of significance for the automatic shut down of the sprinkling system after 30 seconds.
Service Training
Description of the seat contact module (part-no.: 88003042)
L ED 2
RS 232
LE D3
OUT
L ED 5
4 3
30
Pin assignment:
PIN 1 2 3 4 BTS OUT OUT + 30 87 87a 15/54 -
Signal IN (Active LOW) IN (Active LOW) IN (Active HIGH) IN (Active HIGH) OUT (BTS) PWM PWM + Relay Contact Relay Contact Relay Contact Supply voltage Ground
Description Seat contact switch Seat contact switch Travel lever sensor 0-position Oil pressure Engine solenoid pickup winding Not used Not used Ground Engine solenoid holding winding Normally closed 10-39 V
LE D1
L ED 4
Service Training
Description of hardware
The inputs are designed in such a way, that the following table is valid: Input Input PIN1 Input PIN2 Input PIN3 Input PIN4 Performance Remark LOW-active LOW-active HIGH-active HIGH-active LED lights when applying ground potential! LED lights when applying ground potential! LED lights when applying positive voltage! LED lights when applying positive voltage!
Pin assignment digital inputs Signal Name Module Pin Seat contact switch 1 Seat contact switch (is presently not evaluated) Sensor Travel lever neutral position Engine oil pressure 2
Description Active-LOW = Driver seated HIGH = Driver standing Active-LOW = Driver standing HIGH = Driver seated Active-HIGH = Brake released LOW = Brake applied Active-HIGH = Oil pressure present LOW = Oil pressure not present LED on LED off LED on LED off LED on LED off LED on LED off
3 4
Pin assignment outputs Signal Name Module Pin Relay contact 15 + 87 30 + 87 (normally open) BTS BTS
Description HIGH = Holding winding of engine solenoid is switched on LED on LOW = Holding winding of engine solenoid is not switched on LED off HIGH = Holding winding of engine solenoid is switched on LED on LOW = Holding winding of engine solenoid is not switched on LED off
Service Training
Description of function
Travel lever in brake lock and driver standing
Travel lever is actuated
Engine emmidiately OFF
Driver seated
Travel lever is actuated
Druver gets up during travel
Engine shuts OFF after 2 seconds
Driver sits down within 2 seconds and oil pressure is present
Engine starts again by centrifugal movement
Service Training
Description of function
Switch ignition on and start the engine Stay-Alive-(Live Signs) LED flashes in one second intervals. Engine running Shut down the engine immediately If the driver seat is not occupied (PIN 2 has HIGHSignal) and the travel lever is actuated (PIN 3 has ActiveHIGHSignal), the module will simulate a oil pressure fault. Relay (PIN 30 + 87) switches immediately for half a second and LED6 lights for half a second. The holding winding of the engine solenoid is not energized for half a second and the engine is shut down. Engine shut down with time delay The driver's seat is occupied (PIN 2 has ActiveLOWSignal) and the travel lever is in neutral position (PIN 3 has LOWSignal). When leaving the drivers seat (PIN 2 has LOWSignal) after shifting the travel lever out of neutral (PIN 3 has ActiveHIGHSignal), the warning buzzer is activated. After 2 seconds the relay (PIN 30 + 87) is switched on for half a second and LED6 lights for half a second. The holding winding of the engine solenoid is not energized for half a second and the engine is shut down. Restarting the engine If the engine has shut down as described in point 3.4 it can be restarted within 2 seconds after occupying the drivers seat. This is only possible if the engine is still rotating and oil pressure (PIN 4 has ActiveHIGHSignal) is present. This is accomplished by switching on the BTS-output (PIN BTS) for 1 second. LED5 lights for 1 second. The pickup winding of the engine solenoid is energized for half a second and the engine is restarted.
Inhaltsverzeichnis: table of contents:

Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 009 101
BW 100 AD/AC4, BW 120 AD/AC4 BW 100 AD/AC4, BW 120 AD/AC4

Funktionsgruppe Stromlaufplan Versorgung, Motor, Starten, NotAus Vibration, Berieselung
Bremse, Mengenteiler, Rundumkennleuchte, Kantenschneidg.
Zeichnungsnummer drawing no. 880 100 51 880 100 51 880 100 51 880 100 51 880 100 51 880 100 51 880 100 51 880 100 51 880 100 51
function unit Circuit Diagram supply, engine, starting unit, emergancy shut off vibration, sprinkler system brake, flow divider, rotary beacon, edge cutter switch seat contact
working head lights, flash and position illum., working head lights
Sitzkontakt
Arbeitsbeleuchtung, Blinkbegrenzung, Arbeitsbeleuchtung
Wetterschutzkabine Zentralelektrik Bauteilliste
cabin, weather protection cross bonding box component listing
4.2.2004 Kneip 4.2.2004 Nallin
Stromlaufplan circuit diagram
001
001
880 100 51
001
2 2 30 3:1 S00 P0123 P01
30
Zndstartschalter ignition switch X25:B X25:A 2 C Box A F04 F119 2:11 1 2 1 R09 2 V43 (A3) 2 1 R21 1 2 X6:14 H08 H49 H09 Kraftstoffanzeige V43 2:11 V41 (A1) Meldeleuchte Ladekontrolle indicator light, charge control Meldeleuchte Motorberhitzung indicator light, engine overheating Meldeleuchte Motorldruck indicator light, engine oil pressure 2:7 V45 2:8 X6:20 V43 K05 2:18 H52 30 BOX A X1:2 X12:2 IG G02 B Generator generator F00 F141 H() 2:6 B 2:18 X1:3 B53 X1:4 B06 P 4 2 M Betriebsstundenzhler engine hour meter X25:C 31 Temperaturgeber Kuehlmittel temperature switch, collant Druckschalter Motorl pressure switch, engine oil Geber Kraftstofftank sender, level gauge 2:16 Hauptsicherung fuse, main Sicherung Generator fuse, generator 2:12 2 2 1 V45 2:11 + P01 H() X6:10 1 1 R03 option 2:9 M Hubmagnet Motor shut off solenoid engine G 4:3 X6:2 X1:5 X11:3 K37 X11:2 X2:4 Glhberwachung indicator light, glowing X10:2 AW Y13 X1:6 X10:1 HW X1:1 X12:1 L D+ P00 3:2 2:16 S01 87a 87 K96 2:13 K32 7:2 3 2:9 F119 86 K96 85 BOX A F119 4:2 4 21 S01 D
15 54
58 2 15 6:1
19 17
50a
15 BOX A 3:1
30 K05 3:2 8 87a 87
11
22 S01 NotAusSchalter emergancy shut off V45 5:12
12 UPM15 3:1
BOX A F48 H R02 2:19
2:16 1 2 (A4) V44 X6:1 2:15 K05
K05 3:12
2:19 A15 berwachungsmodul monitoring module

3X8A
level gauge
X6:17
X6:16
X6:6 X11:6 X11:4 X11:5
X2:2 M 4:3 31 3:1 ST(50) 002
F139 4:9 30 K22 5:19 87a option Sitzkontakt seatswitch 87
UPM4 5:2 R02
R02
V45 (A5)
Glhkerze Header plug 2:3 B B(30)
2:4
H()
G01 7:2 + G01 Batterie battery
_t
R02
M01
Starter starter
4.02.2004 Kneip 4.02.2004 Nallin
Versorgung, Motor, Starten, NotAus supply, engine, starting unit, emergancy shut off
880 100 51
X2:3
30
X2:1
B BOX A F139 2
R02
2:9 2:14
30 30 BOX A 15 BOX A 4:1 UPM15 5:1 BOX A F03 E 5 2:20 K05 1 2 K05 5:1 A BOX A F68 1 2
30 6:1
2:19 15 BOX A 2:17 UPM15 X3:3 X14:1 BR/BN Initiator Bremse proximity switch, brake B08 Intervallschalter interval switch Druckberieselung press. water sprink sys.
Aufnehmer Fahrhebel transducer travel lever 3 B39 2 1
V48 (A8) F45 4:12 Vibrationsschalter man./autom. switch, vibration, man./autom.
SW/BK
BL/BU
X13:2 X18:2 X18:1 X18:3 011 X14:2 A01 X3:1
X13:1
X13:3 S08
13
X22:1
3 X3:6 X3:2 14 S164
X14:3 B08
X3:4
1 9 (8,5V) 11 (GND) 8 1 (15/54) 14 16 15 X22:2 A03 4:1 3 10 (GND) 5 K78 86 K117 V42 (A2) Schwerkraftberieselung sprinkling, gravitation 3 S13 4 4 X20:2 X7:2 X8:2 X19:8 Taster Vibration switch vibration Warnsummer warning buzzer berwachungsmodul monitoring module Berieselungsschalter switch sprinkler system 3:20 4:17 Magnetventil Vibration solenoid valve, vibration Fuschalter switch, foot 3:17 Emulsionspumpe emulsion pump Berieselungspumpe sprinkler pump + H14 3 X19:3 X8:1 2 1 5:6 Druckberieselung press. water sprink sys. option S12 V42 86 option Kantenschneidgert egde cutter K79 85 1 Y71 2 85 K78 M03 V02 X16:2 X19:8 X15:2 31 4:1 2 X1:9 ACTypen ACtypen 3:16 87 30 S164 4:13 Schwerkraftberieselung sprinkling, gravitation Druckberieselung press. water sprink sys. 003
3:2 7
12 3:2 B08 86 K05 A03:12 5:2 X7:1 85 X20:1 X7:1
A03 Modul Vibration modile vibration
13 X3:5 X7:1
6 S05 A15 X6:9 13 14
K79 3:11 87
30
87a X19:5 X16:1 Y06 1
87a X19:6 X15:1 +
86
85
M02
X5:4 2:20 2:19 31
Berieselungsventil solenoid valve sprinkler
2.04.2004 Kneip 2.04.2004 Nallin
Vibration, Berieselung vibration, sprinkler system
880 100 51
3:17 15 BOX A 3:15 A03 BOX A F23 7 Schalter Rundumkennleuchte switch, rotary beacon 11 S01 2:16 12 UMP3 5:2 3:16 S164 K117 3:13 87 87a 30 2:14 F139 3:17 F45 option G option option F
BOX A F45
X5:3 Taster Signalhorn switch warning horn S03 13 S38 13 S34 14 14 86 K11 X6:11 85 K11 4:9 87 30 X24:A V08 87a 1 2 1 X19:2 H01 X1:8 2:10 H() H() 5:5 + 1 Y04 2 2:20 M Meldeleuchte Bremse indicator light brake B11 X4:2 Y90 X19:8 X24:C 2 X5:4 1 2 2 X1:7 X4:1 + E32 X1:10 Y20 1 Y21 Y48 2 2 1 X24:B V09 102 0 14 24 13 23 Schalter Kantenschneidgert switch, edge cutter
3:20
31 Signalhorn warning horn 4:10 Mengenteiler flow divider Rundumkennleuchte rotary beacon Magnetventil Hydr.umsch. solenoid valve, hydr. switch over Kantenschneidgert ab edge cutter, down
31 5:1
Bremsventil solenoid valve, brake
Kantenschneidgert auf edge cutter, up
4.02.2004 Kneip 4.02.2004 Nallin
Bremse, Mengenteiler, Signalhorn, Rundumkennleuchte, Kantenschneidgert brake, flow divider, rotary beacon, edge cutter
880 100 51
004
3:17 K05
3:8
UPM15
2:16 UPM4 3:3 4:5 A03:12 UMP3 86 K137 3 4 15/54
85
2 1
15/54 K137 5:3 X5:1 X5:2 87 87a 30 A68 Modul Sitzkontakt modul seat contact
X23:2
X23:3
3:8
V42
87
30
BTS
2 S06 1 X23:1 X5:4
3 Sitzkontaktschalter switch, seat contact
X6:12 H20
X19:4 X21:1 + X21:2 X19:8 Warnsummer warning buzzer 2:15 V45
H82 K22
86
85
4:5
H()
H()
6:2
4:20
31 5:10
31 6:1 2:14
option
Meleleuchte Sitzkontakt indicator light,drivers seat contact
4.02.2004 Kneip 4.02.2004 Nallin
Sitzkontakt switch seat contact
880 100 51
005
2:19 15 3:20 30 BOX B F07 F 6 Schalter Blinker switch indicator 13 L0R S37 L0R 14 24 23 Schalter Arbeitsbeleuchtung switch, working light C 3 2 BOX B F08 A BOX B F11 B
ZA/option StVZO Beleuchtung
BOX B F12 2
Schalter Arbeitsbel. hinten switch, working head lights rear
Beleuchtungsschalter STVZO switch, lighting STVZO S15 11 012 012 23 S53 13 01 01 12 24 14 24 24 23 S53 23
Blinkgeber flasher 30 31 82 L X6:19 X9:2 X6:18 X9:3 V13 14 X6:7 H06 H06 2 5:8 H() H() 6:8 E08 2 E09 2 1 1 E10 2 E11 2 1 E13 2 24 X27:1 1 X28:1 1 X28:2 H05 6:3 H() 1 X28:3 1 E12 2 X27:2 X27:3 V12 R A15 01 S14 13 23 X9:1 X6:8 49L 49R A02 berwachungsmodul monitoring module BOX B F09 4
D BOX B F10
X9:4
X1:11
X19:1
X27:4 X28:4 1 E14 2 E15 2 1 2 X30:2
ZA/option Arbeitsbeleuchtung
X31:1 X30:1 1 E23 E25 1 2 X31:2 X32:1 X33:1 1 E27 E28 1 2 X32:2 2 X33:2
Meldeleuchte Warnblinker indicator light, hazard light
X27:5 X9:5 Blinkleuchte VL indicator front, LH
X28:5 X9:6
Meldeleuchte Blinker indicator light, indicators
X19:7
5:19 31 Schalter Warnblinker switch, hazard light
31 Blinkleuchte VR indicator front, RH Blinkleuchte HR indicator rear, RH Schluleuchte links tail light, LH Parkleuchte links parking light, LH Scheinwerfer vorne links working head light front, LH Scheinwerfer hinten links working head light rear, LH Scheinwerfer hinten rechts working head light rear, RH
7:1
Blinkleuchte HL indicator rear, LH
Parkleuchte rechts Scheinwerfer vorne rechts parking light, RH working head light front, RH Schluleuchte rechts tail light, RH
4.02.2004 Kneip 4.02.2004 Nallin
Arbeitsbeleuchtung, Blinkbegrenzung, Arbeitsbeleuchtung StVZO working head lights, flash and position illumination,working head lights StVZO
880 100 51
006
2:11 2:3
K32 G01
F39
1 Sicherung fuse 2
K32 7:14 87
30
87a
6 012 S20 2 3 S21 2 012
3 K32
86
+ M04 M + M06 M + M05 M M07 M + 85
6:20
31 Scheibenwischer vorn Scheibenwischer hinten windsceen wiper motor, front windscreen wiper motor, rear Scheibenwascher vorn windscreen washer motor, front Scheibenwascher hinten windscreen washer motor, rear option 7:9
31
4.02.2004 Kneip 4.02.2004 Nallin
Wetterschutzkabine cabin, weather protection
880 100 51
007
X6:120
9 8 7 6 5 4 3 2 1
X11:26
V41 V42 1 2 2 3 2
2
3 6 2 5 4
K37
201918 1716151413 121110

V43 1 4 2
R09
V44 V45 1 5 2
1
V46 1 6 2
V47 1 7 2 8
V48 1
A15
Zentralstecker Sammelanzeige (Ansicht von hinten) mainplug monitoring module (view from backside)
057 664 03
A03
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 1 2
option Rundumkennleuchte rotary beacon
AC typen
K22
86 30 87a 87 85
K11
30 87
K78
30 87
K79
30 87
R21
A02
49R 31 82
30 85 87a 87
86
85 87a 86 85 87a 86 85 87a 86 30 30 30 87 87 87 85 87a 86 85 87a 86 85 87a 86
Box B F11 F12 F08 F09 F10 F07
Box A F68 F139 F04 F119 F03 F45 F23 F48
L R 30 49L option Stvzo Beleuchtung option Sitzkontakt seatswitch
K05
K96
K117
K137
option Sitzkontakt seatswitch
option Kantenschneidgert edge cutter
X10:12
1 2
A68
Y13
option Hubmanget Motor shut off solenoid, engine BTS 4 3 30 87 87a 15/54 2 1 Stvzo Beleuchtung StVZO lights Arbeitsscheinwerfer working lights
4.02.2004 Kneip 4.02.2004 Nallin
Zentralelektrik cross bonding box
880 100 51
009
Name A01 A02 A03 A15 A15 A15 A15 A66 A67 A68 B06 B08 B11 B39 B53 E08 E09 E10 E11 E12 E13 E14 E15 E23 E25 E27 E28 E32 F00 F03 F04 F07 F08 F09 F10 F11 F12 F23 F39 F45 F48 F68 F119 F139 F141 G01 G02 H01 H05 H06 H06 H08 H09 H14 H15 H20 H23 H49 H52 H70 H82 K05 K11 K22 K32 K37 K37 K78 K79 K96 K117 K137 M01 M02 M03 M04 M05 M06 M07 P00 P01 R02 R02 R02 R03 R09 R20 R21 R21 R22
Bl. 003 006 003 002 003 006 009 008 008 005 002 003 004 003 002 006 006 006 006 006 006 006 006 006 006 006 006 004 002 003 002 006 006 006 006 006 006 004 007 004 002 003 002 002 002
Pf. 6 6 10 17 7 11 4 9 15 13 6 2 7 10 5 5 6 7 8 11 10 12 13 14 15 17 18 10 1 11 10 3 6 11 13 14 17 7 9 17 19 17 16 14 2
Benennung Intervallschalter Blinkrelais Modul Vibration Platine Ueberwachungsmodul Platine Ueberwachungsmodul Platine Ueberwachungsmodul Platine Ueberwachungsmodul Elektronik Steuereinheit Eingabeeinheit Modul Sitzkontakt Druckschalter Motoroel Naeherungsinitiator Fahrhebel 0Stell. Signalhorn Aufnehmer Fahrhebel Temperaturgeber Kuehlmittel Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Kennleuchte Hauptsicherung Batterie Sicherung Vibration Sicherung Instrumente Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park u. Schlussl. links Sicherung Park u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Scheinwerfer rechts Sicherung Signalhorn Hauptsicherung Kabine Sicherung Kantenschneidgeraet Sicherung Gluehanlage Sicherung Potential 30 Sicherung Motor Sicherung Hubmagnet Motor Sicherung Hydrauliklkhler Batterie Generator Meldeleuchte Bremse Meldeleuchte Blinker Meldeleuchte Warnblinker Meldeleuchte Warnblinker Meldeleuchte Ladekontrolle Meldeleuchte Oeldruck Motor Warnsummer Rueckwaertsfahrt Meldeleuchte Motorluftfilter Meldeleuchte Sitzkontaktschalter Meldeleuchte Hydraulikoelfilter Meldeleuchte Motorueberhitzung Anzeige Gluehueberwachung Anzeige Wasser im Diesel Warnsummer Sitzkontakt Relais Startstrom Relais Klemme 30 auf 15 Relais Hubmagnet Motor Relais Kabine Zeitrelais Zeitrelais Relais Emulsionsberieselung Relais Berieselungspumpe Relais Motoroeldruck Relais Kantenschneidgeraet Relais Sitzkontaktschalter Starter Berieselungspumpe Emulsionsberieselungspumpe Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Betriebsstundenzaehler Tankanzeige Gluehkerze Gluehkerze Gluehkerze Geber Tankanzeige Vorwiderstand Widerstand Widerstand Widerstand Widerstand
title interval switch indicator relay modul, vibration Printed circuit board, monitoring module Printed circuit board, monitoring module Printed circuit board, monitoring module Printed circuit board, monitoring module Electronic control unit Keyboard Modul seat contact Pressure switch, engine oil Proximity switch, travel lever 0 pos. Warning horn Transducer, travel lever Temperature switch, collant Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Working head light, front, lh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, rh. Warning light Fuse, main, battery Fuse, vibration Fuse, gauges Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, head light, rh. Fuse, warning horn Main fuse, cab Fuse, edgecutter Fuse, glow plug system Fuse, potential 30 Fuse, motor Fuse, shut off solenoid, engine Fuse , cooling air blower Battery Generator Indicator light, brake Indicator light, indicators Indicator light, hazard light Indicator light, hazard light Indicator light, charge control Indicator light, engine oil pressure Backup alarm buzzer Indicator light, engine air filter Indicator light, drivers seat contact Indicator light, hydr.oil filter Indicator light, engine overheating Glow plug indicator Indicator water in fuel Warning buzzer, seat contact Relay, starting current Relay, terminal 30 to 15 Relay, shut off solenoid, engine Relay, cabin Timing relay Timing relay Relay, emulsion sprinkler sys. Relay, sprinkler pump Relay, engine oil Relay, edge cutter Relay, switch, drivers seat Starter Sprinkler pump Emulsion sprinkler pump Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Operating hour meter Level gauge Glow plug Glow plug Glow plug Sender, level gauge Dropping resistor Resistor Resistor Resistor Resistor
TYP 4X21WATT MAX1,5A MAX1,5A
MAX 300MA 420 mA
4. 2. 4 Kneip
21W 21W 21W 21W 10W 10W 10W 10W 55W 55W 55W 55W 5,5A 80A 10A 10A 15A 15A 15A 15A 15A 15A 10A 15A 10A 10A 20A 10A 30A 50A 88 AH 50A
Bauteilliste component listing

1 3
002 1 002 2 004 006 006 006 002 002 003 002 005 002 002 002 002 005 003 004 005 007 002 009 003 003 002 003 005 002 003 003 007 007 007 007 4 9 3 4 4 6 7 7 7 8 5 12 9 10 2 9 19 14 12 18 16 11 13 13 3 19 19 17 9 11 10 12
BOSCHW BOSCHW BOSCHW BOSCHW 5 SEC. BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW 1,4KW 6,4A 6,4A 7,5A 2,5A 2,5A 7,5A
002 4 002 10 002 002 002 002 002 002 002 002 002 18 18 19 10 3 9 3 8 8
8A 8A 8A 82 OHM 82 OHM
880 100 51
101
Name S00 S01 S01 S03 S05 S06 S08 S12 S13 S14 S15 S20 S21 S34 S37 S38 S53 S53 S164 V02 V08 V09 V12 V13 V41 V42 V43 V44 V45 V48 X1:1 X1:2 X1:3 X1:4 X1:5 X1:6 X1:7 X1:8 X1:9 X1:10 X1:11 X2:1 X2:2 X2:3 X2:4 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X4:1 X4:2 X5:1 X5:2 X5:3 X5:4 X5:4 X5:4 X6:1 X6:120 X6:2 X6:3 X6:4 X6:6 X6:7 X6:8 X6:9 X6:10 X6:11 X6:12 X6:13 X6:14 X6:15 X6:16 X6:17 X6:18 X6:19 X6:20 X7:1 X7:1 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 X9:3 X9:4 X9:5 X9:6 X10:1 X10:12 X10:2 X11:2 X11:26
Bl. 002 002 002 004 003 005 003 003 003 006 006 007 007 004 006 004 006 006 003 003 004 004 006 006 002 003 002 002 002 003 002 002 002 002 002 002 004 004 003 004 006 002 002 002 002 003 003 003 003 003 003 004 004 005 005 004 003 004 005 002 009 002 002 002 002 006 006 003 002 004 005 002 002 002 002 002 006 006 002 003 003 003 003 003 003 006 006 006 006 006 006 002 009 002 002 009
Pf. Benennung 18 16 16 7 10 3 12 4 5 3 13 9 11 17 6 9 17 19 16 18 17 19 9 8 3 8 4 16 6 16 3 2 5 6 10 16 7 2 14 13 14 20 20 19 15 9 10 2 2 5 10 10 10 3 3 17 5 17 3 17 6 10 8 8 12 3 11 7 9 4 7 8 3 7 6 5 8 6 10 5 5 5 5 7 7 5 7 11 13 5 6 16 2 15 13 18 Startschalter Schalter NOT AUS Schalter NOT AUS Taster Signalhorn Berieselungsschalter Sitzkontaktschalter links Vibrationsschalter man./autom. Vibrationsschalter Fahrhebel links Vibrationsschalter Fahrhebel rechts Warnblinkschalter Beleuchtungsschalter StVZO Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kantenschneidgeraet Schalter Blinker Schalter Kennleuchte Schalter Arbeitsbeleuchtung Schalter Arbeitsbeleuchtung Fusschalter Diode Diode Diode Diode Diode Diode (A1) Diode (A2) Diode (A3) Diode (A4) Diode (A5) Diode (A8) FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND RUNDUMKENNLEUCHTE RUNDUMKENNLEUCHTE FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT ARMATURENPULT FAHRHEBEL FAHRHEBEL FAHRHEBEL FAHRHEBEL FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND E1/E2 Blende vorn E1/E2 Blende hinten HUBMAGNET HUBMAGNET FAHRERSTAND FAHRERSTAND
title Starter switch Switch, emergency off Switch, emergency off Push button, warning horn Switch, sprinkler system Switch, seat contact, lh. Switch, vibration, man./autom. Switch, vibration, travel lever, lh. Switch, vibration, travel lever, rh. Switch, hazard light Switch, lighting StVZO Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, edge cutter Switch, indicator Switch, warning light Switch, working lights Switch, working lights Switch, foot Diode Diode Diode Diode Diode Diode (A1) Diode (A2) Diode (A3) Diode (A4) Diode (A5) Diode (A8) Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Rotary beacon Rotary beacon Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Instrument board Travel lever Travel lever Travel lever Travel lever Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform E1/E2 srceen front E1/E2 srceen rear Shut off solenoid Shut off solenoid Operators platform Operators platform
TYP
4. 2. 4 Kneip
MAX 2A STECKER FE5B FE5B
MR756 MR756 MR756 MR756 MR756 MR756

2 3
880 100 51
102
Name X11:3 X11:4 X11:5 X11:6 X12:1 X12:2 X13:1 X13:2 X13:3 X14:1 X14:2 X14:3 X15:1 X15:2 X16:1 X16:2 X18:1 X18:2 X18:3 X19:1 X19:2 X19:3 X19:4 X19:5 X19:6 X19:7 X19:8 X19:8 X19:8 X19:8 X20:1 X20:2 X21:1 X21:2 X22:1 X22:2 X23:1 X23:2 X23:3 X24:A X24:B X24:C X25:A X25:B X25:C X27:1 X27:2 X27:3 X27:4 X27:5 X28:1 X28:2 X28:3 X28:4 X28:5 X30:1 X30:2 X31:1 X31:2 X32:1 X32:2 X33:2 X33:1 X35:1 X35:2 X35:3 X35:4 X35:5 X35:7 X35:8 X35:9 X35:10 X35:11 X35:12 Y04 Y06 Y13 Y13 Y20 Y21 Y48 Y71 Y90
Bl. 002 002 002 002 002 002 003 003 003 003 003 003 003 003 003 003 003 003 003 006 004 003 005 003 003 006 003 003 004 005 003 003 005 005 003 003 005 005 005 004 004 004 002 002 002 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 008 008 008 008 008 008 008 008 008 008 008 004 003 002 009 004 004 004 003 004
Pf. 12 13 13 12 3 2 10 9 10 2 2 2 19 18 17 17 5 5 6 17 10 7 10 17 19 17 7 17 10 10 4 4 10 10 16 16 3 3 3 17 19 17 1 1 1 5 7 11 12 5 6 8 10 13 6 14 14 15 15 17 17 18 18 5 5 5 5 5 5 12 5 5 5 5 2 18 16 3 17 19 18 14 13
Benennung FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND GENERATOR GENERATOR SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE BERIESELUNGSPUMPE BERIESELUNGSPUMPE EMULSIONSPUMPE EMULSIONSPUMPE ARMATURENPULT ARMATURENPULT ARMATURENPULT FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRHEBEL FAHRHEBEL FAHRERSTAND FAHRERSTAND FUSCHALTER FUSCHALTER Fahrersitz Fahrersitz Fahrersitz FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND E1/E2 Blende vorn E1/E2 Blende vorn E1/E2 Blende vorn E1/E2 Blende vorn E1/E2 Blende vorn E1/E2 Blende vorn E1/E2 Blende hinten E1/E2 Blende hinten KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD Magnetventil Bremse Magnetventil Berieselung Hubmagnet Motor Hubmagnet Motor Magnetventil Kantenschneidgeraet Magnetventil Kantenschneidgeraet Magnetventil Hydr.Umschaltung Magnetventil Vibration Magnetventil Mengenteiler
title Operators platform Operators platform Operators platform Operators platform Generator Generator Seating unit Seating unit Seating unit Seating unit Seating unit Seating unit Sprinkler pump Sprinkler pump Emulsion sprinkler pump Emulsion sprinkler pump Instrument board Instrument board Instrument board Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Travel lever Travel lever Operators platform Operators platform Footswitch Footswitch Drivers seat Drivers seat Drivers seat Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform E1/E2 srceen front E1/E2 srceen front E1/E2 srceen front E1/E2 srceen front E1/E2 srceen front E1/E2 srceen front E1/E2 srceen rear E1/E2 srceen rear Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Solenoid valve, brake Solenoid valve, sprinkler system Shut off solenoid, engine Shut off solenoid, engine Solenoid valve, edge cutter Solenoid valve, edge cutter Solenoid valve, hydr. switch over Solenoid valve, vibration Solenoid valve, flow divider
TYP
4. 2. 4 Kneip

3 3
2,7A 1,15A 51/0,7A 2,5AMP 2,5AMP 3,5AMP 3,5A 2,7A
880 100 51
103
S15
S53
S38
S14
S08
A15 / X6
H08
H15
H23
H73 H52 H70
H06 H05
H09 H49
H20
S01
H01
P00
P01
S03
S37
S05
A01 X18
BOX A BOX B
X11
S00
S164
S13
X1, X2, X3, X5, X9, X19, X22, X25

H14 X8
M02 X15
H82 X21
S06 X23
B08
B39 / X13
X7 X14
S34
E27 / X32 E09
E28 / X33 E11 X4, X28
F00
F141
G01
B06
G02
R02
B53
Y13
M01
B06
Y71
B53
Y20 Y21 Y48
Y90
X23
X7 X14
B39 X13

BW 120-4 English Service Training

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BW 120-4 English Service Training

Uploaded by

Copyright:

Available Formats

Service Training

BW 100 AD/AC Series 4 BW 120 AD/AC Series 4

________________________________________________________________________________________ BW 100/120 AD-3 1 BW 100/120 AC-3

________________________________________________________________________________________ BW 100/120 AD-4 A1 BW 100/120 AC-4

________________________________________________________________________________________ BW 100/120 AD-4 A2 BW 100/120 AC-4

________________________________________________________________________________________ BW 100/120 AD-4 A3 BW 100/120 AC-4

________________________________________________________________________________________ BW 100/120 AD Series 4 B1 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 B2 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 B3 BW 100/120 AC Series 4

Cross-section of diesel engine

________________________________________________________________________________________ BW 100/120 AD Series 4 C1 BW 100/120 AC Series 4

Pos. 1 Pos. 2 Pos. 3 Pos. 4

________________________________________________________________________________________ BW 100/120 AD Series 4 C2 BW 100/120 AC Series 4

Pos. 1 Pos. 2 Pos. 3

Charge pump Vibration pump Oil pressure switch

________________________________________________________________________________________ BW 100/120 AD Series 4 C3 BW 100/120 AC Series 4

Pos. 1 Pos. 2 Pos. 3 Pos. 4

________________________________________________________________________________________ BW 100/120 AD Series 4 C4 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 C5 BW 100/120 AC Series 4

(The values apply for intake and exhaust valves)

________________________________________________________________________________________ BW 100/120 AD Series 4 C7 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 C8 BW 100/120 AC Series 4

White or blue exhaust gas

Black or dark grey exhaust fumes

Excessive lubrication oil consumption

Lubrication oil in coolant Cylinder head gasket defective

________________________________________________________________________________________ BW 100/120 AD Series 4 C9 BW 100/120 AC Series 4

Excessive oil pressure Engine overheating

Rapid discharging of battery

________________________________________________________________________________________ BW 100/120 AD Series 4 C 10 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 C 11 BW 100/120 AC Series 4

Charge pressure from brake valve

Charge pressure from brake valve

High pressure test ports MA and MB

Charge pressure after hydraulic filter

Leak oil port to tank

________________________________________________________________________________________ BW 100/120 AD Series 4 D2 BW 100/120 AC Series 4

To the travel motors

Leak oil to tank

________________________________________________________________________________________ BW 100/120 AD Series 4 D3 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D4 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D5 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D6 BW 100/120 AC Series 4

Control in neutral position

________________________________________________________________________________________ BW 100/120 AD Series 4 D7 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D8 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D9 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 10 BW 100/120 AC Series 4

High pressure relief valves Charge pressure relief valve

________________________________________________________________________________________ BW 100/120 AD Series 4 D 11 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 12 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 13 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 14 BW 100/120 AC Series 4

To close the brake, proceed in reverse order.

________________________________________________________________________________________ BW 100/120 AD Series 4 D 15 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 16 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 17 BW 100/120 AC Series 4

Pressure test port M3

________________________________________________________________________________________ BW 100/120 AD Series 4 D 18 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 19 BW 100/120 AC Series 4

Charge pressure relief valve

________________________________________________________________________________________ BW 100/120 AD Series 4 D 20 BW 100/120 AC Series 4

________________________________________________________________________________________ BW 100/120 AD Series 4 D 21 BW 100/120 AC Series 4