Professional Documents
Culture Documents
Catalogue number.
008 911 63 02/2007
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Technical data 29
2.1 Technische Daten 30
2.2 Maintenance chart 38
2.3 Table of fuels and lubricants 40
2.4 Fuels and lubricants 40
Connection overview 43
3.1 Connection overview 44
Tests and adjustments 47
4.1 Special tools, tests and adjustments 48
4.2 Checking the rotation speeds 52
4.3 Checking / adjusting the neutral positions of the travel pump 54
4.4 Pressure tests in the travel circuit 56
4.5 Checking / adjusting the vibrator shaft speeds 58
4.6 Pressure measurements in the vibration circuit 59
4.7 Check the leakage rate of the vibration motor 60
4.8 Pressure test in steering circuit 61
Flushing and bleeding 63
5.1 Special tools for flushing 64
5.2 Flushing - general 69
5.3 Flushing schematic travel circuit (distribution travel pump) 71
5.4 Flushing the travel circuit (travel pump distribution) 73
5.5 Flushing schematic travel circuit (distribution axle motor) 79
5.6 Flushing the travel circuit (axle motor distribution) 84
5.7 Flushing schematic for vibration drive 89
5.8 Flushing the vibration circuit 90
5.9 Bleeding the travel circuit 94
5.10 Bleeding the vibration circuit 96
Fundamental electrics 99
6.1 Understanding circuit diagrams 100
6.2 Terminal designations 104
6.3 Current and voltage 108
6.4 Resistance 112
6.5 Series / parallel connection 114
6.6 Ohm's law 116
6.7 Electrical energy 116
6.8 Formula diagram 117
6.9 Metrology 118
6.10 Diodes, relays, fuses 120
6.11 Batteries 123
6.12 Three-phase generator 126
6.13 Electric starter 133
Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information
Danger
!
Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices l Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
l Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
l Start the extraction fan before starting work and
guide with the progressing work as required.
General
l
Always isolate the burner when laying it down (re-
l
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
l Protect cables from being damaged, use cables
l Always secure the machine against unintended roll- with insulated couplings.
ing.
l
Ensure sufficient fire protection, keep a fire extin-
l Secure the engine reliably against unintentional guisher at hand.
starting.
l In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. l Avoid prolonged and repetitive contact with oil, es-
l Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
l Name a fire watch during and after welding work. l Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts l Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
l Place the inert gas bottles in a safe place and se-
place natural skin oils that were lost.
cure them against falling over.
l Do not use gasoline, kerosene, diesel, thinner or
l Use a protective screen or an arcing shield with
solvents to wash the skin.
welding glass, wear welding gloves and clothes,
this applies also for assisting persons. l Do not put oil soaked cloths into your pockets.
l Switch the welding unit off before connecting weld- l Avoid clothes, especially underpants, getting soiled
ing cables. by oil.
l Welding and soldering on refrigeration equipment! l Do not heat up refrigerant bottles with an open
Before starting welding or soldering work on vehi- flame. Excessive temperatures can damage the
cles, (in the vicinity material and cause the decomposition of refriger-
of air conditioning components) all refrigerant must ant.
be drawn out and the rests removed by blowing out l Do not overfill refrigerant bottles, since any temper-
the system with nitrogen. The decomposition prod-
ature increase will cause enormous pressures.
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system Environment
components may be attacked. The substance is In operation, during maintenance and repair work
mainly fluorohydrogen. and when taking refrigeration systems our of
l Pungent smell! In case of a pungent smell the afore service it is not permitted to let refrigerant escape
mentioned decomposition products have already into the atmosphere, which would contradict the
been created. Extreme care must be exercised not current status of technology.
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be Battery
harmed. l Wear goggles and face protection (acid).
l When blowing out components with compressed air l Wear suitable clothes to protect face, hands and
and nitrogen the gas mixture escaping from the body (acid).
components must be extracted via suitable exhaust l Work and store accumulators only well ventilated
facilities (workshop exhaust systems).
rooms. (Development of oxyhydrogen gas).
Handling pressure vessels l Do not lean over the battery while it is under load,
l
Since the fluid container is pressurized, the manu- being charged or tested. (Danger of explosion).
facture and testing of these pressure vessels is gov- l Burning cigarettes, flames or sparks can cause ex-
erned by the pressure vessel directive. (New edition plosion of the accumulator
from April 1989). Paragraph 10 of the pressure ves- l Keep ignition sources away from the battery.
sel directive demands that these pressure contain- l Always shield eyes and face towards the battery.
ers must be periodically inspected and tested by a
specialist, according to paragraph 32. In this case
l Do not use battery chargers or jump leads without
periodically recurring inspections consist of external following the operating instructions.
examinations, normally on containers in operation. l Keep the cell plugs closed.
The refrigerant container must be visually inspected l After an accident with acid flush the skin with water
two times per year, within the frame work of major and seek medical advice.
inspections. Special attention must thereby be paid l
Do not allow children access to batteries.
to signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
l
When mixing battery fluid always pour acid into wa-
placed for safety reasons, in order to protect the op- ter, never vice-versa.
erator or third parties against the dangers when
handling or operating pressure vessels. Special safety regulations
l
Secure pressure vessels against tipping over or roll- l
Use only genuine BOMAG spare parts for repair
ing away. purposes. Original parts and accessories have
l
Do not throw pressure vessels. Pressure vessels been specially designed for this machine.
may thereby be deformed to such an extent, that l We wish to make explicitly clear that we have not
they will crack. The sudden evaporation and escape tested or approved any parts or accessories not
of refrigerant releases excessive forces. This ap- supplied by us. The installation and/or use of such
plies also when snapping off valves on bottles. Bot- products may therefore have an adverse effect on
tles must therefore only be transported with the the specific characteristics of the machine and
safety caps properly installed. thereby impair the active and/or passive driving
l
Refrigerant bottles must never be placed near heat- safety. The manufacturer explicitly excludes any li-
ing radiators. Higher temperatures will cause higher ability for damage caused by the use of non-original
pressures, whereby the permissible pressure of the parts or accessories.
vessel may be exceeded. The pressure vessel di- l Unauthorized changes to the machine are prohibit-
rective therefore specifies that a pressure vessel ed for safety reasons.
should not be warmed up to temperatures above 50 l
If tests on the articulated joint need to be performed
°C.
with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
General Electrics
1.3 General repair instructions
l
Before removing or disassembling and parts, hoses General
or components mark these parts for easier assem-
The electric and electronic systems in construction
bly.
equipment are becoming more and more extensive.
l Before assembly oil or grease all parts, as far as this Electronic elements are increasingly gaining impor-
is necessary. tance in hydraulic and mechanical vehicle systems.
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
l Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
l
Do not disconnect or connect battery or generator
while the engine is running.
l Do not operate the main battery switch under load.
!Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
Fig. 2
l
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip from being damaged by sharp edges,
!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.
Fig. 4
l Clean and thoroughly examine the feather key.
l Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
l Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
l
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
l
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
l Lubricate the bearing with an appropriate lubricant
before reinstalling.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
1 Coefficient of friction μ tot. = 0,14
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
1 Coefficient of friction μ tot. = 0,14
2 These values result in a 90% utilization of the yield point
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
1 Coefficient of friction μ tot. = 0,14
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
1 Coefficient of friction μ tot. = 0,14
Status: 2007-01-29
Engine:
Type: BF4M2012C
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 98 kW
Power data at nominal speed of: 2300 1/min
Low idle speed: 900+/-200 1/min
High idle speed: 2430+/-50 1/min
Spec. fuel consumption: 243 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 220 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limitation: 400 +26 bar
Charge pressure, high idle: 26 bar
Drum drive:
Type: MSE 18 1C
System: Radial piston
Displacement stage 1: 2800 cm3/U
Perm. leak oil quantity: 2 l/min
Vibration pump:
http://bsa.bomag.com/bsa/tk_components/english/search_components_result.asp?Typ... 29.01.2007
Vibration motor:
Type: A10FM 45
System: Axial piston-swash plate
Displacement: 45 cm3/U
Frequency: 30/35 Hz
Amplitude: 2 / 1 mm
Rinsing oil quantity: 6 l/min
Rinsing oil pressure limitation: 13 bar
Steering valve:
Type: OSPC 500 ON
System: Rotary valve
Rear axle:
Type: CHC 192/51HD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,72
Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
http://bsa.bomag.com/bsa/tk_components/english/search_components_result.asp?Typ... 29.01.2007
Fig. 10
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 211 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1
BW 211 D-40 BW 211 PD-40
Weights
Operating weight (CECE) kg 9500 10500
with ROPS and cabin
Axle load, drum (CECE) kg 5750 6750
Rear axle load (CECE) kg 3750 3750
Static linear load kg/cm 27 -
Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
Max. gradability (depend- % 45 49
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved
Fig. 11
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 212 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 212 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1
BW 212 D-40 BW 212 PD-40
Weights
Operating weight (CECE) kg 10900 11350
with ROPS and cabin
Axle load, drum (CECE) kg 7150 7600
Rear axle load (CECE) kg 3750 3750
Static linear load kg/cm 33,6 -
Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
Max. gradability (depend- % 45 49
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved
Fig. 12
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 213 D-40 2960 2250 1500 2268 2972 490 5840 60 60 35 2130
BW 213 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1
BW 213 D-40 BW 213 PD-40
Weights
Operating weight (CECE) kg 12420 12870
with ROPS and cabin
Axle load, drum (CECE) kg 7820 8270
Rear axle load (CECE) kg 4600 4600
Static linear load kg/cm 36,7 -
Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
Max. gradability (depend- % 45 49
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the vibration bear- X
ings
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.18 Drain the sludge from the fuel tank X
5.19 Service the battery Pole grease X
5.20 Check, replace the refrigerant compres- X
sor V-belt
5.21 Service the air conditioning X
5.22 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.23 Check, replace the ribbed V-belt X
5.24 Change the fuel filter cartridge X
5.25 Change the fuel pre-filter cartridge X
5.26 Check the engine mounts X X
5.27 Oil change in drive axle min. 1x per year X X
5.28 Oil change in wheel hubs min. 1x per year X X
5.29 Oil change vibration bearings2 see foot note, min. X X
1 x per year
5.30 Retighten the fastening of the axle on X
the frame
as required
5.31 Tighten the wheel nuts X X
5.32 Check the ROPS X
5.33 Clean the oil bath air filter min. 1x per year X
5.34 Change hydraulic oil and breather filter at least every 2
3
X
years
5.35 Change the hydraulic oil filter*** at least every 2 X
years
5.36 Change the coolant at least every 2 X
years
5.37 Check the injection valves X
5.38 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.39 Adjusting the scrapers X
5.40 Adjust the parking brake X
5.41 Change the tires X
5.42 Change the fresh air filter in the cabin X
5.43 Tightening torques X
5.44 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.
API: CG-4/CH-4
SAE 10W/40
SAE 15W/40
Fuel
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side
Engine oil
Quality
Lubrication oils are classified according to their per-
formance and quality class. Oils according to other
comparable specifications may be used.
Winter fuel
Fig. 13
Danger
!
With their better temperature and oxidation stability
Fire hazard!
synthetic lubrication oils offer quite a few benefits.
Diesel fuels must never be mixed with gasoline.
Oil change intervals
For winter operation use only winter diesel fuel, to
The longest permissible time a lubrication oil should avoid clogging because of paraffin separation. At very
remain in an engine is 1 year. If the following oil low temperatures disturbing paraffin separation can
change intervals are not reached over a period of 1 also be expected when using winter diesel fuel.
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached. In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
ACEA1 Consult the engine manufacturer.
E3-96/E5-02
E4-99 = 500 operating hours
Operation with rape seed oil methyl ester (RME cording to ISO 6743/3. The viscosity index (VI) should
„Bio Diesel“) be at least 150 (observe information of manufacturer).
Due to the extreme quality differences of RMEW-fuels Bio-degradable hydraulic oil
available on the market, which are caused by the non-
existence of a standardization, BOMAG does general- On request the hydraulic system can also be filled with
ly not approve any RME-fuels. If this is neglected the ester based biodegradable hydraulic oil (Panolin HLP
warranty will become null and void! Synth. 46). The biologically quickly degradable hy-
draulic oil meets all demands of a mineral oil based
However, if you still intend to operate the machine hydraulic oil according to DIN 51524.
with RME-fuels you should observe the following in-
formation: In hydraulic systems filled with Panolin HLP Synth. 46
always use the same oil to top up. When changing
l
Reduced engine power (approx. 7%), higher fuel from mineral oil based hydraulic oil to an ester based
consumption. biologically degradable oil, you should consult the lu-
l The quality of RME-fuel should be in compliance brication oil service of the oil manufacturer for details.
with DIN draft 51606. Check the filter more frequently after this change.
l Avoid longer periods of standstill (formation of resin,
corrosion in injection system) ! Caution
l RME-fuel can damage the paint finish of the ma- Oil change bio-degradable hydraulic oil:
chine.
Perform regular oil analyses for content of water
l Fuel dilution of engine oil, therefore shortening of oil and mineral oil.
change intervals to half.
Replace the hydraulic oil filter element every 500
l
Rubber parts, such as leak fuel return lines, seats operating hours.
will be damaged in the long run and need to be re-
placed on a regular basis or should be replaced by Oil for drive axle
parts made of fluorinated rubber. However, fluori-
nated rubber is not resistant against normal diesel For the drive axle use only multi-purpose transmission
fuel. oil of API-class GL5 with viscosity class SAE 90.
l
If the fuel filter is clogged the filter change intervals The additives in this oil ensure low wear lubrication
must be shortened accordingly. under all operating conditions.
Caution
!
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm2/s at 40°C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
Fig. 1
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.
Nominal value:
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.
Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 3
Fig. 4
5. Connect the control chamber ports X3 and X4
(Fig. 5) with a hose
Fig. 5
6. Start the engine and run it with maximum speed.
Nominal value
Both pressure gauges (Fig. 6) must show equal
pressure (charge pressure).
i Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.
Fig. 6
Evaluation of test
Fig. 7
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
4. Start the engine and run it with maximum speed.
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
Fig. 4
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
3. Start the engine and run it with maximum speed.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.
Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
6. Start the engine and run it with maximum speed.
7. Switch on vibration with high or low frequency.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
2. Apply the brake.
Fig. 1
3. Block the flushing valve (Fig. 2) with washers.
Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Start the engine and run it with maximum speed.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (approx. 50 °C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.
Nominal value
Fig. 1
see technical data, max. steering pressure of
steering/charge pump.
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.
Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 3
Evaluation of test 2
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.
Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
Evaluation of test 3
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
steering/charge pump.
Fig. 5
Fig. 1
3. Flushing filter (S connection)
Fig. 2
7. Flushing filter (L connection)
Fig. 3
11. SAE-flange 1“ - 20S
Fig. 4
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
Fig. 9
19. Connecting socket 18L
Fig. 10
20. Connecting socket 16S
Fig. 11
21. Connecting fitting 20S
Fig. 12
Fig. 13
23. Angular fitting 18L
Fig. 14
24. Elbow fitting 16L
Fig. 15
25. Elbow 20S
Fig. 16
Fig. 17
27. Pipe connection 16S - 16S
Fig. 18
28. Connecting hose 15L
Fig. 19
Caution
!
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
Changing a component
Fig. 2
Caution
!
Fig. 3
Fig. 1
l Change the hydraulic oil filter element (1). l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Fig. 4
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
ward)
2 Connecting union (tool)
14 High pressure hose (B, axle motor reverse)
3 Drum drive motor
15 High pressure hose (A, axle motor forward)
4 Axle motor
16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool)
17 High pressure port (B, drum drive motor reverse)
6 Flushing hose 25S - 20S (tool)
18 Flushing hose 25S - 20S (tool)
7 Flushing hose 25S - 20S (tool)
19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 Elbow union (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 8
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
14. Shut down the engine.
Fig. 9 15. Remove the flushing filter and reconnect the high
pressure lines.
Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (14 and
15) on the axle drive motor together.
Fig. 11
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 12
Fig. 13
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 14
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
20. Start the engine and shift the travel lever to travel
direction forward.
21. Perform the flushing process at various engine
speeds for approx. 10 minutes.
22. Shut down the engine.
23. Reconnect the hydraulic hoses (14 and 15) to the
axle drive motor.
Fig. 15
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
26. Pre-select the slow speed range.
Fig. 16
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 17
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
27. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
28. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
29. Shut down the engine.
Fig. 18 30. Remove the flushing filter and reconnect the high
pressure lines.
Fig. 19
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (19) (flushing filter inlet
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 4
4. Block drums and wheels with suitable chocks.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 8
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
14. Shut down the engine.
Fig. 9
Fig. 10
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 11
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
18. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
19. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
20. Shut down the engine.
Fig. 12 21. Remove the flushing filter and reconnect the high
pressure lines.
Function test
24. Check the hydraulic oil level in the tank, fill up if
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
27. Check all ports and connections for leak tightness
(visual inspection).
Fig. 13
i Note
Observe the chapter "Flushing - General"
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
1. Disconnect the high pressure hose 10 (see chap-
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
cuit by joining the high pressure hoses (10 and
11) on the vibration motor together.
Fig. 2
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
6. Start the engine and run it with maximum speed.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
8. Shut down the engine.
9. Reconnect the hydraulic hoses (10 and 11) to the
Fig. 6 vibration motor.
Fig. 7
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 8
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
11. Start the engine and run it with maximum speed.
12. Run the flushing procedure for approx. 10 min-
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
13. Shut down the engine.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
Fig. 9
Bleeding the vibration circuit
15. Bleed the vibration circuit (see corresponding
chapter).
Fig. 10
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
Fig. 4
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
6.1 Understanding circuit dia- l The sequence in which current flows through the in-
dividual elements in the electric circuit.
grams l Connections between the examined, faulty electric
Wiring diagrams are graphical representations of cir- circuit and other circuits in the vehicle wiring sys-
cuitry conditions, related to the electrical system. They tem.
do not contain any information about the actual type of l Pin assignment of plug-and-socket connections.
wiring, they only serve the purpose of visualizing the
circuitry logics. Structure:
The wiring diagram is indispensable for effective and
l Table of contents
systematic trouble shooting in the vehicle wiring sys- l Function groups
tem. This plan provides the following information: l List of components
l Number and type of individual elements in the ex-
amined electric circuit, such as plug connectors, Table of contents
fuses, switches, consumers, relays, ... The table of contents lists all function groups.
Example:
Function group "Warning systems“, drawing number
XXX XX can be found on page no. 8.
Current paths
The pages of a circuit diagram are sub-divided into
current paths (Fig. 8) (0 ..... 20).
List of components
Here you find all components used in alphabetical or-
der, related to the name of the component (A01,
A02....).
Example:
The warning horn "B 11" is located on page no. 8 in
current path 3.
54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated
55 Fog light
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
61 Generator control
76 Loudspeaker
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
6.3 Current and voltage The following statements concerning electric volt-
age can be made
l electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most l the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
l electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)
Circuit
Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring. Pulsating direct current
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
l
The signal voltage cannot be measured.
l
The current can be measured.
Caution
!
6.4 Resistance l The cleaner the contacts, the better the current.
l The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Symbol, R
Unit, Ohm Ω
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
6.5 Series / parallel connection l In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined l The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- l The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
l The component to be measured must not be con-
nected to the power supply during the measure-
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
Diodes
Fig. 1
Fig. 1 Magnet tester
A diode consists of two different semi-conductors,
The magnet tester is used to test solenoid valves and which are connected by a separating layer. The max.
magnetic coils. conducting state current must not be exceeded.
The test lamp responds to the magnetic fields of A.C- Plus-voltage on diode:
voltage, D.C.-voltage and permanent magnets. l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
l
The component to be tested does not need to be re- conductive.
moved.
Negative voltage on diode:
l The magnetic coil can also be tested under a pro-
tective cap.
l The diode does not allow current to pass through.
Fig. 4 LED
The light emitting diode, also referred to as LED, is a
semi-conductor diode, which generates (emits) light
during operation in forward direction. A semi-conduc-
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the
head. Light emitting diodes are available in various
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fuses
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
!
Battery – accumulator
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- l Remove the battery and store it in a cool, dry and
ments, i.e they can be recharged after discharging frost protected room.
electric current. l Check the open circuit voltage on the battery at reg-
The basic element of a lead accumulator is the cell. It ular intervals (at least once every month).
contains the plate blocks consisting of positive and l Recharge immediately if the open circuit voltage
negative plates. These plates are separated from has dropped to 12.25 Volt (no rapid charging).
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of i Note
the cells. The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
! Danger
General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
i Note
Three-phase generators must only be operated in
combination with regulator and battery.
Batteries must not be connected with reversed polari-
ty.
Plus and minus cables must be disconnected during Fig. 6 Rotor with claw poles
rapid charging of the battery or electric welding on the The three stator windings (Fig. 7) are electrically offset
vehicle. to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
! Caution via two carbon brushes and slip rings.
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
In the generator the armature windings are located in-
side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
i Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Stator
i Note
The stator coils can only be measured in disassem-
bled state.
l Measure the resistance of all three coils.
l The coils should not have contact among each oth-
er.
Checking the regulator voltage with the generator l Perform the measurement at raised engine speed.
tester l The voltage (B+) should adjust itself at 13 to 14 Volt.
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 12
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.
l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l
The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.
Fig. 13
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
l The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l If possible switch off all consumers.
Fig. 16
Fig. 17
Fig. 14
The illustrations (Fig. 16) and (Fig. 17) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pressure steam cleaning equipment.
7 Pole shoe The contacts on starter terminals 30, 45, 50 must
8 Carbon brushes be protected against unintended shorting (jump
protection).
9 Armature brake
10 Collector When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
11 Magnetic switch number of teeth - if necessary replace the ring
12 Engagement lever gear.
Always disconnect the battery before starting as-
!Caution sembly work in the starter area of the engine or on
So-called jump starting (using an additional exter- the starter itself.
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
Fig. 2 Disassembly
l Lift up the interlock (5).
Assembly
Fig. 5 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11
This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 1 Sensor
The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
the magnetic field. Since the electrons are deflected in
Fig. 12 Circuit diagram, making contact
transverse direction by the magnetic field, they must
The circuit diagram (Fig. 12) shows a proximity switch enrich on the one side and reduce on the opposite
with normally open contact. side. If a very thin circuit board is now subjected to a
Brown = voltage supply current that is uniformly distributed across its cross
section, no voltage will be measured between two
Blue = ground supply
points A and B, which have an identical distance to the
Black = switching output current supply lines and are connected by a highly
The initiator switches the relay (K05) sensitive galvanometer. When generating a magnetic
field vertical to the circuit board, voltage will be
present between A and B and a current will flow
through the galvanometer connected to these points.
This is referred to as "Hall-Effect". The cause for this
effect is the warping of the originally parallel electron
orbits in the board by the magnetic field.
General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.
Fig. 2 DT Series
Caution
!
Fig. 4
l Insert the contacts through the rubber grommet until
they click into place.
l Insert the orange wedge in direction of arrow.
Caution
!
i Note
Use the same method when assembling the socket.
Disassembling DT contacts
Fig. 5
l Pull the orange wedge out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
l Pull the contact out of the socket.
i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
Fig. 4
l
Insert the contacts through the rubber grommet until
they click into place.
l
Insert the orange wedge, until it clicks into place.
Caution
!
i Note
Use the same method when assembling the socket.
Fig. 5
l Pull the orange wedge (interlock) out with long nose
pliers.
l Slightly pull the lead and unlock the interlocking
hook with a screw driver.
l Pull the contact out of the socket.
i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
General
Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-
ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
! Caution
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!
! Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
Series clamp
!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
Measuring signals
Fig. 3 X-COM plug plugged onto the series clamp
Fig. 4
15. Multimeter
Fig. 5
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 6
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 7
Fig. 10
Fig. 11
32. Clip-on measuring instrument
Fig. 12
33. Battery - generator tester
Fig. 13
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 14) to open spring
clamps (Fig. 15).
Fig. 14
Fig. 15
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 16
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
AWG 12 = 4,0 mm2 cable cross-section
BOMAG part-no.: 079 900 79
Fig. 17
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
Fig. 18
Fig. 19
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 20
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 21
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 22
Fig. 23
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 24
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 25
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 26
Fig. 27
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 28
49. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.
Fig. 29
50. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 30
Fig. 31
Universal tools
52. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 32
53. Precision pressing pliers for non-insulated flat
male and female connectors0.5 - 6,0 mm2.
Fig. 33
Measuring adapter
54. Current measurement adapter for Hirschmann
plugs.
Fig. 34
Fig. 35
56. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 36
Description of function
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
l Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
l After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
l The output signal for the display is a PWM-signal.
Caution
!
i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
l
Disconnect the cable bridge from "Teach" to "15/
54“.
l
Switch the ignition off and on again (Reset).
i Hinweis
The documentation "Service Training Electrics MESX" contains also the documentation BEM (BOMAG Evib-me-
ter).
The BOP (BOMAG Operation Panel) is only installed in connection with BVC machines, BEM-machines are
equipped wit display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
Service Training
Electrics
MESX
Version 3.01
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................5
4 Known faults ......................................................................................................................................6
5 How to proceed when replacing components? .................................................................................7
5.1 How to proceed when replacing an ESX control? .......................................................................7
5.2 How to proceed when replacing a rear axle sensor? ..................................................................7
5.3 Which components can be replaced without a subsequent adjustment procedure? ..................7
5.4 List of machine types ...................................................................................................................8
6 Possible adjustments on machines without BOP ..............................................................................9
6.1 Description of the Display Module ...............................................................................................9
6.2 Input of code numbers.................................................................................................................9
6.3 Changing the machine type (only via display module)...............................................................10
6.4 Inverting the direction signal (only via display module)..............................................................11
6.5 Changing the bit rate (only with display module) .......................................................................12
7 Adjustment/display possibilities on machines with BOP .................................................................13
7.1 Adjusting the machine type (BOP).............................................................................................13
7.2 Inverting the direction signal via the BOP control terminal ........................................................15
7.3 Accessing the diagnostics menu ...............................................................................................17
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)................ 19
7.3.2 Extended diagnose BVC machines.......................................................................................... 20
7.4 Changing the printout language.................................................................................................21
7.5 Setting the machine serial number ............................................................................................23
7.6 Teaching distance pulses ..........................................................................................................25
7.7 Activating the amplitude limitation (only BVC machines)...........................................................27
7.8 Changing the display mode (metric/imperial) ............................................................................29
8 Possible settings on the BCM05mobile...........................................................................................31
8.1 Reading the software version ....................................................................................................31
8.2 Changing the language..............................................................................................................31
8.3 Changing the unit system (metric/imperial) ...............................................................................31
9 Block diagram BEM.........................................................................................................................33
10 Block diagram BTMplus / VARIOCONTROL.............................................................................34
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile ..............................................35
12 Description of the Signals on the ESX-Control..........................................................................36
13 Fault codes of the ESX control ..................................................................................................41
13.1 Overview ...............................................................................................................................41
13.2 Description of fault reactions .................................................................................................42
13.3 Detailed description of fault codes and their possible causes..............................................43
14 Input codes for ESX control (only via display module on BEM).................................................47
14.1 Travel system ........................................................................................................................47
14.2 Vibration ................................................................................................................................48
14.3 Light.......................................................................................................................................48
14.4 Acceleration transducer.........................................................................................................49
14.5 Diesel engine.........................................................................................................................49
14.6 Setting the machine type.......................................................................................................50
14.7 Parameter change.................................................................................................................51
15 Terminology in connection with ESX .........................................................................................52
Status:01.04.2005 Page 2 of 55
Author: T.Löw / TE
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Author: T.Löw / TE
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Author: T.Löw / TE
Status:01.04.2005 Page 5 of 55
Author: T.Löw / TE
4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0" => see "Setting the bit rate"
Status:01.04.2005 Page 6 of 55
Author: T.Löw / TE
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
Therefore set the machine type in the first step! see "5.4 List of
machine types", or "7.1 Adjusting the machine type"
• Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
• Set the machine serial number (only on machines with BOP), see: 7.5
• Set the printer language (only machines with printer), see: 7.4
Check the direction signal, invert the signal if necessary, see 6.4, or 6.4.
Status:01.04.2005 Page 7 of 55
Author: T.Löw / TE
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
Status:01.04.2005 Page 8 of 55
Author: T.Löw / TE
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the
BOP!
(see item 7 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Higher
values lead to the display "- - - - “, negative values are indicated by the "minus dot“ lighting up (see
Vorzeichen
057 667 72
15/54
illustration).
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
) The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
• Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
• Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0
(signal not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14 "14").
• Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
• The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
• By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.
Note: Parameter adjustments can only be performed when the engine is not running.
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
• The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item 5.4 ".
• After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a
restart.
BOP and MESX are now adjusted to the new machine type.
7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running.
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F1" to open the screen page "Invert direction signal". The following screen is displayed:
• The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or "Invert
= 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
Check on the printout or in the diagnostics menu whether the travel direction has been correctly
detected.
• Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".
• By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).
98% Small Ampl: Triggering of solenoid valve for low amplitude in percent
MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
• Press key "F6" to open the screen page "Printout language". The following screen is displayed:
• The desired printout language can be selected by pressing the keys "F11" and "F12".
• After selecting the desired language press key "F14" to save the adjustment. The symbol (F14)
lights green for a moment as a sign of confirmation.
• Press key "F7" to open the screen page "Serial number". The following screen is displayed:
• The desired printout language can be selected by pressing the keys "F11" and "F12".
• After the adjustment press key"F14" to save the adjustment. The symbol (F14) lights green for a
moment as a sign of confirmation.
Note: An adaptation of the distance pulses is only possible within a range of +/- 10% of the
preset value.
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:
• Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:
• The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
• Press key "F4" to open the screen page "Display mode". The following screen is displayed:
• The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
Note: After this setting the service window must be closed to avoid unauthorized access.
Press "Close window" at the bottom right in the service window.
Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".
Note: After this setting the service window must be closed to avoid unauthorized access.
Press "Close window" at the bottom right in the service window.
008 911 63
9 Block diagram BEM
Electrics BEM (BOMAG Evib-meter)
BOMAG
Status: 01.04.2005 Block diagram Page 33 of 55
Author: T. Löw / TE
10.1
209
210
10.1
BOMAG
Status: 01.04.2005 Block diagram Page 34 of 55
Author: T. Löw / TE
Electrics BEM (BOMAG Evib-meter)
008 911 63
Service Training MESX Block diagram
008 911 63
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
Electrics BEM (BOMAG Evib-meter)
BOMAG
Status: 01.04.2005 Block diagram Page 35 of 55
Author: T. Löw / TE
10.1
211
212
10.1
X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X44:6
BOMAG
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Top stop ) approx. 6.6 V
008 911 63
Service Training MESX Description of signals
008 911 63
ESX terminal Signal description Nominal values (voltage / current)
X44:10
X44:11
X44:12
X44:13
X44:14
BOMAG
)
X44:19 Input button "CLEAR" (option) Push button pressed ) 12 V
Digital input active high Push button not pressed ) 2V
X44:20
X44:21
X44:22
213
214
10.1
X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
BOMAG
Open circuit voltage (vibration off): ) 4,2..4,3 V
Analogue input / voltage input 0..8.5 V
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)
X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34
X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on machine
type.
Digital input active high
008 911 63
Service Training MESX Description of signals
008 911 63
ESX terminal Signal description Nominal values (voltage / current)
X44:36
X44:40
X44:41
Electrics BEM (BOMAG Evib-meter)
X44:42
X44:43
X44:44
BOMAG
X44:45
X44:49
X44:50
X44:51
X44:52
215
216
10.1
X44:61
BOMAG
X44:62
X44:63
X44:64
008 911 63
Electrics BEM (BOMAG Evib-meter) 10.1
13.1 Overview
BOMAG
) the diesel engine is shut down.
Fault code is displayed.
Signal light in BOP (option) lights in 1 second intervals.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.
Note: Errors with error reaction 1 are only warning messages and are NOT stored in the error log.
008 911 63
Service Training MESX Description of fault codes on the ESX control
008 911 63
13.3 Detailed description of fault codes and their possible causes
BOMAG
Status: 01.04.2005 Description of fault codes on the ESX control Page 43 of 55
Author: T. Löw / TE
10.1
219
220
10.1
452 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:47 2
6 Valve for exciter down ) Current path has non-permitted connection to another current
BOMAG
Output current too low. path
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X44:47 2
7 Valve for exciter down ) Current path has non-permitted connection to another current
Output current too high. path
008 911 63
Service Training MESX Description of fault codes on the ESX control
008 911 63
Fault Fault description Possible cause Terminal Input Fault
code on ESX code for reaction
diagnose
453 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
1 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
453 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
2 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
Electrics BEM (BOMAG Evib-meter)
460 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
1 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:31
BOMAG
460 Input acceleration transducer 1 ) Current path connected to +12 V / +8,5 V X44:29, 4601 2
2 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:31
460 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
6 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:07
460 Input acceleration transducer 2 ) Current path connected to +12 V / +8,5 V X44:30, 4606 2
7 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:07
221
222
10.1
BOMAG
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)
008 911 63
Service Training MESX Description of input codes for the control
008 911 63
14 Input codes for ESX control (only via display module on BEM)
BOMAG
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 ) Direction signal is not inverted
Eeprom Parameter is displayed 000I ) Direction signal is inverted
223
224
10.1
14.2 Vibration
14.3 Light
BOMAG
Status: 01.04.2005 Description of input codes for the control Page 48 of 55
Author: T. Löw / TE
Electrics BEM (BOMAG Evib-meter)
008 911 63
Service Training MESX Description of input codes for the control
008 911 63
14.4 Acceleration transducer
BOMAG
Status: 01.04.2005 Description of input codes for the control Page 49 of 55
Author: T. Löw / TE
10.1
225
226
10.1
BOMAG
Status: 01.04.2005 Description of input codes for the control Page 50 of 55
Author: T. Löw / TE
Electrics BEM (BOMAG Evib-meter)
008 911 63
Service Training MESX Description of input codes for the control
008 911 63
14.7 Parameter change
BOMAG
Status: 01.04.2005 Description of input codes for the control Page 51 of 55
Author: T. Löw / TE
10.1
227
10.1 Electrics BEM (BOMAG Evib-meter)
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• chafed
• chafed mostly in connection with a short circuit to ground
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I = Current
I=
R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
Service Training
11/2005
Service Training
Table of contents
Travel system E1
Travel pump E3
Control E6
Charge pressure relief valve E 11
High pressure relief valve E 12
Pressure override E 14
Axle drive motor E 16
Drum drive motor E 20
Test and adjustment points, travel system E 25
Trouble shooting in travel system E 29
Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Charge pump F8
Vibration motor F9
Drum F 12
Test and adjustment points, vibration system F 14
Trouble shooting in vibration system F 16
Steering G1
Steering pump(s) G2
Steering valve G4
Articulated joint G6
Measuring and adjustment points G8
Trouble shooting steering system G9
Travel circuit
from brake valve
M4 M5
from speed
ø 0.8
ø 0.81
ø 0.6
6
ø 0.6
4 8
BOMAG
T3
25 bar 9
3
1
M2
B
1 Travel pump Sauer 90 R 075 4 Multi function valve 7 Speed range valve
2 Servo control 5 Rear axle 8 Flushing valve
3 Charge pressure relief valve 6 Axle drive motor Sauer 51 D 110 9 Drum drive motor Poclain MSE 18 1C
Service Training
-E1-
Service Training
008 911 63
Service Training 10.2
Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (Δp = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (Δp between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.
Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
M4 M5
2
A from/to
Travel motor
25 bar 4
3
1
from/to
Travel motor
B
Charge pressure to vibration pump
Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6
5
Fig. 3: Travel pump
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
Note:
These machines are equipped with two charge pumps.
Service Training
Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Service Training
View of the rotating group
4 3
5
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
Service Training
Description of function
2 3 4 5 6
1
8 6 7
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
Service Training
Tandem pump
Service Training
Tandem pump, connections and adjustment points
32
Thermostat
housing
Service Training
1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 End plate with integrated charge pump (only in vibration pump)
19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Adjustment screw for mechanical neutral position, vibration
Service Training
servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.
The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
Service Training
• when shutting the engine down,
Service Training
Multi-function valves
Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
Service Training
In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
Service Training
Charge pressure relief valve
The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.
The pressures of both pumps are limited by a charge pressure relief valve.
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multi-
disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).
Service Training
Flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
Service Training
Axle drive motor,
The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable
displacement.
5 7 8
6
9
11
10
4
2
Service Training
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
Service Training
Rear axle
Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Service Training
Front drum drive motor: Radial piston motor MSE 18 2 CX
On single drum rollers of series D-40 the drum is driven by a hydraulic radial piston motor.
These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.
2 3
4
1
43090070
6 5 4 5
Service Training
• bearing section (drive shaft bearings),
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.
This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.
The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.
The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.
The movement of a piston along the cam race must be examined in several phases during a full rotation:
2
3
Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. 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.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
Service Training
Travel circuit: Drum drive with radial piston motor
1
4
6 1
n
ctio 1 Travel pump
i r e
e ld 2 Vibration pump
av 3 Travel lever
Tr 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)
Fig. 16: Single drum rollers D-40, travel circuit, hose installation
Service Training
Brake control: Travel motor in axle
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Service Training
Travel drive, components and test points
Travel pump:
2
2 1
1
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A
3 Charge pressure port 7, MA 26 bar
Service Training
Travel pump: right hand side
2 3
1
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)
Service Training
Front travel motor, without brake (radial piston motor)
2 1
2 1
45 3
4
6
3
Service Training
Rear travel motor: Axle motor
1
4
3 2
6
5
7
Service Training
Brake valve
11
Service Training
Travel lever console
Service Training
Travel lever
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle-drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Clutch- Dieselmotor-Pumpe 2
Dieselmotor 1
Service Training
Vibration system
The vibration system of the single drum rollers of generation D-40 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of:
L2 N
Block
M1
M2
S
B
2
1
M4
M5
1 Vibration pump
2 Vibration motor
Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.
When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.
Fig. 2:
Service Training
Vibration pump
Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.
The displacement of the pump is proportional to the engine speed and the chosen displacement.
When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from ”0” to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.
1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
A
M1
M2
S
B
M4
M5
Service Training
Function
1 2
5 4 3
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
Service Training
1
2
5
4 3
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.
Charge pumps
One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.
The second pump is an internal gear pump and is located in the end cover of the vibration pump.
The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.
Service Training
High pressure relief valves
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".
Service Training
Vibration motor
The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
2 3
4 5
1
8 7
10 9
Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
A MA
3 1
B MB
1 Vibration motor
2 Flushing valve
3 Flushing pressure relief valve
Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.
1
A
1 Flushing spool
2 Flushing pressure limitation valve
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Service Training
Vibration system: Components and test ports
Vibration pump
11
2
3
2
5 6 3
6
5 4
4
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Pressure test port, charge pressure MA 26 bar
2 Hydraulic oil filter (charge circuit) 07
with visual pressure differential
indicator
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3,33A
6 Solenoid valve, high amplitude Y07 12V / 3,33A
Service Training
Vibration pump
Service Training
Vibration motor
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1
Service Training
Steering
Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (Δp =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both 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.
When the pump is running the chambers transport hydraulic oil 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. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
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.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
9 2
5
8
Service Training
240 bar
Δp = 175 bar
240 bar
0,5 bar
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 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 is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
Service Training
Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.
Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
Service Training
Steering: Components and test ports
Steering pump
Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
Service Training
Steering valve
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
POSSIBLE CAUSES
Steering orbitrol valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
Fig. 1 Engine compartment The pistons are made of aluminium alloy. The side
Single drum rollers of series BW211/213 D/PD-4 are walls of the slightly externally arranged combustion
powered by Deutz diesel engines type BF4M 2012 C trough are inclined towards the inside by 10°. All pis-
with intercooling. The intercooler reduces the thermal tons are fitted with three piston rings and a cast iron
load on the engine, the exhaust temperature and the ring carrier for the first ring. The pistons are oil mist lu-
fuel consumption and thus enables a higher power bricated.
output. The forged crankshaft is designed with integrated
The engines are characterized by the following posi- counter weights.
tive features: The block-type cylinder head is made of cast steel.
l short and compact design Each of the cylinders has an inlet and an outlet valve.
l
low noise level The valve guides are shrunk into the cylinders. The
valve seat rings are made of high quality steel and
l
almost vibration free operation
also shrunk fit.
l
low fuel consumption
l
low exhaust emissions (EPA II)
l
high power reserves and
l
excellent access to all service locations.
Crankcase and cylinders on this engine are made of
alloyed cast iron. This provides rigidness and high
wear resistance.
The forged steel conrods are designed with balancing
weights in the area of the conrod bearing seats. These
weights compensate manufacturing tolerances with
respect to weight and position of the centre of gravity.
Fig. 1
1 Oil pressure switch
! Danger
Danger of injury!
Support the engine hood for all maintenance and
repair work.
i Note
The machine must be parked horizontally with the en-
gine shut down.
!Caution
Before longer work periods you should always top
the oil up to the "MAX"-mark.
Caution
!
Danger
!
Fig. 5
Danger of scalding! l Thoroughly clean the outside of both filter cartridges
When draining off hot oil. (Fig. 5).
By hot oil when unscrewing the engine oil filter. l Unscrew both filter cartridges using an appropriate
filter wrench.
Environment
Catch running out oil and dispose of environmen- i Note
tally together with the engine oil filter cartridge. The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal and
installation.
l Clean the sealing face on the filter carrier from any
dirt.
l
Slightly oil the rubber seal on the new filter cartridg-
es.
Fig. 4
l Unscrew the drain plug (Fig. 4) and catch running
out oil.
l
Turn the drain plug tightly back in.
Fig. 6
l Turn the new filter cartridges (Fig. 6) on by hand,
until the seal contacts.
l Tighten the filter cartridges for another half turn.
Fig. 7
l Fill in new engine oil (Fig. 7).
! Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
l
After a short test run check the oil level on the dip-
stick, if necessary top up to the top dipstick mark.
l
Check filter cartridge and drain plug for leaks after a
short test run.
l
Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
l
Check the oil level again, if necessary fill up to the
Max.-mark.
Brief description
The coolant pump ("water pump") draws coolant
through the hose lines directly out of the radiator and
forces it first of all through the lubrication oil cooler,
which is integrated in the engine. The coolant then en- Fig. 2 Direct heating
ters into the engine, flows up along the cylinders into
the cylinder head and to the thermostat at the coolant 1 Thermostat
outlet. Form their the coolant is returned through the 2 Coolant pump
corresponding lines to the radiator inlet. When the en- 3 Lubrication oil cooler
gine is cold the coolant is pumped in a short circuit 4 Heat exchanger
through the engine, until the response temperature of
the thermostat (start of opening) is reached. The wa-
ter pump draws cold coolant out of the radiator, as re-
quired to replenish the hot out flowing coolant.
The coolant is a mixture of water and anti-freeze
agent. The anti-freeze agent increases the boiling
temperature of the mixture and thus enables temper-
atures of up to 120° C at an overpressure of up to 1.4
bar.
The coolant compensation tank enables reliable gas
separation, thus avoiding cavitation in the cooling sys-
tem, which mainly occurs in the suction side of the
pump. The air volume inside the compensation must
be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any
escape of coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated
in the engine into the into the environment.
Part of the combustion heat is transferred to the lubri-
cation oil. The lubrication oil cooler (5) serves the
function of cooling the lubrication oil.
Heating
Water-cooled DEUTZ diesel engines utilize the cool-
ant to heat the driver's cab. For this purpose the en-
gine coolant is guided directly to the heat exchanger
and the heat is directly dissipated into the environ-
ment (direct heating).
i Note
Check the area around the coolant temperature sen-
sor for leaks.
l Let the engine cool down and check the coolant lev-
el again, top up if necessary.
Environment
Dispose of escaping coolant environmentally
l Unscrew the temperature switch.
Danger
!
Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
l Drain the coolant from the engine and catch it.
Environment
Catch running out coolant and dispose of environ-
mentally. Fig. 6
l Assemble the outlet socket (Fig. 6).
l Tightening torque: 30 Nm
l Install the coolant hose again.
l Fill in coolant up to the “MAX” mark .
i Note
Check for leaks around the thermostat.
l Let the engine cool down and check the coolant lev-
Fig. 4 el again, top up if necessary.
l
Disconnect the coolant hose.
l Remove the outlet socket (Fig. 4).
l Remove the thermostat.
Fig. 5
l
Fit a new seal to the thermostat.
l Insert the new thermostat with the seal ring (Fig. 5).
i Note
Mind the installation position. The arrow (ventilation
groove) points up.
Fig. 3
l Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
l Calculate the stroke.
Stroke = b - a
i Note
Fig. 1 The stroke at the given temperature (T2) should be
min. 8 mm.
l Measure and write down the measurement "a" on
the thermostat (Fig. 4).
i Note
"a" = beginning of stroke at approx. 83 ± 2°C (T1)
"b" = end of stroke at approx. 95 °C (T2)
Fig. 2
l Warm up the thermostat in a water bath (Fig. 2).
i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.
! Danger ! Danger
Environment
Catch running out coolant and dispose of environ-
mentally.
Fig. 4
l
Check the coolant level (Fig. 4).
!Caution
Fig. 5
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and l
Set the cock valve for the cabin heater to position
engine for leaks. "warm".
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.
Fig. 6
l Unscrew the plug, let the coolant run out and catch
it.
l Screw the plug back in once all coolant has run out.
Danger
!
Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.
Caution
!
Fig. 8
i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 8) out with compressed air.
Caution
!
11.16Three-phase generator
Fig. 1
1 Generator (G02)
i Note
The generator is maintenance free. Function tests and
repair work must only be performed in authorized
workshops.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
11.17Fuel supply
! Danger
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may de-
viate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.
Check valve
Fig. 1
l According to our experience, it is not always as-
sured that only clean fuel will be used. Fuel tanks
are frequently filled without suitable precautions
against contamination or fuel filters are inappropri-
ately serviced. Many damage analyses on injection
pumps and injection valves have revealed that most
of these components had failed due to premature
wear. Wear on injection pump plunger and injection
valve needle seat is caused by contaminated fuel. Fig. 2 Observe the direction of flow
Modern exhaust optimized diesel engines with high
pressure injection systems strictly require clean fuel i Note
to be able to work reliably over their entire lifetime. From August 2006 the check valve (Fig. 2) is used by
If the throttle resistances of pre-cleaner/main filter BOMAG in series machines.
caused by contaminated fuel are so high that the
fuel pump is no longer able to ensure a sufficient
fuel supply, the injection pumps will draw the re- ! Caution
quired fuel through the leak fuiel return line from the This valve must strictly be installed into the fuel
tank without filtration. The engine is no longer able return line by our customers.
to provide its full power, operation of construction
equipment or other machines, however, may still be
possible to a limited extent. After short time opera-
tion under such conditions the injection system
components may already be pre-damaged.
1 Tensioning nut l
Disassemble pressure control valve and cylinder
2 Nozzle head cover (Fig. 1).
3 Intermediate piece l
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
4 Pressure bolt
5 Pressure spring
l Swing the holding plate to the side.
6 Shim
i Note
A thicker shim 6 (Fig. 4) increases the opening pres-
sure.
!Caution
When replacing an injection pump and/or an injec-
tion valve, you must also replace the high pres-
sure line between pump and valve.
Fig. 2
l Remove the engine shut-down assy (Fig. 2).
Fig. 3 Fig. 5
l Use the shut-down lever to push the governor rod to l Set the cylinder of the injection pump to be disas-
stop position (Fig. 3). sembled to top dead centre (TDC) for ignition
(valves overlapping) (Fig. 5).
l Insert and fasten the pressing device 100 830.
l Turn the crankshaft for approx. 120° against the
sense of rotation.
i Note
Illustration shows view on flywheel.
Fig. 4
l Use the knurled fastening screw to force the gover-
nor rod to stop position (Fig. 4).
i Note
Tighten the knurled fastening screw by hand. Fig. 6
l
Remove the injection line (Fig. 6).
i Note
Close the connections with protection caps.
Fig. 7
l Carefully remove the shim with a rod-type magneto
(Fig. 7).
i Note
Old injection pump and shim are not required for this
purpose.
Example:
The injection pump for cylinder 3 is to be replaced on
an engine BF6M 2012.
Procedure:
l Read the EP-code for cylinder 3 in the column "EP"
on the type plate (table) (Fig. 8), e.g. 295.
i Note
Sequence of reading: Line 1 = cyl.1, line 2 = cyl.2, etc.
l Take the corrected injection pump installation
measurement (EK) matching the EP-code from the
table (Fig. 11), e.g. 120.875 mm.
i Note
Measurement "A" (Fig. 3) determines by how many 1/
100 of a mm the distance between cylinder crankcase
contact surface and plunger foot is longer than the ba-
sic measurement Lo.
Basic measurement of injection pump (Lo) = 117.5
mm.
l Determine the theoretical thickness of the shim
(TS).
TS = EK - (Lo + A/100)
TS = 2.955 mm
Fig. 9 Length of injection pump (A) l Choose the shim thickness (SS) from the table.
l Read the coefficient for the injection pump length
(A) (Fig. 9) on the new injection pump, e.g. 42.
TS 2.955 mm = SS 3.0 mm
Theor. thickness "TS" Shim thickness "SS" Theor. thickness "TS" Shim thickness "SS"
(mm) (mm) (mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.849 3.8
2.35 - 2.449 2.4
Assembly
Fig. 15
l Slightly oil the receiving bore in the crankcase and
Fig. 12 the O-rings on the injection pump.
l
Carefully insert the injection pump control lever into
the governor rod. (Fig. 15).
Caution
!
Fig. 13
l Lay the newly determined shim on roller plungers
(Fig. 12) and (Fig. 13).
Fig. 16
l Attach the flange (Fig. 16).
! Caution
The chamfer must face towards the injection
pump body.
Fig. 14
l Turn the injection pump control lever approx. to
middle position (Fig. 14).
Fig. 20
Fig. 17
l Turn the screws in again for 60°, then tighten in
l
Slightly oil the screws and tighten with a torque of 5
steps to a torque of 7 Nm, 10 Nm and 30 Nm. (Fig.
Nm (Fig. 17).
20).
i Note
Always start with the outer screw furthest away from
the flywheel.
Fig. 18
l Loosen the screws again for 60° (Fig. 18).
Fig. 21
l Turn the knurled fastening screw back (Fig. 21).
l Remove the pressing device.
Caution
!
Fig. 19
l Carefully turn the injection pump with an open end
spanner anti-clockwise against the noticeable end
stop (Fig. 19).
Fig. 22
l Assemble a new O-ring (Fig. 22). Fig. 24
i Note Caution
!
Cover the O-ring slightly with oil. Take care that the sealing cones match exactly
when assembling the injection line. Subsequent
bending is not permitted. The injection line must
never be used twice.
l
Install the new injection line with the sealing rubber
(Fig. 24).
l Pre-tension the injection line cap nuts on injection
pump and injection valve with a torque of approx. 5
Nm (use claw spanner 8018).
l
Tighten the cap nut with 25 ± 3.5 Nm.
Fig. 23
l
Use the shut-down lever to push the governor rod to
stop position and hold it (Fig. 23).
l
Assemble the engine shut-down assy.
l
Tighten the screws with 21 Nm.
l Plug the cable plug onto the shut-down magneto.
Fig. 25
l Install the gasket (Fig. 25).
i Note
Injection valves may wear mechanically over the
course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hy-
drostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
Fig. 26
l
Assemble cylinder head cover and holding plate !Caution
(Fig. 26). Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
l Tighten the screws with 11 Nm.
ISO 4113 or clean diesel fuel to test the injection
valves.
i Note
Ensure the sealing rubber is fitted correctly. Removal
l If necessary assemble the pressure control valve
with a new seal.
l Tighten the screws with 8.5 Nm.
Fig. 1
l
Disassemble pressure control valve and cylinder
head cover (Fig. 4).
l
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
l
Swing the holding plate to the side.
Installation
Fig. 2
l Disassemble the injection lines (Fig. 2). Fig. 1
l Slide the new seal rings with some grease over the
i Note injection valves and insert the injection valves (Fig.
Close connections on injection valves and injection 1).
pumps with protective caps.
Caution
!
Fig. 3
l
Disassemble the claws and take out the injection
valves (Fig. 3).
Fig. 2
i Note l Attach the claws and turn the screws in loosely (Fig.
In case of tight fit use the extracting device 150 800 2).
with puller 110 030.
Pull out the seal ring with the extracting device 120
680.
Fig. 3 Fig. 5
l Pre-tension the injection line cap nuts on injection
Caution
! pumps and injection valves with a torque of approx.
Take care that the sealing cones match exactly 5 Nm (Fig. 5).
when assembling the injection line. Subsequent l Tighten the cap nuts with 25 + 3.5 Nm.
bending is not permitted. The injection line must
never be used twice.
i Note
l Install the new injection lines with the sealing rub-
Use a claw spanner 8018.
bers (Fig. 3).
l Tighten the cap nuts finger tight.
Fig. 6
l
Install the gasket (Fig. 25).
Fig. 4
l
Tighten the screws for the claws with 16 + 5 Nm
(Fig. 4).
!Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
Fig. 7 ISO 4113 or clean diesel fuel to test the injection
l
Assemble cylinder head cover and holding plate valves.
(Fig. 26).
l Tighten the screws with 11 Nm. Check the injection valves
i Note i Note
Ensure the sealing rubber is fitted correctly. The injection valves are leak fuel free. Fuel cannot
flow off and will accumulate above the nozzle needle
l If necessary assemble the pressure control valve in the spring chamber of the nozzle holder. Operation
with a new seal. of the nozzle tester hand leever is in this case no long-
l Tighten the screws with 8.5 Nm. er possible. In order to eliminate the pressure inside
the spring chamber the clamping nut must be slack-
ened and retightened again before each test.
Fig. 1
l
Loosen the clamping screw by approx. 180° and
tighten it again (Fig. 1).
Tightening instructions: 30 - 40 Nm
i Note
Use injection valve holder 110 110.
i Note
If the opening pressure needs toi be corrected: De-
tach the injection valve from the nozzle tester 8008.
Unscrew the clamping nut and remove all parts. Use
injection valve holder 110 110.
Fig. 2
l
Mount the injection valve to the nozzle tester (Fig.
2).
! Danger
Fig. 3
l Slowly press the lever of the nozzle tester 8008
down with the pressure gauge connected (Fig. 3).
Fig. 5
Opening pressure: 220 bar Sequence of disassembly (Fig. 5):
1 Tensioning nut
i Note 2 Injection nozzle
The opening pressure is reached, when the pointer 3 Intermediate piece
stops or suddenly drops. 4 Pressure bolt
The pressure inside the spring chamber will have 5 Pressure spring
build up again after approx. 3 - 4 strokes. In order to 6 Shim
repeat the test the clamping nut needs to be slack-
ened and retightened again, as specified.
l Clean all parts with clean diesel fuel and blow off
with compressed air.
Once identical values are measured during 3 tests,
the values can be considered valid.
Fig. 6 Fig. 8
l
Assemble the shim (Fig. 8).
!Caution
Nozzle needle and nozzle body have been fitted i Note
by lapping and must never be mixed up by mis- Adjust the opening pressure by choosing the required
take or replaced individually. Do not touch the shim. A thicker shim increases the opening pressure.
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 6).
i Note
If the needle slides down jerkily, wash out the nozzle
body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fu-
el.
Fig. 9
l
Assemble the pressure spring.
Fig. 7
l Check the seat areas of the intermediate piece for
signs of wear. Make sure that the centring pins are
present (Fig. 7).
Fig. 10
l Install the pressure bolt with the centring collar to-
wards the pressure spring (Fig. 10).
Fig. 11 Fig. 13
l
Insert the centring pins of the intermediate piece l
Screw on the clamping nut.
into the bores of the nozzle holder (Fig. 11).
i Note
The chamfer points towards the pressure bolt.
Fig. 14
l Tighten the clamping nut.
i Note
Fig. 12
Use the injection valve holder 110 110 and a long
l Attach the centring bores of the injection nozzle to socket 8012.
the centring pins of the intermediate piece (Fig. 12).
Tightening torque: 30 to 40 Nm
i Note
The nozzle needle must not drop out of the nozzle
body.
Fig. 1 Fig. 1
l Dry nozzle and nozzle holder - blow dry with com- l
Switch off the pressure gauge on the tester.
pressed air.
l Press the hand klever of the tester slowly down, to i Note
a point about 20 bar before the previously indicated The rattle test enables audible testing of the nozzle
opening pressure (Fig. 1). needle movement inside the nozzle body. In compar-
ison with used injection valves, new ones have a dif-
ferent rattling behaviour. It becomes worse as the
wear in the needle seat area progresses.
!Caution
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the le-
ver quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!
Fig. 2
i Note
The nozzle is leak tight, if no drop drips off within a pe-
riod of 10 seconds.
! Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a suc-
cess, replace the injection nozzle.
Rework is not permitted!
General l Open the drain valve and drain off approx. 0.5 l of
The quality of the fuel filter and the compliance with fuel. The fuel above the filter element presses
the specified service intervals are decisive for the life- through the filter element and frees the underside
time of the fuel injection system. The heart of the fuel from dirt.
filter is made of hydrophobic special paper, which is l Close the drain valve again.
spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spa- Perform
tial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity. A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a fil-
The fuel pre-filter / water separator mainly consists of:
ter problem, you should check whether bleeding
l
the dirt / water collecting bowl screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
l and the filter element
connections for leaks and the lines for clogging or po-
rous points.
Function
The fuel lift pump draws the fuel through this filter. Main fuel filter
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coa-
lescence effect).
Water is heavier than diesel fuel, it settles as a differ-
ent colour fluid on the bottom.
Once the water level reaches the height of the warn-
ing connections (sensor B124), the warning lamp
(H70) in the monitoring board (A15) will come on.
Danger
! Danger
!
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 4
l
Unscrew the fuel filter cartridge (Fig. 4) using an ap-
propriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.
Fig. 3
l
Slacken the drain plug (Fig. 3) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.
Fig. 5
l Unscrew the water separator from the filter car-
tridge (Fig. 5).
! Danger
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 6
l Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 6).
l Screw the water separator on by hand (2), until the
seal contacts.
l Tighten the water separator for another half turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6). Fig. 8
Fig. 9
l Slightly oil the rubber seal (Fig. 9) on the new filter
cartridge.
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until the
Fig. 7 seal contacts.
l Slacken the bleeding screw (Fig. 7) on the fuel pre- l Tighten the filter element for another half turn.
filter for 2 to 3 turns. l Check the filter cartridge for leaks after a short test
l Operate the hand pump manually, until fuel flows run.
out of the slackened bleeding screw (Fig. 7) without
air bubbles.
l Then tighten the bleeding screw while pumping.
Fig. 4
l Connect the compression tester 8005 (Fig. 4).
l
Crank the engine with the starter.
Fig. 1 i Note
l Insert the connecting piece 100 110 with seal ring Check the compression on each of the cylinders.
(Fig. 4).
Compression: 30 - 38 bar
The measured compression depends on the starter
speed during the measuring process and the altitude
of the engine location. Limit values can therefore not
be specified exactly. It is recommended to use the
compression measurement to compare the cylinders
of an engine among each other. Should a deviation of
more than 15% be measured, the affected cylinders
should be dismantled to examine the cause.
l Remove the compression tester 8005 and the con-
necting piece 100 110.
l Install the injection valves.
Fig. 2
l
Attach the claws (Fig. 2).
l Tighten the screw.
Fig. 3
l
Screw on the adapter for connecting piece 100 110
(Fig. 3).
Caution
!
Fig. 5
Valve 1 (Fig. 5) white = not adjustable
Valve (2) black = adjustable
Fig. 8
l
Remove the valve cover (Fig. 8).
l Crankshaft position as per "valve adjustment sche-
matic".
Fig. 6
Fig. 9
l Check valve clearance 2 (Fig. 9) between rocker
arm (1) and valve (3) with a feeler gauge.
Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
The feeler gauge must fit with little resistance.
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.
Fig. 10
l
Slightly slacken the counter nut. Adjust setscrew 7
(Fig. 10) with a screwdriver, until the feeler gauge
(6) can be inserted and pulled out with little resist-
ance after retightening the counter nut.
l
Perform tests and adjustments on all other adjusta-
ble valves.
l Check the gasket of the valve cover, replace it if
necessary.
l Reassemble the cylinder head cover.
l
Swivel the ventilation valve back to correct position
and fasten it.
l Fasten the air filter again and ensure correct fit of
combustion air hoses and clamps.
Fig. 1
1 Boost fuel solenoid valve
General
During the starting process the solenoid valve is sup-
plied with 12 Volt.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
sure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.
Fig. 1
1 Engine shut-down solenoid
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure (terminal 9).
11.30Air filter
Fig. 1
! Caution The air filter has the additional function of damping the
air intake noise. This damping is achieved by the de-
Combustion air lines between filter and engine sign of the air filter in from of a reflection silencer
("clean air lines") must be absolutely leak tight based on the principle of a Helmholz resonator, damp-
and withstand mechanical loads caused by en- ing the intake noise by its resonance frequency.
gine vibrations and pressure pulsation.
Crankcase ventilation
General
During the combustion process in a diesel engine cer-
The air filter retains the dust contained in the intake air tain waste gas quantities escape through the ring
and keeps it away from the engine in order to avoid gaps on pistons and piston rings into the crankcase.
engine wear. The crankcase ventilation serves the discharge of
On paved roads the dust content in the air is 1 mg/m3 these waste gases.
on average, on sealed roads or construction sites the The engines are by standard and currently only
dust content can rise up to 40 mg/m3. equipped with open crankcase ventilation. A crank-
Dry air filters with integrated dust separator are char- case ventilation valve with oil separator separates
acterized by a good filtering effect (irrespective of en- most of the oil from the waste gas and returns it into
gine speed and inclination) and thus enable long the engine. The waste gas itself escapes into the at-
lasting and low wear engine operation. mosphere.
Caution
!
Fig. 4
l Pull the main filter element (Fig. 4) with light turning
movements.
!Caution
If necessary, the main filter element may be
Fig. 2 cleaned up to five times. It must be renewed at the
Servicing of the dry air filter is necessary when the yel- latest after a maximum utilization period of two
low piston (Fig. 2) has reached the inscription "Serv- years.
ice" in front of a red background, but at the latest after The number of cleaning intervals of the main filter
2 years. element can be marked on the safety element with
After completion of the filter service reset the indicator a ball pen or a felt pen.
back to "Zero" by pressing the button. Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new
Removing the main filter element filter cartridge.
l
Fully open the engine hood. Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage
to the engine.
Replace the safety cartridge if the main filter ele-
ment is defective!
Additional cleaning intervals between two filter
services signalized by the fault monitoring board
are not necessary.
Fig. 3
l Unclip three clamps on the housing cover and take
off the cover (Fig. 3).
!Caution
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.
Caution
!
if the warning light comes on again after servicing
the main filter cartridge.
Do not continue to run the machine with a dam-
aged main filter element. If in doubt use a new l Remove the housing cover and pull the main filter
main filter element. element off.
Fig. 7
l
Perforate the seal of the safety filter element from
Fig. 6 inside to outside using a suitable tool (Fig. 7) and
pull both latches up.
l Pull the internal part (Fig. 6) out and remove the
dust from the cover. l Grip the safety element by both latches and pull it
out with slight turning movements.
l Reinsert the inner part.
l
Push in a new safety filter element.
l Reassemble main filter element and cover.
i Note
Pre-heating is triggered by switching on the ignition
(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30°C the preheating
time will be max. 52 seconds, with +5°C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
After-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a cool-
ant temperature of -30°C the subsequent heating time
will be max. 180 seconds, with +25°C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.
! Caution
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of au-
tomatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of
Fig. 3
1 Heating control unit (A13)
2 Heating relay (K14)
11.33Checking the heating flange After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
control ing time is not indicated by the control light (K) .
i Note
During the preheating period the control light K (Fig. 1)
is permanently on. In case of a fault the lamp (K) will
flash.
l The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.
i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-
perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
l
Start the heating process.
i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.
Fig. 4
l Switch on the ignition.
l Turn the rotary switch (Fig. 4) to position "MAX".
Fig. 1
1 Monitoring board (A15)
Water separator l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.
Engine overheating
i Note l
Press the emergency stop switch (Fig. 5). The en-
The control light b (Fig. 1) flashes. An audible warning gine should stop immediately.
will sound and the engine is shut down after 10 sec-
onds.
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist
Engine oil level too low Top up engine oil to the upper dipstick
mark
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
35409 ©
Kompressionsdruckprüfer 8005
Compression tester
Compressiomètre
Compresímetro
35410 ©
Düsenprüfgerät 8008
Nozzle tester
35411 ©
35421 ©
Turning gear
Dispositif vireur
Dispositivo de viraje
35422 ©
Turning gear
Dispositif vireur
Dispositivo de viraje
35423 ©
35424 ©
35426 ©
35427 ©
35428 ©
35429 ©
35431 ©
35432 ©
35436 ©
35437 ©
35438 ©
35439 ©
35440 ©
35441 ©
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35443 ©
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35446 ©
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35452 ©
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
Compressor
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
Fig. 2
! Danger
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (± 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5,5°C (± 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
l Run the compressor for 10 minutes at engine idle
speed.
l In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. l Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
l Insert the oil dipstick.
l Pull out the dipstick and count the notches covered
by oil.
l Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
l Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
l
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.
Fig. 1
i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
1 Optional equipment
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 6
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .
1 Optional equipment
Fig. 7 Fig. 9
l Switch the air conditioning (Fig. 7) on. l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the outflowing air is noticeably cool-
er. Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
l Open the hood. The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Caution
!
!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
12.14Leak test
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- l b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator l c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Noise in system
Inspection glass
Monitoring devices
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
Fig. 1
2. Suction lifter
commercial
Fig. 2
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
Fig. 4
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub and flanged
hub
Fig. 3
Fig. 4
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 3
Fig. 4
5. Unscrew screws 1 (Fig. 5) from holding plate (2)
for hydraulic hoses from both sides.
Fig. 5
6. Unscrew screws (Fig. 6) from the spacer piece on
vibration and travel motors.
Fig. 6
7. Fasten the lifting gear to the side plate on the vi-
bration side.
8. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).
9. Unscrew plugs (1) and screws (2).
Fig. 7
! Danger
Fig. 8
13. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 9).
! Danger
Fig. 9
14. Check all rubber buffers (Fig. 10), replace if nec-
essary (see corresponding chapter).
Fig. 10
15. Check rectangular rubber buffers (Fig. 11), re-
place if necessary.
Fig. 11
Fig. 12
2. Attach the side plate, insert screws 2 (Fig. 13) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Close the screw holes with plugs (1).
Fig. 13
4. Attach the side plate, insert screws 2 (Fig. 14) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
5. Close the screw holes with plugs (1).
Fig. 14
6. Fasten the spacer pieces with screws (Fig. 15)
and nuts to the side plate.
Fig. 15
Nominal value:
Distance "X" + 2 mm
9. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
Fig. 16
10. Insert the compensation plates (Fig. 17). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
11. Unscrew the screws from the welded nuts.
Fig. 17
12. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking.
Fig. 18
13. Fasten holding plate 2 (Fig. 19) for hydraulic hos-
es with screws (1).
! Caution
After connecting the hydraulic components
and before starting operation bleed the hy-
draulic system, check the function and in-
spect the system for leaks.
Fig. 19
Fig. 1
4. Unscrew the nuts, pull out the screws and re-
move the support legs (Fig. 4).
Fig. 2
5. Attach the lifting tackle to the travel motor (Fig. 3).
! Danger
Danger of squashing!
Do not stand or step under suspended loads.
Fig. 3
! Caution
Flush the hydraulic system if dirt or chips are
found in the travel motor.
Fig. 4
Fig. 5
2. Mount bracket 1 (Fig. 8) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 6
Fig. 7
! Danger
Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 8).
7. Take the coupling element off the coupling half.
Fig. 8
Fig. 9
Fig. 10
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 11).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 11
8. Unclip the circlip from the groove in the flange
(Fig. 12).
Fig. 12
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 13).
Fig. 13
Fig. 14
11. Knock the radial seal (Fig. 15) out of the flanged
housing.
Fig. 15
12. Unclip the circlip from the groove in the flanged
housing (Fig. 16).
Fig. 16
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 17).
Fig. 17
14. Extract inner ring 1 (Fig. 18) for the radial seal
and inner bearing races (2).
! Danger
Danger of burning!
Wear safety gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 18
15. Unclip the circlip from the basic weight (Fig. 19).
Fig. 19
16. To change shaft 1 (Fig. 20) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 20
i Note
Remove both rectangular rubber buffers.
Fig. 21
3. Unscrew fastening screws 1 (Fig. 22).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.
Fig. 22
5. To change the vibration motor loosen clamping
screw 1 (Fig. 23) and pull off coupling half (2).
Fig. 23
Fig. 24
8. Remove the coupling element (Fig. 25).
Fig. 25
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 26).
! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).
Fig. 26
11. Press the exciter unit out of the drum with forcing
screws (Fig. 27).
i Note
The second forcing screw is covered by the side
plate.
Fig. 27
Fig. 28
Fig. 29
3. Attach the disassembly device to the side plate
(Fig. 30) and force off the side plate.
Fig. 30
4. Lift the side plate of the flanged hub (Fig. 31).
Fig. 31
Fig. 32
6. Unclip the circlip from the side plate (Fig. 33).
Fig. 33
7. Take the mechanical seal off the flanged hub
(Fig. 34).
Fig. 34
Fig. 35
3. Loosen hose clamp 1 (Fig. 36).
4. Pull coupling hub (2) off the shaft.
Fig. 36
5. Unscrew all other fastening screws 1 (Fig. 37)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 37
Fig. 38
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 39).
Fig. 39
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
40).
Fig. 40
11. Knock the radial seal (Fig. 41) out of the flanged
housing.
Fig. 41
Fig. 42
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 43).
Fig. 43
14. Extract inner rings 1 (Fig. 44) for the radial seals
and inner bearing races (2) from the shaft.
!Danger
Danger of burning!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 44
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 45).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 45
i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 46 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 47
! Caution
Close the bores on the short shaft with a
screw.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
48).
Fig. 48
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 49
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 50).
Fig. 50
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 51).
Fig. 51
! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 52).
Fig. 52
! Danger
Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
!Danger
Danger of burning!
Wear safety gloves.
11. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 54).
Fig. 54
!Danger
Danger of burning!
Wear safety gloves.
12. Heat the inner ring up to approx. 50° C and slide
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 55).
Fig. 55
13. Press cylinder roller bearing 1 (Fig. 56) with
pressing plate (2) into the flanged housing until it
bottoms.
Fig. 56
Fig. 57
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 58).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 58
!Caution
Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 59).
Fig. 59
18. Press cylinder roller bearing 1 (Fig. 60) with
pressing plate (2) into the flanged hub until it bot-
toms.
Fig. 60
19. Insert the circlip into the groove in the flanged hub
(Fig. 61).
Fig. 61
20. Attach the flanged hub to the flanged housing
(Fig. 62).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 62
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 63).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Fig. 63 !Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 64).
Fig. 64
Fig. 65
28. Cover the thread of screw 1 (Fig. 66) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 66 ! Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 67) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 67
Fig. 68
3. Insert the circlip into the groove in the side plate
(Fig. 69).
Fig. 69
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
70).
Fig. 70
i Note
Grease the other side after installing the exciter
unit.
Fig. 71
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 72).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 72
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 73).
Fig. 73
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 74).
Fig. 74
Fig. 75 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 76).
Fig. 76
13. Attach bushing 2 (Fig. 77) of the assembly device
and turn on nut (1).
Fig. 77
14. Pull the side plate with the assembly device onto
the flanged hub.
! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 78).
Fig. 78
Fig. 79
! Caution
Ensure strict cleanliness.
1. Cool the shaft down in liquid nitrogen.
Fig. 80
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
80).
3. Secure shaft 1 (Fig. 81) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
Fig. 81
Fig. 82
! Danger
Danger of burning!
Wear safety gloves.
5. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 83).
Fig. 83
! Danger
Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 84).
Fig. 84 ! Danger
Danger of burning!
Wear safety gloves.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 85).
Fig. 85
Fig. 86
9. Insert the circlip into the groove in the flanged
housing (Fig. 87).
Fig. 87
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 88).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 88 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 89).
Fig. 89
Fig. 90
14. Insert the circlip into the groove in the flange (Fig.
91).
Fig. 91
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 92).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Fig. 92
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 93).
Fig. 93
Fig. 94
19. Cover the thread of screw 1 (Fig. 95) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 95
21. Insert the fitting key into the keyway of the shaft
(Fig. 96).
Fig. 96 !Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 97) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 97
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.
Fig. 98 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
4. Insert the vibrator unit into the drum (Fig. 99).
Fig. 99
i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
100) is in line with bore (2) in the drum.
Fig. 100
Fig. 101
7. Cover the thread of screws (Fig. 102) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.
Fig. 102
Danger of squashing!
Do not stand or step under suspended loads.
1. Fasten the lifting tackle to the travel motor and at-
tach the motor to the drive disc (Fig. 103).
Fig. 103
2. Turn in and tighten the fastening screws (Fig.
104).
Fig. 104
Fig. 105
! Danger
Danger of squashing!
Do not stand or step under suspended loads.
4. Attach the drive disc with the assembled travel
motor to the rubber buffers. Turn on and tighten
the nuts (Fig. 106).
Fig. 106
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
! Danger
Danger of squashing! Do not stand or step
under suspended loads.
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 107).
Fig. 107
Fig. 108
2. Turn in and tighten screws 1 (Fig. 109).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 109
5. Check the end float of the exciter shafts (Fig.
110).
Fig. 110
6. Attach disc 1 (Fig. 111), turn in and tighten the
fastening screws (2).
Fig. 111
Fig. 112
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 113).
Fig. 113
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 114) and ventilation bore (2) are
opposite each other.
Fig. 114
12. Slide on coupling half 2 (Fig. 115) and secure with
clamping screw (1).
Fig. 115
Fig. 116
14. Install rectangular rubber buffers 2 (Fig. 117) with
attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 117
Fig. 1
2. Force the cover with forcing screws (Fig. 4) off the
basic weight.
Environment
Environmental hazard!
Catch running out oil and dispose of environ-
mentally.
Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).
Fig. 3
Fig. 4
Fig. 5
2. Place the change-over weight into the basic
weight (Fig. 6).
Fig. 6
3. Fill aprox 2,5 litres of silicone oil 47 V 1000 cst (up
to the upper edge of the change-over weight) into
the basic weight (Fig. 10).
Fig. 7
iNote
The shaft must have clearance.
Fig. 8
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
Fig. 2
4. Remove the compensation shims 1 (Fig. 3).
Fig. 3
Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance „X“ + 2 mm
Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).
Fig. 7
Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.
Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.
Fig. 10
Fig. 1
2. Pressing sleeve for outer race of rocker bearing
Fig. 2
3. Pressing sleeve for inner race of rocker bearing
Fig. 3
4. Guide journal
Fig. 4
Fig. 5
6. Disassembly device
Fig. 6
Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 3
Fig. 4
!Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
Fig. 4
9. Unscrew fastening screws 1 (Fig. 5).
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 11
Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
Fig. 16
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
Do not use any grease.
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
24. Turn in screws (1) and tighten crosswise.
Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 17
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
Fig. 21
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
Do not use any grease.
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
43. Turn in screws (2) and tighten crosswise.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 32
Fig. 33
Series 42 Introduction
1. Introduction
WARNING WARNING
When Series 42 units are used in vehicular Use caution when dealing with hydraulic fluid
hydrostatic drive systems, the loss of hydro- under pressure. Escaping hydraulic fluid un-
static drive line power in any mode of opera- der pressure can have sufficient force to pen-
tion (e.g. acceleration, deceleration or “neu- etrate your skin causing serious injury. This
tral” mode) may cause a loss of hydrostatic fluid may also be hot enough to burn. Serious
braking capacity. A braking system which is infection or reactions can develop if proper
independent of the hydrostatic transmission medical treatment is not administered immedi-
must, therefore, be provided which is adequate ately.
to stop and hold the system should the con-
dition develop. Flammable Cleaning Solvents
Series 42 Introduction
Contents
1. Introduction ................................................................................................................................ 2
1.1 Using This Manual................................................................................................................................. 2
1.2 Safety Precautions ................................................................................................................................ 2
Filtration Options
Auxiliary (No Filtration Adapter Shown Here) Charge Relief Valve
Mounting Pad (Loop Flushing
Valve)
Left Side View (Side "2") Right Side View (Side "1")
P100101 E
Auxiliary
Mounting Filtration Options
Pad Charge Relief Valve (No Filtration Adapter
(Loop Flushing Valve)
Shown Here)
Left Side View (Side "2") Right Side View (Side "1")
P100102 E
Proper servicing of pumps and motors requires that ments. The following outlines show the locations of
pressure be measured and monitored at various the various gauge ports. The tables show the recom-
points in the hydraulic circuit. The Series 42 pump mended gauge size and the fitting size for each port.
has several locations at which to take these measure- Refer to this page when installing pressure gauges.
Left Side View (Side "2") Right Side View (Side "1")
P100103 E
System
Pressure
Port A
Case Drain Charge Pump
Port L1 Inlet Port S
System Pressure
Gauge Port M1
Left Side View (Side "2") Right Side View (Side "1") P100104 E
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E
Servo Gage
Port M4
11/16 in Hex
27-47 Nm
(20-35 ft•lbf)
11/16 in Hex
System Ports 27-47 Nm
A and B (20-35 ft•lbf)
115 Nm (85 ft•lbf)
E100001 E
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
Pump "Neutral"
ground, work function disconnected, etc.) while Adjustment Screw
performing the procedure in order to prevent
injury to the technician and bystanders.
IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
injury to the technician and bystanders.
3. Start the prime mover and operate at normal Control Neutral Adjustment Screw
speed. (EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ft•lbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.
CAUTION E100004 E
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts MDC Control Module Assembly
List to determine the correct gasket.
WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.
F100201
Link Pin Into Cam Slot
CAUTION
The control orifices are part of the control
Control Retaining
gasket. Refer to the appropriate Service Parts Screws (note different sizes)
List to determine the correct gasket.
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con- E100006 E
trol operation, which may lead to loss of con-
trol of the vehicle / machine. EDC Control Module Assembly
4. Install and torque the control spool bore plug [41- Fork on summing link
must engage flats on
94 Nm (30-70 ft•lbf)]. Or install the control spool
Slot in "neutral" adjust link control spool
cover (with a new gasket) or plug, and torque the must engage groove in
screws [15-17 Nm (11-13 ft•lbf)]. adjusting screw E100008 E
5. Install the summing link. Hold the control spool in Servo Piston Linkage and Control Spool
position while engaging the fork on the summing (Internal Parts Shown with Housing Removed)
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
6. Install a new control gasket. Hold the summing
link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).
The Neutral Start Switch (NSS) prevents the engine NSS Cover
and pump from being started when the pump is out of NSS Control Nut
neutral. The NSS should be wired in series with the
NSS Cam
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2° from neutral.
The Backup Alarm Switch (BUA) outputs an elec- NSS Cavity
tronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the NSS with
control handle is rotated 2.6 to 3.75° in the reverse Weatherpack
direction.
CAUTION
The control handle's neutral position must
NSS with Screw
agree with the pump's neutral position for the Terminals
NSS/BUA to work effectively (see section 4.3).
E100009 E
The Neutral Start / Backup Alarm Switch assembly
can be configured for three different settings. NSS Assembly on MDC
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for Control
units where counterclockwise (CCW) handle ro- Yolk Cam
tool. Dimensions are given at right. Top View of NSS Showing Cam Positions
35.0
1.250
.306 .354
2.000
Installation
Washer
1. Replace O-ring. Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female
notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid over- Spring
ride bore. Plunger
5. Snap retaining ring over base of solenoid.
Spool
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ft•lbf)].
E100011 E
the NFPH are located in the NFPH ports. Orifice Position of NFPH Ports
plugs may be cleaned or replaced.
Note: Future models may contain orifice plate
Control Solenoid
between module and pump housing.
Control Module
Removal and Installation of FNR and NFPE
Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module Control Ports
from pump housing. Locator Pin
E100014 E
CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.
CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation. E100015 E
6. Inspect the seal carrier and the new seal for Shaft Seal Components
damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary. O-Ring
Press Seal
to bottom of Seal Carrier
E100020 E
E100021 E
Shaft Components
Geroter
Cavity
Outlet Plug
(Charge Charge
Pump Defeat) Inlet
Charge Pump
Charge Pump Inlet Plug Inlet Plug
Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)
E100024 E
4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is M3 Gauge Partial Flow
of primary importance. Dirt and foreign fluids within Port Plug Pressure
Filtration
the hydraulic circuit will greatly reduce the life of the
Full Flow
hydraulic equipment. Pressure
Filtration
Filter-Related Pump Hardware Filtration Plate
Retaining Screws
Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure Suction
Filtration
filtration) the charge pump. Sauer-Sundstrand pro-
vides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Pumps equipped with housings without filtration
adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these
pumps are equipped with suction filtration, the exter-
nal charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ft•lbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ Housing with
16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending Filtration Adapter
on filtration type.
Filter Specifications
Charge Inlet
The selection of a filter depends on a number of
Plug
factors including the contaminant ingression rate,
the generation of contaminants in the system, the Plug
Construction
required fluid cleanliness, and the desired mainte- Bore Plug
nance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump. E100025 E
Housing without
Filter capacity depends on desired maintenance Filtration Adapter (Suction Filtration Only)
levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many Filtration Type β-ratio
closed circuit systems. Closed Circuit Suction Filtration or
β10 ≥ 2
Open Circuit Return Line Filtration
Filter efficiency as measured by a "Beta" (β) ratio* Systems Sharing a Reservoir with
should be as in the table at right. β10 ≥ 10
Other Gears, Clutches, or Cylinders
See Sauer-Sundstrand publication BLN-9887 or Charge Pressure Filtration β10 ≥ 10
697581 and ATI-E 9201 for more information on
* Filter ßx-ratio is a measure of filter efficiency defined by ISO
filtration. 4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The ßx-ratio
applies to a specific particle size, measured in microns.
CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
Displacement Limiter – Right Side (Side "1")
1. Mount pump on test stand. (Exploded View, No Need to Remove Limiter or Nut)
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
Displacement Limiter
3. Adjust displacement limiter [4 mm Int. Hex]. Seal Lock Nut
Tighten the seal lock nut every time the pump
Displacement
is to be tested [20-26 Nm (15-19 ft•lbf)].
Limiter
One full turn of the displacement limiter adjust-
ment screw will change the displacement of the Servo Piston
Cover
pump approximately as follows.
F096
C020
C017
C018
C015
C005
C002
C003
C001
C015 F001
OR
C001
OR
C001
E100028
(F086)
(F086A)
(F043)
(F043A)
(F040)
(F042)
(F043)
(F043A)
(F040) OR
(F042)
F043
F043A OR K001
F040 OR K001
F042
K005
F091 K001A
K002
F091A K001B
F030 K001C K006
F030A K007
G043
F041
G042
G040 K008
G040A G043 K009
G041 G042 K010
G041
G040A
G040
OR
J005
J002
045A F062
G045 F061 J003
F063 H005
F060A
F060 H002
H003
OR F051 F0511
(F060A)
(F060) F0512
F0513
F0514
F0515
F050A
F050 (F091A)
F093
(F091)
OR F093A
F093
(F051)
(F050A) F093A
(F050) N002A
N002
E100029
L010
L010A
F020
F020A
G005
G010
(G075)
G015
G002 G020
(G021)
G022
G065
G075
G030 G023
F009
G001
M001
OR
(M001)
OR
(G001)
M005
M010A
G036
M010
(M005) OR
(M010A)
(M010) (G080)
G085
M020
M025
(G090)
(G036) (G080)
(G085)
E100030
D038 D039
D037
D081
D003
D003A
(D017)
D080 D082 D019
D016
D002 OR
OR
D056 D017
D040
D010
F035 D012
F035
F034 D081
D081
OR
D060
(F010)
F010
D090
D014
D015
D032A
E100031
D032
A10FM
A10FE
RDE 92172-01-R/08.01
ersetzt / replaces 06.99
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design without notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
2 Brueninghaus Hydromatik
730 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Schnittbild
16.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE
A10FM
A10FE
Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application
Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!
4 Brueninghaus Hydromatik
732 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Triebwelle abdichten
16.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE
2
1
2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal
Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.
Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.
7 Sicherungsring einsetzen.
6 Brueninghaus Hydromatik
734 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Triebwelle abdichten
16.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE
Hinweis! Note!
Die hier beschriebene Möglichkeit zum Wechsel der This discription showes how th change the drive shaft
Antriebswellen - Abdichtung stellt nicht die serienmäßi- sealing ring but it isn't the way of serial assembly.
ge Montage dar. Für sicheres Dichtungsverhalten ist eine The sealing ring is assembled together with the taper
Montage des Dichtringes zusammen mit dem Kegel- roller bearing from inside the motor housing normally to
rollenlager von innen her durch das Montagegehäuse get a secure sealing condition. If you decide to repair the
durchzuführen. Soll aus Gründen der Vereinfachung im motor in the shown way be very careful while handling
Reparaturfall die vorgehend beschriebene Vorgehens- so that the drive shaft wouldn't be damaged during
weise durchgeführt werden, so ist beim Ausbau der disassembly of the shaft sealing ring.
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.
A10FM
8 Brueninghaus Hydromatik
736 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE
A10FE
10
11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.
Disassembly position
Mark the location of the connection plate
on the housing.
13 Anschlußplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.
10 Brueninghaus Hydromatik
738 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE
14 Verteilerplatte abheben.
12 Brueninghaus Hydromatik
740 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE
23 Sicherungsring entfernen.
26 Sicherungsring demontieren.
Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
27
14 Brueninghaus Hydromatik
742 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Überprüfungshinweise
16.4
Reparaturanleitung A10FM / A10 FE
Inspection hints Repair Instructions A10FM / A10FE
28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).
29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).
32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged
16 Brueninghaus Hydromatik
744 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE
37 Hubscheibe montieren.
40
42 Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.
Assembly aid:
Hold the pistons by using an O-ring.
Assembly:
Hold the components in place with grease.
18 Brueninghaus Hydromatik
746 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE
44 Verteilerplatte montieren.
Montagehilfe: Fett
A10FM A10FE
46
1
2
2
1
20 Brueninghaus Hydromatik
748 BOMAG 008 911 63
RDE 92172-01-R/08.01
Vibration motor A10FM
Abstimmung- Lagerung / Hinweise
16.4
Reparaturanleitung A10FM / A10 FE
Bearing adjustment / Note Repair Instructions A10FM / A10FE
AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm
Pos. 12
Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.
49 Plastikhammer
Soft hammer
50 Schleuder
...
Anziehdrehmomente /
Tightening torques
8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220
Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670
12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000
22 Brueninghaus Hydromatik
750 BOMAG 008 911 63
16.5 MS/MSE 02 ..... 18
02 05 08 11 18
MS
MSE
Störungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
5763 5765
0549 5766 0545
5764
0550 0547
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer- POCLAIN HYDRAULICS designs products that are integrated by its
den, die auf die Anwendung der in diesem Dokument empfohlenen Ver- customers in the machines they design.
fahren zurückgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion Subsequently POCLAIN HYDRAULICS disclaims liability for conse-
und die Betriebsbedingungen der Maschinen und Systeme, die mit PH- quences of improper integration of its products and of improper set-up
Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we- of adjustable devices. In the same way, POCLAIN HYDRAULICS may
der für die Folgen eines falschen Einbaus der Produkte noch für ein fal- not be liable for incomplete or improper operating and maintenance in-
sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll- structions provided to the end user by the machine manufacturer nor for
ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau- failures resulting from operations performed by any person using these
chern von den Maschinenherstellern zur Verfügung gestellt worden sind, suggested procedures.
verantwortlich. A re-certification of the machine may be required for every change in
Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine set-up of adjustable devices.
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- In order to offer the best quality service, POCLAIN HYDRAULICS rec-
DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- ommends to its customers to have applications approved by POCLAIN
DRAULICS prüfen und freigeben zu lassen. HYDRAULICS.
Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Opening of products voids the warranty contract.
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy- from different sources could reduce the performance of the product and
stems sowie die Sicherheit beeinträchtigen. pose a safety hazard..
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich In accordance with its policy of continuous improvement, POCLAIN
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung HYDRAULICS reserves the right to modify the specifications of all
alle Änderungen vorzunehmen, die als nützlich für die in diesem Doku- products described herein without prior notice.
ment beschriebenen Produkte bewertet werden.
Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab- This document contains sections written in German and sections
schnitte, die Übersetzung in englischer Sprache darstellen. printed in italics composing the English translation of the French sec-
Im Zweifelsfall ist die französische Version ausschlaggebend. tions. The French sections will be the reference in case of dispute.
Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen All measures are expressed in metric units. Converted values to other
in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter- systems (notably US and UK) are given for reference only.
richtung angegeben.
Die Abbildungen haben unverbindlichen Charakter. The illustrations for information only.
Inhaltsverzeichnis Contents
INHALTSVERZEICHNIS ............................................. 3 CONTENTS................................................................. 3
MS18-2-D11-F19-2A10-K000
B D
000143896J
C 40712
001
0349
Der Motor wird nicht ver- Den Antrieb der Pumpe und ih-
sorgt re Versorgung überprüfen
Kein Druckanstieg im Hochdruck-Begrenzungsventile
MOTOR DREHT SICH Kreis kontrollieren (Regler)
NICHT Zylinderblock und Ölverteiler
Interne Lecks zu groß
ersetzen
Die Bremse bleibt angezo- Den Steuerkreis der Bremse
gen kontrollieren
Trouble shooting
DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……
Einbau Installation
Die zum Ausbau angegebenen Arbeitsgänge in umge- Execute the removal operations in the reverse order.
kehrter Reihenfolge ausführen.
Für weitere Informationen beziehen Sie sich bitte auf Please refer to the following documentation brochures:
folgende Dokumente:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS D/GB (ref: 677777853U) • INSTALLATION CIRCUITS F/GB (ref: . 677777831V)
• Stopfen (142) aus der Schutz- • Extract and release the plug 142
kappe (141) herausziehen. (142) from the brake cover (141).
6499
6556
• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.
6555
Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142).
Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground.
Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• Sich vergewissern, daß der Bremsversorgungs- Make sure that the brake supply pressure is zero,
druck gleich Null ist,
• Die Bremse über die höchstgelegene Schraube • Purge the brake using the screw (112) located at
(112) entlüften, the highest level,
• Den Motor mit Maximaldruck beaufschlagen, • Supply the motor up to the setting pressure.
• Die Motorwelle darf sich nicht drehen, da andern- • The motor shaft must not turn, otherwise it is nec-
falls die Bremse ausgetauscht werden muß : essary to replace the brake :
Reparaturen. Repairs.
6500
6501
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a
Schraube Klasse 12.9 (siehe screw class 12.9 (see tools 6502
Werkzeug Seite 36) page 36)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
beibehalten (siehe Schaubild (see table page 9)
Seite 9)
6503
!
se das Lagerteil nicht auf
den Gewindebolzen ab- ! not place the bearing
support on the studs.
stützen.
108
6508
6513
6511
Wiedereinbau. Reassembly.
Vor dem Wiedereinbau ist unbedingt Before reassembling, it is neces-
sicherzustellen, daß alle Teile, Nuten sary to ensure that all parts, the
und Dichtungs-Auflageflächen sauber surface condition of the piston seal
sind. contact surface and the grooves are
clean.
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
All traces of rust, mud,
spuren vorhanden sein
! water must be removed.
6512
6509
6513
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
einbehalten (siehe Schaubild (see table page 9) 6502
Seite 9)
Bei Verwendung der If you use the press do
!
Presse das Lagerteil
nicht auf den Gewinde- ! not place the bearing
support on the studs.
bolzen abstützen.
6503
• Sicherungsring (109) mit Hilfe • Install the snap ring (109) using
einer Zange für Innenringe gemäß internal snap ring pliers in line with
der bei der Demontage ange- the mark made during disassembly
brachten Kennzeichnung montie- . (see tools page 36)
ren: (siehe Werkzeuge Seite 36) 6504 6505
• Abzieher und Zange (fig • Extractor and pliers (fig 6504
6504 und 6505) and 6505)
• Presse und Zange (fig 6506 • Press and pliers (fig 6506
und 6507) and 6507)
6506 6507
6515
6516
!
der Außenrand des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517
6518
040
6519
042
6520
6521
6524
041
6525
071
6522
071
6523
041
6525
Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.
6521
6527
042
6520
2055
Demontage Disassembly
154.a
6529
6530
154.b
2
6531
6532
154.c
6533
154.1
6534
6535
6536
Wiedereinbau Reassembly
154.2
6536
6535
6537
6538
6539
6532
154.c
6533
6532
154.b
2 6531
154.a
6530
Durchmesser D diameter
6529
Trommeldurchmesser (mm)
Bremsen Drum diameter [in] Total Spiel (mm)
Brake Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70] 0.80 [0.03]
325 x 80 325 [12.79] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]
6528
Demontage Disassembly
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausführen, port" section "disassembly" page 16
Seite 16
Wiedereinbau Reassembly
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter " Wiederein- "replacement of the bearing sup-
bau " beschriebenen Arbeiten ausfüh- port" section "reassembly" page 18.
ren, Seite 18. The angular position of the cam
Allerdings muß bei Motoren mit 2 must be respected on dual dis-
Schluckvolumen mit einem placement motors with a displace-
Schluckvolumenverhältnis über ment ratio different from 2.
oder unter 2 die Winkelposition be-
rücksichtigt werden. Example : Motor MS18 with dis-
Beispiel: Motor MS18, Schluckvolu- placement 1747-1049-698.
3
men 1747-1049-698 Small displacement : 698 cm
3
Kleines Schluckvolumen: 698 cm [42.59 cu.in] letter P
Buchstabe P 3
3
Medium displacement : 1049 cm
Mittleres Schluckvolumen: 1 049 cm [64.01 cu.in] letter M.
Buchstabe M The letter P or M must be located in
Die Buchstaben P oder M müssen the axis and towards the displace-
sich in der Achse befinden und in ment change spool, with the blind
Richtung des Schiebers für das hole towards the fixing of the cam
Wechseln des Schluckvolumens on the bearing support.
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
M P
M P
MS08
MSE08
A R A R
MS18
MSE18
P M
M P
A R A
MS11
MSE11
P M 2035
Demontage Disassembly
6541
Wiedereinbau Reassembly
6542
6541
• Den Verteiler (047) durch An- • Separate the valving (047) from
heben an den Ausrichtungszapfen the cover (041) by levering at the
oder am Flansch vom Verteilerdek- indexing pins or at the flange.
kel (041) abmontieren.
2031
Wiedereinbau Reassembly
1135
• Die Federn (052) in ihr zuvor • Place the springs (052) in their
mit Fett gefülltes Gehäuse einset- housings, previously filled with
zen. grease.
• Die Dichtungsauflageflächen • Lubricate the faces of the seals
des Verteilers (047) fetten. of the valving (047).
• Den Verteiler(047) in den Ver- • Press the valving (047) into the
cover (041).
teilerdeckel (041) drücken
041
047 2031
041
R 047
L
053
6758
R A
053
3 2 2 7
047
R L 041
6757
R A
053
3 2 2 8
SE02 Motor :
SE02 motor : G/L Links D/R Rechts
G/L Left D/R Right
6 9 5 9
6959
S05 Motor :
S05 motor
G/L Links D/R Rechts
G/L Left D/R Right
053
6 9 4 8
6948
Demontage Disassembly
•
• Motor auf Lagerteil stellen • Place the motor on the bearing
(Muttern sind zum Schutz der Ge- support (fitted with nuts for studs
windebolzen aufgesetzt) protection)
• Schrauben (066) herausneh- • Remove the screws (066)
066
men.
6543
6544
6545
6546
Wiedereinbau Reassembly
6547
6548
6544
6543
6550
6551
• Sensor (161) mit dem Träger • Extract the sensor (161) with its
166
(166) abziehen support (166)
161
6552
Wiedereinbau Reassembly
6552
• Sensor (041) in die Bohrung • Push the sensor into the valving
des Verteilerdeckels bis zum Kon- cover (041) until it comes in contact
takt mit dem Zylinderblock (011) with the cylinders block (011),
schieben.
2064
1 5 ° m a x i
6558
6551
6550
6553
• Sechskantschlüssel für
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
Ø A
Ø B
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
Schutzkappe oder zum brake cover or to compress the
F
E
G
Komprimieren der Tel- spring washer.
lerfeder.
Ø C
Ø D
0759
ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21
Tube to immobi-
Ø 2 5
Ø 1 6
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2 x 1 2 0 M 1 6 x 1 2 0
c l. 1 0 .9
H M 1 2 H M 1 6
Z 1 2 N
A = 2 0 0 A = 2 8 0 A
• Werkzeuge zur me- Tools for me-
F 0 2 F 1 1
chanischen Bremslö- chanical brake F 0 3 F 1 2
sung. release F 0 4 F 1 8
F 0 5 F 1 9 Ø 1 6 .5
F 0 7 F 2 1 [0 .6 4 ]
F 0 8
F 0 9
6 0 x 3 0 5 0 x 5
0987
Dichtungssatz
Seal kit 0988
0990
Dichtungssatz
Seal kit
0989
France
Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422
e-mail: info-deutschland@poclain-hydraulics.com e-mail: info-japan@poclain-hydraulics.com
Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
USA
Tel.: 31 76 5021152 Tel.: 1 262 554 6739
Fax: 31 76 5012279 Fax: 1 262 554 4860
e-mail: info-netherlands@poclain-hydraulics.com e-mail: info-america@poclain-hydraulics.com
008 911 63
table of contents: BW 177..219 D−4/D−40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram
BOMAG
16.11.2005
001 001
Vogt Stromlaufplan 582 702 09
16.11.2005
17.1
929
circuit diagram 001
Seis
930
30 6:1
K30
9:2
15:54
17.1
2:10 K11 30
X1
X1:15E 2:10
17E
87 87a
1
X1:9
F13 1
X1:10
F105
30A
2 20A
X1:15A 2 K11/87 3:1
X1
X37:A
17A X1
S00 30 X1:30E
X36:B
X36:A
30 27E
B+
2:11 K35 1
2:16 F14 1 F39
15A 15A
4qmm
Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
2:13 80 K32:86
X1 9:2
79 S120 11 23
30 F14:2
5:9
K114
X37:B 2:14 S01:21
X1:3 X1:4 5:9
nur ohne Sitzkontaktschalter
without switch seat−contact
V01
3:2 87a 87
Schalter Motordrehzl
2 1 K11:86 K05 X1:151
4:5
6:5
30(3)
main fuse
125mA
4:3
Hauptsicherung
K14 21 11 31 ?
heating−flange
K61 87 87a
Sicherung Heizflansch
3:5 86 1 K61 30 S01
87(4) 86
F48 2 F00 2 R10 2:5 22 12 32 ?
82 OHM K35
87 87a NOT−AUS
85 2 K05/87
125A
125A
1 1 3:2 85 Emerg.−Stop
X1:53
BOMAG
4:13 X1:152
K61/85
6:2 B+ X1 X1 X1 X1 30
X1:60 K22
X1 D+ MESX 2:5 7 8 58 59
1 4:9
G03 + G01 + X1 2x2.5qmm 87 87a
65 X38:A 2
125mA
50A / 10A
30 50 1 AW 54
86
AUX
86 86 86 Y01 2 + HW 1
167A
K09 Y13
B− W M01 K114 Y120
1 1 K36 K11 M
S30 W 1 70A/1A − 2
31−1
R19 85
X1:66 85 85 85 −
2 X1
X1 X1 55
62 63
Option
option
X1:168
31 31 3:1
2:8 4:4 10:7 2:18 2:16 2:13
Trennschalter Batterie
break switch battery
Heizflansch Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug
heating−flange battery battery generator starter start boost fuel sol. engine speed fuel shut off
16.05.2005
1 1
008 911 63
Wiring diagram
F24:2
4:10
4:19
GLÜH
2:10 K11:86 X1
008 911 63
52
2:13 K05/87 X1
78 X1
X1 28E
Wiring diagram
75
F23 1
10A
2 X1
X1 92
28A
X1:155 +
15/54
Lern
Test
OUT+
5 2 7 1 S03 −
−
in
Geschwindigkeitsanz.
X1
OUT−
14 24
A13
93
X1 X1
3 4 6 97 98
Anbau im Motorbereich
X1 X1 ZA Geschwindigkeitsanzeige
assembled in engine−area
101 102 option speedometer
Modul Heizflanschsteuerung
modul heating−flange−control
1
Taster Signalhorn
push but. warning horn
BOMAG
X1:171
K14
2
2
+
V21
V22
dir. X1:173
4.2A
4.2A
1
1
B60 DIR MESX 6:2
Relais Heizflansch
Nur bei BW 219 D−4 und D−40 USA Version, sonst Option
only at BW 219 D−4 and D−40 USA version, otherwise option
speed
relais heating−flange
B11 1 B11 1 SPEED MESX 6:2
Anbau im Motorbereich
assembled in engine−area
− X1:172
2 SPEED TAC
9:6
1 2 2
nicht bei D−40/BW211D−4 ohne SN1
not at D−40/BW211D−4 ohne SN1
B113
2
X1 X1 X1 X1
57 64 99 100 X1:174
2:20 31 31 4:1
16.11.2005
1 1 582 702 09
Vogt Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz.
16.11.2005
17.1
931
Seis engine heating−flange cont., warning horn, speedometer 003
932
3:20 K11/87 K11/87 5:1
Zentralstecker Sammelanzeige (Ansicht von hinten)
X1 X1:31E mainplug monitoring module (view from backside)
29E
17.1
9 8 7 6 5 4 3 2 1
1 1
F25 F24
10A 10A
2 2 X5:1−20
Sammelanzeige 201918 1716151413 121110
X1
X1:31A monitoring module
29A 6 Vorglühen
A15 GLÜH
F24:2 3:5
3:15 Warnbl.
7 BL−W
8:16
X1 15/54 Blinker rechts
20 FUEL 19 BL−R
HOURS 8:17
X1:156 86 OUT2 Blinker links
9 18 BL−L
F25:2 8:17
5:2 OUT1 Sitz
1 12 A68/6
5:9
Bel.
8 4
X12 X13 8:5
1 1 BEL 10 3
geöffnet in 0
Position (Bremse ein)
BR/BN 30 BR/BN
30 2 14 11 13 15 17 16 5
D+
K48 K26
GND
B13 B14
4:2 4:6
Bremse
5:9
5:9
Luftfilter
87a 87 87a 87
Tankanzeige
BL/BU SW/BK BL/BU SW/BK
Motoröldruck
Öltemperatur
Hydraulikölfilter
D+
Wasserabscheider
30 X1 X1 X1
B06:1
Kühlmittelfüllstand
K36 69 87 76
Initiator Farhebel"0
2:7
BOMAG
X1:147 K26/87A
S01 X1
K61/85
2:18 109 2:6
X1:61
12 SITZWARN.
K48/86 5:9 5:9 X1
X1:150 X1 X1
105
X1:148 X1:153 114 90 K48:87A X8 1 X8 2
6:2 4:3
X10
300mA
X1:113 BRAKE MESX 2 X21:1
Sensor
2.5A
125mA
X9 89 +
86 86 Y04 86 1 86 R03
K48 K05 1 K26 K22 P P _t P Q
H14+ + bl 4 4 B30 2 −
− P
H07
85 85 2 85 X9 85 X10 X21:2
2 3 X1:117 X1:57
125mA
125mA
X1:149 X1 X1:82 X1:117
X1:117 129 X1:117
3:20 31 31 5:1
Magnetventil Bremse Rückfahrwarnsummer Warnsummer Störung Tankgeber Luftfilter Motoröldruck Sensor Wasserabschei
solenoid valve brake buzzer back up alarm buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydraulikölfilter Öltemperatur Kühlmittelstand
Resist. buzzer hydraulik oil cleaner oil temperature coolant stock level
16.11.2005
1 1
008 911 63
Wiring diagram
X1:32E
D+ F03 1
4:13
15A 2
008 911 63
B06:1
4:17 X1:32A
4:3 K48/86
2:20
only with switch seat−contact
Fahren
Öldruck
D+
F25:2 1 12 13 14 30 56
4:8
K04
31
A68 Modul Sitzschalter/Vibration
module seatswitch/vibration
S 56b
modul vibration
Modul Vibration
13 4 6 9 11 15 5
S42 1234 2
S42
1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A
Schalter Fahrstufen
2
1
B 1 X1:159
V09 X1 14
S13
88
23 13
A68/6 3 S35
S58
4:19 13
BOMAG
2
1
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
6:2
Taster Vibration
pushbutton vibration
KA MESX 6:2
X1:141 X1:137 X1:142 X1:141
X1:116 X1:115
switch seat−contact
Sitzkontaktschalter
1.23A
1.23A
1.23A
X6 X7
Y31 Y30 Y31 X14 X11 1 1
1 1 1 1 Y07 Y08
3.33A
3.33A
A 2
9:7 KA
9:6 GA
a b
2 2 2 2
X6 X7
2 2
X1:124 X1:138 X1:124 X1:124
X1:149
X1:154
X1:149
X1:149
31
X1:118
4:20 31 6:1
16.11.2005
1 1 582 702 09
Vogt Fahrstufen, Sitzkontaktsch., Vibration
16.11.2005
17.1
933
Vogt speed−ranges, seat−switch, vibr. 005
934
Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP
GND
30
17.1
2:20 30 8:1
Pot 30
K11/87
8:20 Pot 15
X4:C
X4:E
X4:D
P16
B62 B62 F1 F2
+/sw
+/sw
nur bei BEM
only at BEM
X74:3
X74:5
X74:4
2 X42:4 X42:5
X2:57 X1:34A P11
20g/br
20g/br
nur bei BTM prof
X48:3 X48:4 X49:3 X49:4
Pot. 15
Leistung
Elektronik
AGND MESX
RxD TxD
BOMAG
X44:1
X44:7
X44:5
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:27
X44:26
X44:28
X44:54
A83
Messtechnik−Rechner
X44:38
X44:15
X44:35
X44:14
X44:32
X44:36
X44:37
X44:38
X44:41
X44:53
X44:33
X44:55
X44:65
X44:66
X44:67
X44:68
GND
5:17
EVIB
KA MESX
GND
EVIB−Meter
EVIB−meter
nur bei BEM
only at BEM
16.11.2005
1 1
008 911 63
Wiring diagram
008 911 63
CAN3−
6:18
6:18 CAN3+
Wiring diagram
CAN3+ CAN3−
1 R242
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
X2:70
BOMAG
X76:1 X4:G
X76:2
P15
X4:F
X2:63
BCM 05
nur bei BCM
only at BCM
6:20 31 31 8:1
16.11.2005
1 1 582 702 09
Vogt BOMAG Compaction Management BCM
16.11.2005
17.1
935
Seis BOMAG Compaction Management BCM 007
936
5:20 K11/87 K11/87 6:2
6:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
17.1
X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307
X1:302
9:17 A02
STV2
9:17
X1:23E X1:24E
K16 30 31 82 L R
8:9 F09 F10
15A 15A
87 87a X1:23A X1:24A
BOMAG
switch, working head lights
Schalter Arbeitsbeleuchtung
X1:308
X1:304
X1:303
13 23
01
01
S14
X1:311
X1:310
X1:319
X1:312
Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:314
X1:84
Warnblinkschalter 14 24
6:2 switch, hazard light
X61:3 X1:320
X59:5
X60:3
X59:3
X58:5 X1:309
X58:3
X61:1 X1:322
X60:1 X1:321
X59:2
X58:2
0,125A
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 4:19 E08 1 E09 1 E10 1 E11 1
+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
−
X61:2
X59:6
X58:6
X60:2
85 85
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X1:323 X60:4
X1:324 X61:4
X1:315
X1:316
X1:323
X1:324
7:20 9:1
31
8:10 Schlußleuchte links 8:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
16.11.2005
1 1
008 911 63
Wiring diagram
008 911 63
8:13
87 87a E F
G H A B C
X3:3
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
Wiring diagram
F42 10:8
F130 9:9 F130 F130 10:7
9:14
A12
15
1,75A
0,83A
K141 30 1 B51 + + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + B51
01 01 E72
9:16 E29 E70
− − − − 1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
radio
Steckdose Fahrerst.
3,8A
3,8A
1 Tachographenmodul
2 4 6 A1 XS
Nachtleuchte
− 3:16 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
12V 2 1
X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25
Kontrolleuchte
Innenleuchte
inside light, cabin
socket cabin
−
12V
Steckdose Kabine
+ 7,8,9 2 B4 2 2 2 2
A01 5 3 C3
A5+A6
S45 TK −
Heizung Heckscheibe
4 1
BOMAG
A51
Schalter Innenleuche
switches interior lights
3
5A
86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
X3:16
X3:15
− −
3 min
85 − M07 − M06 4
KA
GA
2,9A
ZA
only at hand−rail/Rops/sun−roof
5:17
5:16
10:18
Relais Kabine Türkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
8:20 31 31 10:1
16.11.2005
1 1 582 702 09
Vogt ZA Kabine, Beleuchtung, Radio, Tachograph
16.11.2005
17.1
937
Seis opt. cabin, headlights, radio, tachograph 009
938
9:20 K32:87 9:19 F41:5
Potential 15 aus Kabine
9:17 F130 F42:H
9:4
F42 Potential 15 aus Kabine
9:9
17.1
2.5qmm
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
heater timer
X53:L
X53:H
X53:M
2:8
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1
_t
BOMAG
_t 2 2
Thermofühler Klimaanlage
X19:2
X20:1 X18:2
X17:1 X1:163
temperature sensor air conditioning
X17:3 X1:166
X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP X77:1
1A
LP 3
ge rt or ge rt or
Y138 1 1
X1:170 9:19
X20:4
X20:3
V06 Y14 KABINE 31
Überwachung Kühlmitteldruck
monitoring coolant pressure
M09 M M09 M
Kabinenlüfter 2 2
br br
X20:2
X77:2
Y15 1 2
X17:4 V04 X1:168
2 1
3,5A
X1:164
9:20 31 31
Vogt
1 1
008 911 63
Wiring diagram
E08 008 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 008 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 008 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 008 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 008 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 008 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 008 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 008 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
component listing
E23 008 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 009 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 008 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 009 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 008 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 009 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 008 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 009 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 009 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 010 13 Heizgeraet Heating unit
E32 009 19 Kennleuchte Warning light 5A
E70 009 15 Nachtleuchte Night lamp 0,83A
E71 009 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 009 16 Beleuchtung Bedienschalter illum. Switches
F148 006 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)
K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 009 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
Y01 002 12 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 005 14 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
6
Y08 005 16 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 010 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 010 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
582 702 09
Y30 005 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 005 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 005 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
Y138 010 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
106
008 911 63
Wiring diagram
BOMAG
A02 R10 K05
K36 K22
K48
K61
A68 K114
K26
945
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8
946
F1 F2
CAN 1
17.1
BOMAG
CAN 1 OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
008 911 63
Wiring diagram
1 05756417
2 05756421
3 2 x 05756425 "L" + 793-501
7 05756422
8 4 x 05756423 "L" + 05756419 + 793-501
32 05756435
33 05756417
1 05756417
9 05756537
10 4 x 05756538 "R" + 793-501
14 05756537
15 3 x 05756538 "R" + 793-501
18 05756537
19 3 x 05756540 "R" + 793-501
23 05756537
24 5 x 05756540 "R" + 793-501
29 05756537
30 2 x 05756538 "R" + 793-501
34 05756537
35 4 x 05756538 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
46 05756537
47 05756540 "R" + 793-501
48 05756535 "R" + 793-501
49 05756537
50 2 x 05756538 "R" + 793-501
52 05756537
53 4 x 05756540 "R" + 793-501
58 05756537
59 4 x 05756540 "R" + 793-501
63 05756537
64 05756540 "R" + 793-501
65 05756535 "R" + 793-501
66 05756537
67 05756540 "R" + 793-501
68 05756535 "R" + 793-501
69 05756537
70 05756538 "R" + 793-501
71 2 x 05756540 "R" + 793-501
74 05756537
75 05756417
1 05756417
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
18 05756537
19 05756417
008 911 63
Wiring diagram
X5
X21
X11 X12
X59 X13
X58 X42
X20
X46 X14
X18 X77
X17 X6 X7
X22 X19 X4 X3
X8
X48 X49 X10
X36 X60
X37 X1 X61
X38 X2
X9
X44
BOMAG
X61
X77 X9
X21
X74 X75
X59
X76
X42 X11 X12 X8
X10
X46 X13
X56
X53
X20
X18
X5 X17 X14
X19 X55 X6 X7
X54
X58
X4 X3
X36 X1
X37 X44 X2
X38 X60
X48 X49
X22
961
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 301
Name: Seis Connector overview BW 177...219 D-4/D-40 Replaces: Sheet No.: 301
17.1 Wiring diagram