BOMAG BC 672 RB-2 BC 772 RB-2 RS-2 EB-2 Service Manual – Sanitary Landfill & Soil Compactor Repair Guide
$39.95Original price was: $39.95.$23.95Current price is: $23.95.
Complete 1022-page BOMAG service manual for BC 672 RB-2, BC 772 RB-2, BC 772 RS-2, BC 672 EB-2 and BC 772 EB-2 compactors. Covers Deutz TCD 2015 engines, travel and working hydraulics, ESX/EMR electronics, diagnostics, wiring diagrams, maintenance and repair procedures.
BOMAG BC 672 RB-2 / BC 772 RB-2 / BC 772 RS-2 / BC 672 EB-2 / BC 772 EB-2 Service Manual
This is the complete BOMAG service manual for the BC 672 RB-2, BC 772 RB-2, BC 772 RS-2, BC 672 EB-2 and BC 772 EB-2 sanitary landfill compactors and fast moving soil compactors. Document number 008 911 53. At over one thousand pages, it is the deep workshop reference for anyone maintaining, diagnosing or rebuilding these machines. It covers the Deutz TCD 2015 V06 diesel engine, hydrostatic travel system, working hydraulics, electrical and electronic control systems including EMR3 and ESX, air conditioning, central lubrication, and the oscillating articulated joint, with full wiring and hydraulic diagrams in the back.
File Details
Manual type: Service / Repair Manual
Brand: BOMAG
Models covered: BC 672 RB-2, BC 772 RB-2, BC 772 RS-2, BC 672 EB-2, BC 772 EB-2
Document number: 008 911 53
Language: English
Page count: 1022
File format: PDF
Serial number ranges shown on cover: S/N 101 570 59, 101 570 58, 101 570 57, 101 570 93, 101 570 92
Chapters Covered
1 General – Introduction, safety regulations, general repair instructions, tightening torques
6 Electronic control – ESX control functions, display module, fault codes, input codes, parameter setting, machine type setting
7 Trouble shooting – Machine drives in neutral, machine does not drive, travel power loss, steering faults, hydraulic oil overheating, central lubrication faults, travel system and working hydraulic troubleshooting charts
8 Installed components / connection overview – Component list, measuring and adjustment points on tandem travel pump, control valve block, connection overview
10 Central lubrication system – System layout, technical description, control, lubrication process, progressive distributor, lubrication oil pump, fault-cause-remedy tables
11 Engine – Deutz TCD 2015 diesel engine description, lubrication oil circuit, coolant circuit, fuel circuit, injection system (MVS), exhaust gas recirculation, Wastegate charge pressure control, valve clearance, oil and filter changes, radiator and cooler cleaning, coolant change, fan V-belt, engine mounts, general troubleshooting chart
12 Working hydraulics – Hydraulic system, working hydraulics, steering and working pump, control valve block, load-sensing, steering and dozer blade control, individual component descriptions
13 Tests and adjustments in working hydraulics – Measuring and adjustment points on control valve block, tests and adjustments on steering/working pump
14 Travel hydraulics – Hydraulic system, travel system description, travel pump A4VG, travel motors A6VM, filtration, transfer box filter unit
15 Tests and adjustments in travel hydraulics – Measuring and adjustment points on tandem travel pump unit, pressure tests, high pressure relief and pressure override checks, charge pressure checks, DA-control valve adjustment, control chamber pressure, travel motor adjustment
16 Special tools, tests and adjustments – Special tools, test equipment and adjustment aids
17 Oscillating articulated joint – Removing and installing live ring, repairing the oscillating articulated joint, removing and installing steering cylinders
With this BOMAG service manual on hand, a technician can carry out the full range of repair and maintenance tasks on the BC 672 RB-2, BC 772 RB-2, BC 772 RS-2, BC 672 EB-2 and BC 772 EB-2 compactors. The engine chapter walks through the Deutz TCD 2015 V06 – valve clearance adjustment, oil and filter changes, coolant circuit service, fuel system bleeding, MVS injection system, exhaust gas recirculation and turbocharger checks. The travel hydraulics chapters cover the A4VG variable pump and A6VM travel motors, including high pressure relief and pressure override settings, charge pressure tests, DA-control valve adjustment and displacement checks. The working hydraulics chapters handle the steering and dozer blade control valve block, load-sensing circuit, LS-pressure limitation and stand-by pressure adjustment. The electronics section covers the EMR3 engine control unit, ESX control, CAN-bus diagnostics and the full fault code lists, with flashing code tables and input codes for reading live data. Wiring and hydraulic diagrams at the end allow circuit tracing for any electrical or hydraulic fault. The air conditioning and central lubrication chapters round out the systems coverage with servicing, leak testing and fault tables.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BC 672 RB-2 BC 772 RB-2 RS-2 EB-2 Service Manual – Sanitary Landfill & Soil Compactor Repair Guide” are as follows:
+This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 10
This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 10
This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts…p. 10
+Documentationp. 10
Documentationp. 10
For the BOMAG machines described in this manual the following documentation is additionally available:p. 10
+1 Operating and maintenance instructionsp. 10
1 Operating and maintenance instructionsp. 10
2 Spare parts cataloguep. 10
3 Wiring diagram*p. 10
4 Hydraulic diagram*p. 10
5 Service Informationp. 10
Use only genuine BOMAG spare parts.p. 10
Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.p. 10
These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins".p. 10
In case of a new release all necessary changes will be included.p. 10
In the course of technical development we reserve the right for technical modifications without prior notification.p. 10
Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.p. 10
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 10
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 10
BOMAG GmbHp. 10
Printed in Germanyp. 10
Copyright by BOMAGp. 10
* The applicable documents valid at the date of printing are part of this manual.p. 10
+Generalp. 11
Safety regulationsp. 11
+Important notesp. 11
Important notesp. 11
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 11
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 11
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obv…p. 11
This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment.p. 11
+Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 11
Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 11
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 11
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 11
+Paragraphs marked like this highlight possible dangers for persons.p. 11
Paragraphs marked like this highlight possible dangers for persons.p. 11
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 11
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 11
Observe the regulations for the protection of the environment.p. 11
+Generalp. 11
Generalp. 11
+l For repair and maintenance work move the machine on a firm base and shut it down.p. 11
l For repair and maintenance work move the machine on a firm base and shut it down.p. 11
l Always secure the machine against unintended rolling.p. 11
l Secure the engine reliably against unintentional starting.p. 11
l Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard.p. 11
l Block the articulated joint with the articulation lock.p. 11
l Use protective clothes like hard hat, safety boots and gloves.p. 11
l Keep unauthorized persons away from the machine during repair work.p. 11
l Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.p. 11
l Use only safe and approved lifting gear of sufficient load bearing capacity to remove and install parts or components from and to the machine.p. 11
l Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.p. 11
l Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank.p. 11
l When performing welding work strictly comply with the respective welding instructions.p. 11
+Transport work with cranes and lifting tacklep. 11
Transport work with cranes and lifting tacklep. 11
+Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 11
Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 11
+l Follow the operating instructions of the manufacturer when working with cranes.p. 11
l Follow the operating instructions of the manufacturer when working with cranes.p. 11
+l Follow the operating instructions of the operator when working with cranes.p. 11
l Follow the operating instructions of the operator when working with cranes.p. 11
l Always comply with the applicable accident prevention instructions when working with cranes and lifting tackle.p. 11
+Precautions and codes of conduct for welding workp. 11
Precautions and codes of conduct for welding workp. 11
Welding work must only be carried out by properly trained personnel.p. 11
+Electric shock!p. 11
Electric shock!p. 11
Sparks, fire hazard, burning of skin!p. 11
Infrared or ultraviolet radiation (arc), flashing of eyes!p. 11
Health hazard caused by welding work on highly alloyed work pieces, metal coatings, paint coatings, plastic coatings, oil containing dirt deposits, grease or solvent residues, etc.!p. 11
+l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 11
l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 11
l Ensure good conductivity between ground cable and workpiece, avoid joints and bearings.p. 11
l Start the extraction fan before starting work and guide with the progressing work as required.p. 12
l Always isolate the burner when laying it down (remove possible electrode residues).p. 12
l Protect cables from being damaged, use cables with insulated couplings.p. 12
l Ensure sufficient fire protection, keep a fire extinguisher at hand.p. 12
l Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission.p. 12
l Remove any combustible materials from the welding area or cover such items appropriately.p. 12
l Name a fire watch during and after welding work.p. 12
l Place welding rod holders and inert gas welding guns only on properly insulated bases.p. 12
l Place the inert gas bottles in a safe place and secure them against falling over.p. 12
l Use a protective screen or hand shield with welding filter, wear welding gloves and clothes.p. 12
l Switch the welding unit off before connecting welding cables.p. 12
l Check electrode holders and electric cables at regular intervals.p. 12
Behaviour in case of faultsp. 12
+l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 12
l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 12
l In case of failure of the extraction system switch the system off and have it repaired by expert personnel.p. 12
Maintenance; waste disposalp. 12
+l Replace damaged insulating jaws and welding rod holders immediately.p. 12
l Replace damaged insulating jaws and welding rod holders immediately.p. 12
l Replace the welding wire reels only in de-energized state.p. 12
What to do in case of accidents; First Aidp. 12
+l Keep calm.p. 12
l Keep calm.p. 12
l Call first air helpers.p. 12
l Report the accident.p. 12
l In case of an electric accident: Interrupt the power supply and remove the injured person from the electric circuit. If breathing and heart have stopped apply reactivation measures and call for an emergency doctor.p. 12
+Old oilsp. 12
Old oilsp. 12
Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appr…p. 12
+l Wear protective clothes and safety gloves, if possible.p. 12
l Wear protective clothes and safety gloves, if possible.p. 12
l If there is a risk of eye contact you should protect your eyes appropriately, e.g. chemistry goggles or full face visor; a facility suitable for rinsing the eyes should also be available.p. 12
l Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately.p. 12
l Apply protective cream before starting work, so that oil can be easier removed from the skin.p. 12
l Wash affected skin areas with water and soap (skin cleansers and nail brushes will help). Lanolin containing agents will replace natural skin oils that were lost.p. 12
l Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin.p. 12
l Do not put oil soaked cloths into your pockets.p. 12
l Avoid clothes getting soiled by oil.p. 12
l Overalls must be washed at regular intervals. Dispose of non-washable clothes environmentally.p. 12
l If possible degrease components before handling.p. 12
+It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 12
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 12
+Hydraulicsp. 12
Hydraulicsp. 12
+l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 12
l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 12
l Always make sure that all screw fittings have been tightened properly and that hoses and pipes are in mint condition before pressurizing the system again.p. 12
l Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When injured by hydraulic oil escaping under pressure consult a physician immediately, as otherwise this …p. 12
l Do not step in front of or behind the drums, wheels or crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums, wheels or crawler tracks with wedges.p. 12
Reattach all guards and safety installations after all work has been completed.p. 13
+It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 13
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 13
+Fuelsp. 13
Fuelsp. 13
+Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 13
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 13
Follow the valid accident prevention instructions when handling fuels.p. 13
The following notes refer to general safety precautions for danger free handling of fuel.p. 13
Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilution with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop …p. 13
+l Fire extinguishers charged with FOAM, COp. 13
+l Fire extinguishers charged with FOAM, COp. 13
2p. 13
l The vehicle battery must always be disconnected, BEFORE work in the fuel system is started. Do not disconnect the battery while working on the fuel system. Sparks could cause explosion of the fuel fumes.p. 13
l Wherever fuel is stored, filled, drained off or where work on fuel systems is carried out, all potential ignition sources must be extinguished or removed. Search lights must be fire proof and well protected against possible contact with running out…p. 13
+Hot fuelsp. 13
Hot fuelsp. 13
Please apply the following measures before draining of fuel to prepare for repair work:p. 13
+l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 13
l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 13
l Vent the system, by removing the filler cap in a well ventilated area. Screw the filler cap back on, until the tank is finally emptied.p. 13
+Synthetic rubberp. 13
Synthetic rubberp. 13
Many O-rings, hoses, etc. are made of synthetic material, a so-called fluorocarbon elastomer. Under normal operating conditions this material is safe and does not impose any danger to health.p. 13
However, if this material becomes damaged by fire or extreme heat, it may decompose and form highly caustic hydrofluoric acid, which can cause severe burns in contact with skin.p. 13
+l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use.p. 13
l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use.p. 13
l If the material has contacted the skin despite these measures, take off the soiled clothes and seek medical advice immediately. In the meantime cool and wash the affected area of skin over a sufficient time with cold water or lime water.p. 13
+Poisonous substancesp. 13
Poisonous substancesp. 13
Some of the fluids and substances used are toxic and must under no circumstances be consumed.p. 13
Skin contact, especially with open wounds, must be avoided.p. 13
These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, fuels, washing additives, refrigerants, lubricants and various bonding agents.p. 13
+Enginep. 13
Enginep. 13
+Do not work on the fuel system while the engine is running. (Danger to life!)p. 13
Do not work on the fuel system while the engine is running. (Danger to life!)p. 13
Once the engine has stopped wait approx. 5 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!)p. 13
Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!)p. 13
When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!)p. 13
+l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att…p. 13
l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att…p. 13
l Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/- 0105 Electric precautions against dangerous contact voltages).p. 13
l Cover all electric components properly before wet cleaning.p. 14
+Air conditioning systemp. 14
Air conditioning systemp. 14
+Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment.p. 14
Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment.p. 14
+l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi…p. 14
l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi…p. 14
l Perform maintenance and repair work on air conditioning systems only in well ventilated rooms! Escaping refrigerant vapours will mix with the ambient air and displace the oxygen required for breathing (danger of suffocating).p. 14
l Smoking is prohibited when performing maintenance and repair work on air conditioning systems! Toxic breakdown products may be generated if refrigerant comes into contact with heat.p. 14
l Refrigerant should always be extracted and removed by flushing with nitrogen before starting welding or soldering work near components of the air conditioning system. The development of heat may cause the refrigerant to develop toxic and highly cor…p. 14
l Pungent smell! The toxic substances, which are responsible for the pungent smell, must not be inhaled, since this may cause damage to the respiratory system, the lung and other organs. Extract toxic breakdown products with a suitable extraction sys…p. 14
l When blowing out components with compressed air and when flushing with nitrogen the gas mixture escaping from the components must be extracted via suitable extraction facilities (workshop extraction systems).p. 14
+Handling pressure vesselsp. 14
Handling pressure vesselsp. 14
+l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert…p. 14
l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert…p. 14
l Secure pressure vessels against tipping over or rolling away.p. 14
l Do not throw pressure vessels! Pressure vessels may thereby be deformed to such an extent, that they will crack. The sudden evaporation and escape of refrigerant releases excessive forces. This applies also when snapping off valves on bottles. Bott…p. 14
l Refrigerant bottles must never be placed near heating radiators. Higher temperatures will cause higher pressures, whereby the permissible pressure of the vessel may be exceeded.p. 14
l Do not heat up refrigerant bottles with an open flame. Excessive temperatures can damage the material and cause the decomposition of refrigerant.p. 14
l Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures.p. 14
+It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service.p. 14
It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service.p. 14
+Batteryp. 14
Batteryp. 14
+l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin.p. 14
l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin.p. 14
l Work only well ventilated rooms (formation of oxyhydrogen gas).p. 14
l Do not lean over the battery while it is under load, being charged or tested (danger of explosion).p. 14
l Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the batteryp. 14
l Use battery chargers etc. only in strict compliance with the operating instructions.p. 14
l After an accident with acid flush the skin with a sufficient amount of water and seek medical advice.p. 14
l Do not allow children access to batteries.p. 14
l When mixing battery fluid always pour acid into water, never vice-versa.p. 14
+Special safety regulationsp. 15
Special safety regulationsp. 15
+l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine.p. 15
l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine.p. 15
l The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explici…p. 15
l Unauthorized changes to the machine are prohibited for safety reasons.p. 15
l Do not perform any cleaning work while the engine is running.p. 15
l If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine (danger of crushing!).p. 15
l If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!).p. 15
l Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous!p. 15
l Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.p. 15
l Always ensure an adequate supply of fresh air when refuelling in closed rooms.p. 15
l Dispose of used filters in accordance with applicable environmental regulations.p. 15
l When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations.p. 15
l Do not heat up oils higher than 160 °C because they may ignite.p. 15
l Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations.p. 15
l Dispose of old batteries according to applicable environmental regulations.p. 15
l There is a danger of scalding when draining off engine or hydraulic oil at operating temperature! Allow engine and hydraulic system to cool down to a sufficient level.p. 15
l Do not exceed the max. permissible tire pressure.p. 15
+The values specified in the table apply for screws:p. 16
General repair instructionsp. 16
+Generalp. 16
Generalp. 16
+l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 16
l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 16
l Before assembling and installing parts, assemblies or components oil or grease all movable parts or surfaces as required and in compliance with the compatibility of materials.p. 16
+The values specified in the table apply for screws:p. 16
Electricsp. 16
+Generalp. 16
Generalp. 16
Due to the fast technical development electric and electronic vehicle systems become more intelligent and more comprehensive day by day, and can hardly be dispensed with in hydraulic and mechanical vehicle systems.p. 16
Diagnostics according to planp. 16
Well structured trouble shooting procedures can save time and money.p. 16
Random tests have revealed that purely electronic components or control units only very rarely are the actual cause of failures:p. 16
+l In approx. 10 % of the examined cases the problems were caused by control units.p. 16
l In approx. 10 % of the examined cases the problems were caused by control units.p. 16
l In approx. 15 % sensors and actuators were the cause of the problems.p. 16
By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.).p. 16
General:p. 16
+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. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed…p. 16
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. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed…p. 16
l Check for good cable and ground contacts, therefore keep all mechanical transition points between electric conductors (terminals, plugs) free of oxide and dirt, as far as this is possible.p. 16
l Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately.p. 16
l Do not disconnect or connect battery or generator while the engine is running.p. 16
l Do not operate the main battery switch under load.p. 16
l Do not use jump leads after the battery has been removed.p. 16
l Sensors and electric actuators on control units must never be connected individually or between external power sources for the purpose of testing, but only in connection with the control unit in question.p. 16
l It is not permitted to pull plugs off while the voltage supply is switched on (terminal 15 "ON")! Switch the voltage supply "OFF" first and pull out the plug.p. 16
l Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!p. 16
l Plug-in connectors on control units are only dust and water tight if the mating connector is plugged on! Control units must be protected against spray water, until the mating connector is finally plugged on!p. 17
l Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions.p. 17
l Do not use any radio equipment or mobile phones in the vehicle cab without a proper aerial or in the vicinity of the control electronics!p. 17
+Electrics and weldingp. 17
Electrics and weldingp. 17
+Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o…p. 17
Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o…p. 17
+l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 17
l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 17
l Isolate the generator and all control units from the electric circuit.p. 17
l Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.p. 17
l When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings.p. 17
+The values specified in the table apply for screws:p. 17
Batteryp. 17
Rules for the handling of batteriesp. 17
When removing a battery always disconnect the minus pole before the plus pole. When installing the battery connect the minus pole after the plus pole to avoid short circuits.p. 17
Fasten the terminal clamps with a little force as possible.p. 17
Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related development of heat.p. 17
Make sure the battery is properly fastened in the vehicle.p. 17
+The values specified in the table apply for screws:p. 18
Generatorp. 18
Before removing the generator you must disconnect 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 running, because this may cause extremely high voltage peaks…p. 18
When disassembling the battery cable, the B+-nut underneath on the generator side may also be loosened. This nut must in this case be retightened.p. 18
When connecting e.g. the battery cable to the terminal 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 …p. 18
The generator can only be operated with the battery connected. Under special conditions emergency operation without battery is permitted, the lifetime of the generator is in such cases especially limited.p. 18
Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle.p. 18
When cleaning the generator with a steam or water 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 de…p. 18
+The values specified in the table apply for screws:p. 18
Starter motorp. 18
So-called jump starting (using an additional external battery) without the battery connected is dangerous. When disconnecting the cables from the poles high inductivities (arcs, voltage peaks) may occur and destroy the electrical installation.p. 18
For purposes like e.g. purging the fuel systems, starters may be operated for maximum 1 minute without interruption. Then you should wait for at least 30 minutes (cooling down) until trying again. During the 1 minute starting period this process shou…p. 18
Starter motors must not be cleaned with high pressure steam cleaning equipment.p. 18
The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection).p. 18
When replacing the starter the ring gear on the engine flywheel must be checked for damage and its number of teeth – if necessary replace the ring gear.p. 18
Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.p. 18
+The values specified in the table apply for screws:p. 19
Hydraulic systemp. 19
+Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 19
Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 19
+Please notep. 19
Please notep. 19
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 19
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 19
+l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 19
l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 19
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 19
l During repair work keep all openings closed with clean plastic plugs and caps.p. 19
l Never run pumps, motors and engines without oil or hydraulic oil.p. 19
l When cleaning hydraulic components take care not to damage any fine machine surfaces.p. 19
l Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not let such substances come in contact with rubber parts.p. 19
l Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.p. 19
l Avoid the formation of rust on fine machined caused by hand sweat.p. 19
l Use new O-rings or seal rings for reassembly.p. 19
l Use only hydraulic oil as sliding agent when reassembling. Do not use any grease!p. 19
l Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.p. 19
l Check the hydraulic oil level before and after the work.p. 19
l Fill in only clean oil as specified in the maintenance instructions.p. 19
l Check the hydraulic system for leaks, if necessary find and rectify the cause.p. 19
l Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions.p. 19
l After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system.p. 19
l Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).p. 19
l After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.p. 19
l The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. On hard ground place the drums on a suitable base and check the drum pressure. Do not activate the vibration on a hard, concreted base, dang…p. 19
l After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized.p. 19
+Before commissioningp. 19
Before commissioningp. 19
+l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions.p. 19
l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions.p. 19
l After changing a component flush the hydraulic system as described in the flushing instructions.p. 19
+Taking into operationp. 19
Taking into operationp. 19
+l Bleed the hydraulic circuits.p. 19
l Bleed the hydraulic circuits.p. 19
l Start up the hydraulic system without load.p. 19
l Check the hydraulic oil level in the tank, if necessary top up with hydraulic oil as specified in the operating and maintenance instructions or drain oil off into a suitable container.p. 19
+After taking into operationp. 19
After taking into operationp. 19
+l Check fittings and flanges for leaks.p. 19
l Check fittings and flanges for leaks.p. 19
l After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary.p. 19
l Do not adjust pressure relief valves and control valves to values above their specified values.p. 19
+The values specified in the table apply for screws:p. 20
Air conditioning systemp. 20
+Chemicals/ozone layer regulationp. 20
Chemicals/ozone layer regulationp. 20
The chemicals/ozone layer regulation, which became effective on 01.12.2006, supplements the still directly applicable regulation (EG) no. 2037/2000 from 29.06.2000 concerning substances, which cause decomposition of the ozone layer and at the same ti…p. 20
Work on air conditioning systems must only be carried out by persons who:p. 20
+l have proven to have sufficient expert knowledge,p. 20
l have proven to have sufficient expert knowledge,p. 20
l have the necessary equipment to undertake such tasks,p. 20
l are reliable andp. 20
l are not any directives regarding their activities when carrying out inspection and maintenance work acc. to § 4 section 2 of the chemical/ozone layer regulation.p. 20
The inspection and maintenance tasks, including leak tests and possible repair activities, must be recorded in the operating instructions together with information about the refrigerant quantities used and regained, whereby the operator is obliged to…p. 20
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 20
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 20
+l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 20
l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 20
l During repairs on refrigerant lines and components, these must be kept closed, as far as this is possible, to prevent the system from being contaminated by air, moisture and dirt. The operational safety of the system can only be assured as long as …p. 20
l Connections, screw fittings and their immediate surrounding areas must be cleaned before removal.p. 20
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 20
l During repair work keep all openings closed with clean plastic plugs and caps.p. 20
l All parts to be reused should be cleaned with a gasoline free solvent and blow-dried with clean compressed air or dried with a lint-free cloth.p. 20
l Before opening all components should have warmed up to ambient temperature, to avoid that damp air is drawn into the component by the difference in temperatures.p. 20
l Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but must generally be replaced.p. 20
l Do not fill up refrigerant, but extract existing refrigerant and refill the system.p. 20
l Different types of refrigerant must not be mixed. Only the refrigerant specified for the corresponding air conditioning system must be used.p. 20
l Refrigerant circuits with refrigerant type R134a must only be operated with the compressor oil / refrigeration oil approved for the compressor.p. 20
l Used compressor oil/refrigeration oil must be disposed of in strict compliance with applicable environmental regulations.p. 20
l Due to its chemical properties compressor oil / refrigeration oil must never be disposed of together with engine or transmission oil.p. 20
l Compressor oil / refrigeration oil is highly hydroscopic. Oil cans must strictly be kept closed until use. Oil rests should not be used, if the can had been opened over a longer period of time.p. 20
l All O-rings/seal rings as well as pipe/ hose fittings must be oiled with compressor/refrigeration oil bfore assembly.p. 20
l 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.p. 20
l A too high compressor oil / refrigeration oil level adversely affects the cooling performance and a too low oil level has a negative effect on the lifetime of the compressor.p. 20
l Use new O-rings or seal rings for reassembly.p. 20
l Always used 2 spanners to work on pipes/hoses to avoid damages .p. 20
l Tighten screw fittings with the specified torque.p. 20
l Check all pipes/hoses, screw fittings or components for damage, replace if necessary.p. 20
l Do not leave the refrigerant circuit unnecessarily open to the atmosphere.p. 20
l In case of a repair on the refrigeration system you should first evacuate the air conditioning system for at least 45 minutes to remove any moisture from the system, before you start to refill. Moisture bonded in the compressor oil / refrigeration …p. 20
l Compressor valves must only be opened after the system has been properly sealed.p. 20
l The use of leak detection spray is not permitted. If such substances are used the WARRANTY will become null and void.p. 20
l If the air conditioning system had been opened for repair work, a new drier should be installed in the refrigerant circuit.p. 21
l After completion of repair work screw locking caps (with seals) on all valve connections service connections.p. 21
l Before start up of the air conditioning system after a new filling: – Turn the compressor approx. 10 revolutions by hand using the clutch or V-belt pulley of the magnetic clutch. – Start the engine with the compressor/control valve switched off. – …p. 21
l Never run the compressor with an insufficient amount of refrigerant.p. 21
+The values specified in the table apply for screws:p. 21
Notes on cleanliness for Common Rail enginesp. 21
Special requirements with respect to cleanliness in the fuel system do apply for commissioning, maintenance and repair work, particularly for TEIRIII engines with the DEUTZ Common Rail System. Contamination like dirt, welding residues or similar can …p. 21
Fig. 1p. 21
+l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 21
l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 21
+l When parts are unpacked any connections must be closed with suitable plugs or caps, in order to preventp. 21
(Fig. 1)p. 21
+Notes and measures to be applied before starting work in the fuel systemp. 21
Notes and measures to be applied before starting work in the fuel systemp. 21
+l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 21
l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 21
l Before starting work in the fuel system clean the complete engine and the engine compartment with the system still closed.p. 21
l The engine should be dry before work is started in the fuel system.p. 21
l Blow drying with compressed air is only permitted while the fuel system is still closed.p. 22
l When using steam cleaning equipment cover control unit, cable plugs, all other electrical connections and the generator beforehand and do not expose these items to the direct steam jet.p. 22
l Electrical plug connections must be plugged in during jet cleaning.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 22
l Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 22
l Perform work on the fuel system only in a clean environment (no dust, no grinding or welding work). Avoid draughts (dust). The workshop floor must be cleaned at regular intervals. No brake or power test stand should be present or operated in the sa…p. 22
l Air movements, which could swirl up dust, such as brake repairs or starting of engines, must be strictly avoided.p. 22
l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l No general machine tools should be operated in this room.p. 22
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 22
l Engine compartment area where dirt particles could come loose, should be covered with new, clean foil.p. 22
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 22
+Notes and measures to be applied during work in the fuel systemp. 22
Notes and measures to be applied during work in the fuel systemp. 22
+l Wear clean working clothes.p. 22
l Wear clean working clothes.p. 22
l Use only lint-free cleaning cloths for work in the fuel system.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction. Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 22
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 22
l Do not use any previously used cleaning or testing fluids for cleaning.p. 22
l Compressed air should never be used for cleaning when the fuel system is open.p. 22
l Work on disassembled components must only be carried out at a specially furnished work place.p. 22
l When disassembling or assembling components you should not use any materials from which particles or fibres could flake off (cardboard, wood, towels).p. 22
l Dismantled parts must only be wiped off with clean, lint-free cloths if required. No dirt particles must be wiped into the components.p. 22
l Close openings on components and engine immediately with suitable plugs/caps.p. 22
l Plugs/caps must only be removed just before the installation.p. 22
l Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use.p. 22
l Take new parts out of their original packaging just before installation.p. 22
l Disassembled components must be stored in new, sealable bags or – if available – in the packaging material of the new components.p. 22
l Always use the original packaging material of the new part to return the disassembled old component.p. 22
+Notes and measures concerning the workshop areap. 22
Notes and measures concerning the workshop areap. 22
+l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l The workshop floor must be sealed or tiled.p. 22
l No welding equipment, grinding machines, general machine tools, brake or power test benches must be operated in this room.p. 22
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 22
+Notes and measures for work place and tools in the workshopp. 22
Notes and measures for work place and tools in the workshopp. 22
+l A special work place must be set up for work on disassembled components.p. 22
l A special work place must be set up for work on disassembled components.p. 22
l Clean disassembly and assembly tools at regular intervals and keep these in a closed tool cabinet.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 23
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 23
+The values specified in the table apply for screws:p. 23
Fuel hosesp. 23
Fig. 2p. 23
+All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 23
All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 23
+The values specified in the table apply for screws:p. 24
Gaskets and mating surfacesp. 24
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 24
+l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 24
l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 24
l Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 24
l Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 24
l If necessary remove any old sealing compound before assembling. For this purpose do not use any tools that could damage the sealing surfaces.p. 24
l Sealing compound must be applied thin and evenly on the corresponding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores.p. 24
l Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone; take care that no grinding dust and dirt enters into tapped bores or enclosed components.p. 24
l Blow out lines, ducts and gaps with compressed air, replace any O-rings and seals that have been dislodged by the compressed air.p. 24
Assembly of radial sealsp. 24
Fig. 3p. 24
+l Lubricate the sealing lips (2)p. 24
+l Lubricate the sealing lips (2)p. 24
(Fig. 3)p. 24
l Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 24
+If possible, use an assembly sleeve (1p. 24
+If possible, use an assembly sleeve (1p. 24
(Fig. 3)p. 24
to protect the lip from being damaged by sharp edges, threads or splines.p. 24
+l Lubricate the outer rim (arrow 3p. 24
+l Lubricate the outer rim (arrow 3p. 24
(Fig. 3)p. 24
Fig. 4p. 24
+l Press or knock the seal into the housing, until it is flush with the housing surface.p. 24
l Press or knock the seal into the housing, until it is flush with the housing surface.p. 24
+If possible, use a "bell" (1p. 24
+If possible, use a "bell" (1p. 24
(Fig. 4)p. 24
that the seal will not skew.p. 24
If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0,4 mm smaller than the outer diameter of the seal. Use VERY LIGHT blows with the hammer if no press is available.p. 24
+The values specified in the table apply for screws:p. 25
Feather keys and keywaysp. 25
+Feather keys may only be reused if they are free of damage.p. 25
Feather keys may only be reused if they are free of damage.p. 25
Fig. 5p. 25
+l Clean and thoroughly examine the feather key.p. 25
l Clean and thoroughly examine the feather key.p. 25
l Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 25
+The values specified in the table apply for screws:p. 25
Ball and roller bearingsp. 25
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 25
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 25
Fig. 6p. 25
+l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 25
l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 25
l Remove any lubricant residues from the ball or roller bearing to be examined by washing it with gasoline or any other appropriate degreasing agent. Ensure strict cleanliness.p. 25
l Check balls or rollers, running surfaces, outer faces of outer races and inner faces of inner races for visible damage. Replace the ball or roller bearing if necessary.p. 25
l Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 25
l Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 25
l On greased bearings (e.g. wheel bearings) fill the space between ball or roller bearing and outer seal with the recommended type of grease before assembling the seal.p. 25
l Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 26
l Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 26
l Always mark the individual parts of separable ball or roller bearings (e.g. taper roller bearings) to enable correct reassembling. Never assemble the rollers to an outer race that has already been used, replace the complete ball or roller bearing i…p. 26
Fig. 7p. 26
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 26
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 26
(Fig. 7)p. 26
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 26
+The values specified in the table apply for screws:p. 26
Screws and nutsp. 26
Tightening torquep. 26
+Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 26
Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 26
Damaged screws must under no circumstances be used any longer. Recutting threads with thread cutters or taps adversely affects the strength and leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque value rea…p. 26
Self-locking nuts must generally be replaced after disassembly.p. 26
The use of screws with too high strength can cause damage!p. 26
+l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 26
l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 26
l When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque.p. 26
+l Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 26
The same applies for self-locking nuts.p. 26
l Make sure that no oil or grease will enter into blind tapped bores. The hydraulic power generated when turning in the screw could cause breakage of the effected part.p. 26
Strength classes, metric screwsp. 27
The strength classes (from 3.6 to 12.9) are specified for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw.p. 27
Fig. 8 Identification of screwsp. 27
Example: A screw is identified with 12.9.p. 27
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 27
2p. 27
+l The nominal tensile strength is 12 X 100 N/mmp. 27
+l The nominal tensile strength is 12 X 100 N/mmp. 27
2p. 27
2p. 27
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 27
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 27
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 27
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 27
+l The lower tensile strength is 9/10 X 1200 N/mmp. 27
+l The lower tensile strength is 9/10 X 1200 N/mmp. 27
2p. 27
2p. 27
+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.p. 27
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.p. 27
Strength classes of metric nutsp. 27
Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified.p. 27
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 27
Fig. 9 Identification of nutsp. 27
+In a connection with a screw, these nuts 1p. 27
(Fig. 9)p. 27
Nut height above 0.8 d (d = nominal dimension).p. 27
+Strength class of nutp. 27
Strength class of nutp. 27
+Strength class of associated screwp. 27
Strength class of associated screwp. 27
+4p. 27
4p. 27
+3.6, 4.6, 4.8p. 27
3.6, 4.6, 4.8p. 27
+5p. 27
5p. 27
+3.6, 4.6, 4.8p. 27
3.6, 4.6, 4.8p. 27
5.6, 5.8p. 27
+6p. 27
6p. 27
+6.8p. 27
6.8p. 27
+8p. 27
8p. 27
+8.8p. 27
8.8p. 27
+9p. 27
9p. 27
+9.8p. 27
9.8p. 27
+10p. 27
10p. 27
+10.8p. 27
10.8p. 27
+12p. 27
12p. 27
+12.8p. 27
12.8p. 27
Nuts for screw joints with limited load factor (04, 05)p. 27
+The preceding "0" indicates that, due to their low height, nuts 2p. 27
(Fig. 9)p. 27
Nut height below 0,8 d (d = nominal dimension).p. 27
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 27
+This standard contains strength classes (hardness classes) for nuts 3p. 27
(Fig. 9)p. 27
Nut height below 0,5 d (d = nominal dimension).p. 27
Identification in clock systemp. 28
Fig. 10 Identification of nuts in clock systemp. 28
+For small nutsp. 28
(Fig. 10)p. 28
+l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 28
l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 28
l The strength class is identified by a dash (b).p. 28
Identification of UNF-threadsp. 28
Fig. 11p. 28
Screwsp. 28
+The screw head is marked with a stamped in, round cavity 3p. 28
(Fig. 11)p. 28
Nutsp. 28
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 28
Studs and brake rodsp. 28
At the outmost end a short end of the component is reduced to its core diameter (1).p. 28
Cotter pinsp. 29
Fig. 12p. 29
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 29
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 29
+The values specified in the table apply for screws:p. 30
Tightening torquesp. 30
+The values specified in the table apply for screws:p. 30
The values specified in the table apply for screws:p. 30
+l black oiledp. 30
l black oiledp. 30
l with surface protection A4Cp. 30
l with surface protection DACROMETp. 30
+DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 30
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 30
+Tightening torques for screws with metric unified threadp. 30
+Tightening torques for screws with metric unified threadp. 30
+Tightening torques for screws with metric unified threadp. 30
+Coefficient of friction m tot. = 0,14p. 30
mp. 30
+Screw dimensionp. 30
Screw dimensionp. 30
+Tightening torques Nmp. 30
Tightening torques Nmp. 30
+8.8p. 30
8.8p. 30
+10.9p. 30
10.9p. 30
+12.9p. 30
12.9p. 30
+M4p. 30
M4p. 30
+3p. 30
3p. 30
+5p. 30
5p. 30
+5p. 30
5p. 30
+M5p. 30
M5p. 30
+6p. 30
6p. 30
+9p. 30
9p. 30
+10p. 30
10p. 30
+M6p. 30
M6p. 30
+10p. 30
10p. 30
+15p. 30
15p. 30
+18p. 30
18p. 30
+M8p. 30
M8p. 30
+25p. 30
25p. 30
+35p. 30
35p. 30
+45p. 30
45p. 30
+M10p. 30
M10p. 30
+50p. 30
50p. 30
+75p. 30
75p. 30
+83p. 30
83p. 30
+M12p. 30
M12p. 30
+88p. 30
88p. 30
+123p. 30
123p. 30
+147p. 30
147p. 30
+M14p. 30
M14p. 30
+137p. 30
137p. 30
+196p. 30
196p. 30
+235p. 30
235p. 30
+M16p. 30
M16p. 30
+211p. 30
211p. 30
+300p. 30
300p. 30
+358p. 30
358p. 30
+M18p. 30
M18p. 30
+290p. 30
290p. 30
+412p. 30
412p. 30
+490p. 30
490p. 30
+M20p. 30
M20p. 30
+412p. 30
412p. 30
+578p. 30
578p. 30
+696p. 30
696p. 30
+M22p. 30
M22p. 30
+560p. 30
560p. 30
+785p. 30
785p. 30
+942p. 30
942p. 30
+M24p. 30
M24p. 30
+711p. 30
711p. 30
+1000p. 30
1000p. 30
+1200p. 30
1200p. 30
+M27p. 30
M27p. 30
+1050p. 30
1050p. 30
+1480p. 30
1480p. 30
+1774p. 30
1774p. 30
+M30p. 30
M30p. 30
+1420p. 30
1420p. 30
+2010p. 30
2010p. 30
+2400p. 30
2400p. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Coefficient of friction m tot. = 0,14p. 30
mp. 30
+Screw dimensionp. 30
Screw dimensionp. 30
+Tightening torques Nmp. 30
Tightening torques Nmp. 30
+8.8p. 30
8.8p. 30
+10.9p. 30
10.9p. 30
+12.9p. 30
12.9p. 30
+M8 x 1p. 30
M8 x 1p. 30
+26p. 30
26p. 30
+37p. 30
37p. 30
+48p. 30
48p. 30
+M10 x 1.25p. 30
M10 x 1.25p. 30
+52p. 30
52p. 30
+76p. 30
76p. 30
+88p. 30
88p. 30
+M12 x 1,25p. 30
M12 x 1,25p. 30
+98p. 30
98p. 30
+137p. 30
137p. 30
+126p. 30
126p. 30
+M12 x 1.5p. 30
M12 x 1.5p. 30
+93p. 30
93p. 30
+127p. 30
127p. 30
+152p. 30
152p. 30
+M14 x 1.5p. 30
M14 x 1.5p. 30
+152p. 30
152p. 30
+216p. 30
216p. 30
+255p. 30
255p. 30
+M16 x 1.5p. 30
M16 x 1.5p. 30
+225p. 30
225p. 30
+318p. 30
318p. 30
+383p. 30
383p. 30
+M18 x 1.5p. 30
M18 x 1.5p. 30
+324p. 30
324p. 30
+466p. 30
466p. 30
+554p. 30
554p. 30
+M20 x 1.5p. 30
M20 x 1.5p. 30
+461p. 30
461p. 30
+628p. 30
628p. 30
+775p. 30
775p. 30
+M22 x 1.5p. 30
M22 x 1.5p. 30
+618p. 30
618p. 30
+863p. 30
863p. 30
+1058p. 30
1058p. 30
+M24 x 2p. 30
M24 x 2p. 30
+780p. 30
780p. 30
+1098p. 30
1098p. 30
+1294p. 30
1294p. 30
+M27 x2p. 30
M27 x2p. 30
+1147p. 30
1147p. 30
+1578p. 30
1578p. 30
+1920p. 30
1920p. 30
+M30 x 2p. 30
M30 x 2p. 30
+1568p. 30
1568p. 30
+2254p. 30
2254p. 30
+2695p. 30
2695p. 30
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 31
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 31
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 31
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.p. 31
+Screw dimensionp. 31
Screw dimensionp. 31
+Tightening torques Nmp. 31
Tightening torques Nmp. 31
+8.8p. 31
8.8p. 31
+10.9p. 31
10.9p. 31
+12.9p. 31
12.9p. 31
+M16p. 31
M16p. 31
+169p. 31
169p. 31
+240p. 31
240p. 31
+287p. 31
287p. 31
+M16 x 1.5p. 31
M16 x 1.5p. 31
+180p. 31
180p. 31
+255p. 31
255p. 31
+307p. 31
307p. 31
+M18p. 31
M18p. 31
+232p. 31
232p. 31
+330p. 31
330p. 31
+392p. 31
392p. 31
+M18 x 1.5p. 31
M18 x 1.5p. 31
+260p. 31
260p. 31
+373p. 31
373p. 31
+444p. 31
444p. 31
+M20p. 31
M20p. 31
+330p. 31
330p. 31
+463p. 31
463p. 31
+557p. 31
557p. 31
+M20 x 1.5p. 31
M20 x 1.5p. 31
+369p. 31
369p. 31
+502p. 31
502p. 31
+620p. 31
620p. 31
+M22p. 31
M22p. 31
+448p. 31
448p. 31
+628p. 31
628p. 31
+754p. 31
754p. 31
+M22 x 1.5p. 31
M22 x 1.5p. 31
+495p. 31
495p. 31
+691p. 31
691p. 31
+847p. 31
847p. 31
+M24p. 31
M24p. 31
+569p. 31
569p. 31
+800p. 31
800p. 31
+960p. 31
960p. 31
+M24 x 2p. 31
M24 x 2p. 31
+624p. 31
624p. 31
+879p. 31
879p. 31
+1036p. 31
1036p. 31
+M27p. 31
M27p. 31
+840p. 31
840p. 31
+1184p. 31
1184p. 31
+1520p. 31
1520p. 31
+M27 X 2p. 31
M27 X 2p. 31
+918p. 31
918p. 31
+1263p. 31
1263p. 31
+1536p. 31
1536p. 31
+M30p. 31
M30p. 31
+1136p. 31
1136p. 31
+1608p. 31
1608p. 31
+1920p. 31
1920p. 31
+M30 x 2p. 31
M30 x 2p. 31
+1255p. 31
1255p. 31
+1804p. 31
1804p. 31
+2156p. 31
2156p. 31
+3/4“ – 10 UNCp. 31
3/4“ – 10 UNCp. 31
+276p. 31
276p. 31
+388p. 31
388p. 31
+464p. 31
464p. 31
+3/4“ – 16 UNCp. 31
3/4“ – 16 UNCp. 31
+308p. 31
308p. 31
+432p. 31
432p. 31
+520p. 31
520p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Coefficient of friction m tot. = 0,14p. 31
mp. 31
These values result in a 90% utilization of the yield pointp. 31
+Thread diameterp. 31
Thread diameterp. 31
+Tightening torques Nmp. 31
Tightening torques Nmp. 31
+10.9p. 31
10.9p. 31
+M12x1.5p. 31
M12x1.5p. 31
+100p. 31
100p. 31
+M14x1.5p. 31
M14x1.5p. 31
+150p. 31
150p. 31
+M18x1.5p. 31
M18x1.5p. 31
+300 – 350p. 31
300 – 350p. 31
+M20x1.5p. 31
M20x1.5p. 31
+400 – 500p. 31
400 – 500p. 31
+M22x1.5p. 31
M22x1.5p. 31
+500 – 600p. 31
500 – 600p. 31
The values specified in the table apply for screws:p. 32
+l black oiledp. 32
l black oiledp. 32
l with surface protection A4Cp. 32
l with surface protection DACROMETp. 32
+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°.p. 32
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°.p. 32
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 32
+Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 32
+Tightening torques for screws with UNC thread,p. 32
+Tightening torques for screws with UNC thread,p. 32
+Coefficient of friction m tot. = 0,14p. 32
mp. 32
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 32
+Screw dimensionp. 32
Screw dimensionp. 32
+Tightening torques Nmp. 32
Tightening torques Nmp. 32
+8.8p. 32
8.8p. 32
+10.9p. 32
10.9p. 32
+12.9p. 32
12.9p. 32
+1/4“ – 20p. 32
1/4“ – 20p. 32
+11p. 32
11p. 32
+15p. 32
15p. 32
+19p. 32
19p. 32
+5/16“ – 18p. 32
5/16“ – 18p. 32
+23p. 32
23p. 32
+32p. 32
32p. 32
+39p. 32
39p. 32
+3/8“ – 16p. 32
3/8“ – 16p. 32
+39p. 32
39p. 32
+55p. 32
55p. 32
+66p. 32
66p. 32
+7/16“ – 14p. 32
7/16“ – 14p. 32
+62p. 32
62p. 32
+87p. 32
87p. 32
+105p. 32
105p. 32
+1/2“ – 13p. 32
1/2“ – 13p. 32
+96p. 32
96p. 32
+135p. 32
135p. 32
+160p. 32
160p. 32
+9/16“ – 12p. 32
9/16“ – 12p. 32
+140p. 32
140p. 32
+200p. 32
200p. 32
+235p. 32
235p. 32
+5/8“ – 11p. 32
5/8“ – 11p. 32
+195p. 32
195p. 32
+275p. 32
275p. 32
+330p. 32
330p. 32
+3/4“ – 10p. 32
3/4“ – 10p. 32
+345p. 32
345p. 32
+485p. 32
485p. 32
+580p. 32
580p. 32
+7/8“ – 9p. 32
7/8“ – 9p. 32
+560p. 32
560p. 32
+770p. 32
770p. 32
+940p. 32
940p. 32
+1“ – 8p. 32
1“ – 8p. 32
+850p. 32
850p. 32
+1200p. 32
1200p. 32
+1450p. 32
1450p. 32
+1 1/8“ – 7p. 32
1 1/8“ – 7p. 32
+1200p. 32
1200p. 32
+1700p. 32
1700p. 32
+2000p. 32
2000p. 32
+1 1/4“ – 7p. 32
1 1/4“ – 7p. 32
+1700p. 32
1700p. 32
+2400p. 32
2400p. 32
+2900p. 32
2900p. 32
+1 3/8“ – 6p. 32
1 3/8“ – 6p. 32
+2200p. 32
2200p. 32
+3100p. 32
3100p. 32
+3700p. 32
3700p. 32
+1 1/2“ – 6p. 32
1 1/2“ – 6p. 32
+3000p. 32
3000p. 32
+4200p. 32
4200p. 32
+5100p. 32
5100p. 32
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 32
+Tightening torques for screws with UNF thread,p. 32
+Tightening torques for screws with UNF thread,p. 32
+Coefficient of friction m tot. = 0,14p. 33
mp. 33
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 32
+Screw dimensionp. 32
Screw dimensionp. 32
+Tightening torques Nmp. 32
Tightening torques Nmp. 32
+8.8p. 32
8.8p. 32
+10.9p. 32
10.9p. 32
+12.9p. 32
12.9p. 32
+1/4“ – 28p. 32
1/4“ – 28p. 32
+13p. 32
13p. 32
+18p. 32
18p. 32
+22p. 32
22p. 32
+5/16“ – 24p. 32
5/16“ – 24p. 32
+25p. 32
25p. 32
+35p. 32
35p. 32
+42p. 32
42p. 32
+3/8“ – 24p. 32
3/8“ – 24p. 32
+45p. 32
45p. 32
+63p. 32
63p. 32
+76p. 32
76p. 32
+7/16“ – 20p. 32
7/16“ – 20p. 32
+70p. 32
70p. 32
+100p. 32
100p. 32
+120p. 32
120p. 32
+1/2“ – 20p. 32
1/2“ – 20p. 32
+110p. 32
110p. 32
+155p. 32
155p. 32
+185p. 32
185p. 32
+9/16“ – 18p. 32
9/16“ – 18p. 32
+155p. 32
155p. 32
+220p. 32
220p. 32
+260p. 32
260p. 32
+5/8“ – 18p. 32
5/8“ – 18p. 32
+220p. 32
220p. 32
+310p. 32
310p. 32
+370p. 32
370p. 32
+3/4“ – 16p. 32
3/4“ – 16p. 32
+385p. 32
385p. 32
+540p. 32
540p. 32
+650p. 32
650p. 32
+7/8“ -14p. 32
7/8“ -14p. 32
+620p. 32
620p. 32
+870p. 32
870p. 32
+1050p. 32
1050p. 32
+1“ – 12p. 33
1“ – 12p. 33
+930p. 33
930p. 33
+1300p. 33
1300p. 33
+1600p. 33
1600p. 33
+1 1/8“ – 12p. 33
1 1/8“ – 12p. 33
+1350p. 33
1350p. 33
+1900p. 33
1900p. 33
+2300p. 33
2300p. 33
+1 1/4“ – 12p. 33
1 1/4“ – 12p. 33
+1900p. 33
1900p. 33
+2700p. 33
2700p. 33
+3200p. 33
3200p. 33
+1 3/8“ – 12p. 33
1 3/8“ – 12p. 33
+2600p. 33
2600p. 33
+3700p. 33
3700p. 33
+4400p. 33
4400p. 33
+1 1/2“ – 12p. 33
1 1/2“ – 12p. 33
+3300p. 33
3300p. 33
+4600p. 33
4600p. 33
+5600p. 33
5600p. 33
+2 Technical datap. 35
2 Technical datap. 35
Technical datap. 36
Fig. 13p. 36
+Dimensions in mmp. 36
Dimensions in mmp. 36
+Ap. 36
Ap. 36
+Bp. 36
Bp. 36
+B2p. 36
+Bp. 36
2p. 36
+B3p. 36
+Bp. 36
3p. 36
+Dp. 36
Dp. 36
+Hp. 36
Hp. 36
+H2p. 36
+Hp. 36
2p. 36
+H4p. 36
+Hp. 36
4p. 36
+Kp. 36
Kp. 36
+Lp. 36
Lp. 36
+BC 672 RB-2p. 36
BC 672 RB-2p. 36
+3500p. 36
3500p. 36
+3800p. 36
3800p. 36
+3550p. 36
3550p. 36
+3775p. 36
3775p. 36
+1660p. 36
1660p. 36
+4120p. 36
4120p. 36
+3820p. 36
3820p. 36
+1950p. 36
1950p. 36
+600p. 36
600p. 36
+8120p. 36
8120p. 36
+BC 772 RB-2p. 36
BC 772 RB-2p. 36
+3500p. 36
3500p. 36
+3800p. 36
3800p. 36
+3550p. 36
3550p. 36
+3775p. 36
3775p. 36
+1660p. 36
1660p. 36
+4120p. 36
4120p. 36
+3820p. 36
3820p. 36
+1950p. 36
1950p. 36
+600p. 36
600p. 36
+8120p. 36
8120p. 36
+Subject to technical alterations.p. 36
Subject to technical alterations.p. 37
+BC 672 RB-2p. 36
BC 672 RB-2p. 36
+BC 772 RB-2p. 36
BC 772 RB-2p. 36
+Weightsp. 36
Weightsp. 36
+Operating weight (CECE)p. 36
Operating weight (CECE)p. 36
+kgp. 36
kgp. 36
+32100p. 36
32100p. 36
+36500p. 36
36500p. 36
+Front axle load (CECE)p. 36
Front axle load (CECE)p. 36
+kgp. 36
kgp. 36
+15300p. 36
15300p. 36
+17400p. 36
17400p. 36
+Rear axle load (CECE)p. 36
Rear axle load (CECE)p. 36
+kgp. 36
kgp. 36
+16800p. 36
16800p. 36
+19100p. 36
19100p. 36
+Travel characteristicsp. 36
Travel characteristicsp. 36
+Travel speed range I (forward/reverse)p. 36
Travel speed range I (forward/reverse)p. 36
+km/hp. 36
km/hp. 36
+0 – 4,5p. 36
0 – 4,5p. 36
+0 – 4,5p. 36
0 – 4,5p. 36
+Travel speed range II (forward/reverse)p. 36
Travel speed range II (forward/reverse)p. 36
+km/hp. 36
km/hp. 36
+0 – 12p. 36
0 – 12p. 36
+0 – 12p. 36
0 – 12p. 36
+Max. gradability (depending on soil)p. 36
Max. gradability (depending on soil)p. 36
+%p. 36
%p. 36
+100p. 36
100p. 36
+100p. 36
100p. 36
+Enginep. 36
Enginep. 36
+Engine manufacturerp. 36
Engine manufacturerp. 36
+Deutzp. 36
Deutzp. 36
+Deutzp. 36
Deutzp. 36
+Typep. 36
Typep. 36
+TCD 2015 V06p. 36
TCD 2015 V06p. 36
+TCD 2015 V06p. 36
TCD 2015 V06p. 36
+Coolingp. 36
Coolingp. 36
+Waterp. 36
Waterp. 36
+Waterp. 36
Waterp. 36
+Number of cylindersp. 36
Number of cylindersp. 36
+6p. 36
6p. 36
+6p. 36
6p. 36
+Rated power ISO 9249p. 36
Rated power ISO 9249p. 36
+kWp. 36
kWp. 36
+330p. 36
330p. 36
+330p. 36
330p. 36
+Rated power acc. to SAE J 1349p. 36
Rated power acc. to SAE J 1349p. 36
+hpp. 36
hpp. 36
+442p. 36
442p. 36
+442p. 36
442p. 36
+Rated speedp. 36
Rated speedp. 36
+rpmp. 36
rpmp. 36
+2100p. 36
2100p. 36
+2100p. 36
2100p. 36
+Electrical equipmentp. 36
Electrical equipmentp. 36
+Vp. 36
Vp. 36
+24p. 36
24p. 36
+24p. 36
24p. 36
+Drive systemp. 36
Drive systemp. 36
+hydrostaticp. 36
hydrostaticp. 36
+hydrostaticp. 36
hydrostaticp. 36
+Driven compactor wheelsp. 36
Driven compactor wheelsp. 36
+4p. 36
4p. 36
+4p. 36
4p. 36
+Compactor wheelsp. 36
Compactor wheelsp. 36
+Width, frontp. 36
Width, frontp. 36
+mmp. 36
mmp. 36
+1350p. 36
1350p. 36
+1350p. 36
1350p. 36
+Width, rearp. 36
Width, rearp. 36
+mmp. 36
mmp. 36
+1125p. 36
1125p. 36
+1125p. 36
1125p. 36
+Number of teeth, frontp. 36
Number of teeth, frontp. 36
+60p. 36
60p. 36
+60p. 36
60p. 36
+Number of teeth, rearp. 36
Number of teeth, rearp. 36
+50p. 36
50p. 36
+50p. 36
50p. 36
+Brakep. 36
Brakep. 36
+Service brakep. 36
Service brakep. 36
+hydrostaticp. 36
hydrostaticp. 36
+hydrostaticp. 36
hydrostaticp. 36
+Parking brakep. 37
Parking brakep. 37
+mechanicalp. 37
mechanicalp. 37
+mechanicalp. 37
mechanicalp. 37
+Emergency brakep. 37
Emergency brakep. 37
+hydro-mechanicalp. 37
hydro-mechanicalp. 37
+hydro-mechanicalp. 37
hydro-mechanicalp. 37
+Steeringp. 37
Steeringp. 37
+Type of steeringp. 37
Type of steeringp. 37
+Oscill.-articul.p. 37
Oscill.-articul.p. 37
+Oscill.-articul.p. 37
Oscill.-articul.p. 37
+Steering operationp. 37
Steering operationp. 37
+hydraulicp. 37
hydraulicp. 37
+hydraulicp. 37
hydraulicp. 37
+Steering anglep. 37
Steering anglep. 37
+± °p. 37
± °p. 37
+40p. 37
40p. 37
+40p. 37
40p. 37
+Oscillation anglep. 37
Oscillation anglep. 37
+± °p. 37
± °p. 37
+15p. 37
15p. 37
+15p. 37
15p. 37
+Inner track radiusp. 37
Inner track radiusp. 37
+mmp. 37
mmp. 37
+3090p. 37
3090p. 37
+3090p. 37
3090p. 37
+Dozer bladep. 37
Dozer bladep. 37
+Height adjustment above ground levelp. 37
Height adjustment above ground levelp. 37
+mmp. 37
mmp. 37
+1200p. 37
1200p. 37
+1200p. 37
1200p. 37
+Height adjustment below ground levelp. 37
Height adjustment below ground levelp. 37
+mmp. 37
mmp. 37
+120p. 37
120p. 37
+120p. 37
120p. 37
+Filling capacitiesp. 37
Filling capacitiesp. 37
+Fuel (diesel)p. 37
Fuel (diesel)p. 37
+lp. 37
lp. 37
+500p. 37
500p. 37
+500p. 37
500p. 37
+Engine oilp. 37
Engine oilp. 37
+lp. 37
lp. 37
+36p. 37
36p. 37
+36p. 37
36p. 37
+Coolantp. 37
Coolantp. 37
+lp. 37
lp. 37
+approx. 50p. 37
approx. 50p. 37
+approx. 50p. 37
approx. 50p. 37
+Hydraulic oilp. 37
Hydraulic oilp. 37
+lp. 37
lp. 37
+350p. 37
350p. 37
+350p. 37
350p. 37
Fig. 14p. 38
+Dimensions in mmp. 38
Dimensions in mmp. 38
+Ap. 38
Ap. 38
+Bp. 38
Bp. 38
+B2p. 38
+Bp. 38
2p. 38
+B3p. 38
+Bp. 38
3p. 38
+Dp. 38
Dp. 38
+Hp. 38
Hp. 38
+H2p. 38
+Hp. 38
2p. 38
+H4p. 38
+Hp. 38
4p. 38
+Kp. 38
Kp. 38
+Lp. 38
Lp. 38
+BC 772 RS-2p. 38
BC 772 RS-2p. 38
+3875p. 38
3875p. 38
+3800p. 38
3800p. 38
+3550p. 38
3550p. 38
+3775p. 38
3775p. 38
+1660p. 38
1660p. 38
+4120p. 38
4120p. 38
+3820p. 38
3820p. 38
+1800p. 38
1800p. 38
+600p. 38
600p. 38
+9275p. 38
9275p. 38
+Subject to technical alterations.p. 38
Subject to technical alterations.p. 39
+BC 772 RS-2p. 38
BC 772 RS-2p. 38
+Weightsp. 38
Weightsp. 38
+Operating weight (CECE)p. 38
Operating weight (CECE)p. 38
+kgp. 38
kgp. 38
+37300p. 38
37300p. 38
+Front axle load (CECE)p. 38
Front axle load (CECE)p. 38
+kgp. 38
kgp. 38
+20800p. 38
20800p. 38
+Rear axle load (CECE)p. 38
Rear axle load (CECE)p. 38
+kgp. 38
kgp. 38
+16500p. 38
16500p. 38
+Travel characteristicsp. 38
Travel characteristicsp. 38
+Travel speed range I (forward/reverse)p. 38
Travel speed range I (forward/reverse)p. 38
+km/hp. 38
km/hp. 38
+0 – 4,5p. 38
0 – 4,5p. 38
+Travel speed range II (forward/reverse)p. 38
Travel speed range II (forward/reverse)p. 38
+km/hp. 38
km/hp. 38
+0 – 12p. 38
0 – 12p. 38
+Max. gradability (depending on soil)p. 38
Max. gradability (depending on soil)p. 38
+%p. 38
%p. 38
+75p. 38
75p. 38
+Drivep. 38
Drivep. 38
+Engine manufacturerp. 38
Engine manufacturerp. 38
+Deutzp. 38
Deutzp. 38
+Typep. 38
Typep. 38
+TCD 2015 V06p. 38
TCD 2015 V06p. 38
+Coolingp. 38
Coolingp. 38
+Waterp. 38
Waterp. 38
+Number of cylindersp. 38
Number of cylindersp. 38
+6p. 38
6p. 38
+Rated power ISO 9249p. 38
Rated power ISO 9249p. 38
+kWp. 38
kWp. 38
+330p. 38
330p. 38
+Rated power acc. to SAE J 1349p. 38
Rated power acc. to SAE J 1349p. 38
+hpp. 38
hpp. 38
+442p. 38
442p. 38
+Rated speedp. 38
Rated speedp. 38
+rpmp. 38
rpmp. 38
+2100p. 38
2100p. 38
+Electrical equipmentp. 38
Electrical equipmentp. 38
+Vp. 38
Vp. 38
+24p. 38
24p. 38
+Drive systemp. 38
Drive systemp. 38
+hydrostaticp. 38
hydrostaticp. 38
+Driven compactor wheelsp. 38
Driven compactor wheelsp. 38
+4p. 38
4p. 38
+Compactor wheelsp. 38
Compactor wheelsp. 38
+Width, frontp. 38
Width, frontp. 38
+mmp. 38
mmp. 38
+1350p. 38
1350p. 38
+Width, rearp. 38
Width, rearp. 38
+mmp. 38
mmp. 38
+1125p. 38
1125p. 38
+Number of teeth, frontp. 38
Number of teeth, frontp. 38
+60p. 38
60p. 38
+Number of teeth, rearp. 38
Number of teeth, rearp. 38
+50p. 38
50p. 38
+Brakep. 39
Brakep. 39
+Service brakep. 39
Service brakep. 39
+hydrostaticp. 39
hydrostaticp. 39
+Parking brakep. 39
Parking brakep. 39
+mechanicalp. 39
mechanicalp. 39
+Emergency brakep. 39
Emergency brakep. 39
+hydro-mechanicalp. 39
hydro-mechanicalp. 39
+Steeringp. 39
Steeringp. 39
+Type of steeringp. 39
Type of steeringp. 39
+Oscill.-articul.p. 39
Oscill.-articul.p. 39
+Steering operationp. 39
Steering operationp. 39
+hydraulicp. 39
hydraulicp. 39
+Steering anglep. 39
Steering anglep. 39
+± °p. 39
± °p. 39
+30p. 39
30p. 39
+Oscillation anglep. 39
Oscillation anglep. 39
+± °p. 39
± °p. 39
+15p. 39
15p. 39
+Inner track radiusp. 39
Inner track radiusp. 39
+mmp. 39
mmp. 39
+3750p. 39
3750p. 39
+Dozer bladep. 39
Dozer bladep. 39
+Height adjustment above ground levelp. 39
Height adjustment above ground levelp. 39
+mmp. 39
mmp. 39
+5350p. 39
5350p. 39
+Height adjustment below ground levelp. 39
Height adjustment below ground levelp. 39
+mmp. 39
mmp. 39
+50p. 39
50p. 39
+Filling capacitiesp. 39
Filling capacitiesp. 39
+Fuel (diesel)p. 39
Fuel (diesel)p. 39
+lp. 39
lp. 39
+750p. 39
750p. 39
+Engine oilp. 39
Engine oilp. 39
+lp. 39
lp. 39
+36p. 39
36p. 39
+Hydraulic oilp. 39
Hydraulic oilp. 39
+lp. 39
lp. 39
+350p. 39
350p. 39
+Coolantp. 39
Coolantp. 39
+lp. 39
lp. 39
+approx. 50p. 39
approx. 50p. 39
Fig. 15p. 40
+Dimensions in mmp. 40
Dimensions in mmp. 40
+Ap. 40
Ap. 40
+Bp. 40
Bp. 40
+B2p. 40
+Bp. 40
2p. 40
+B3p. 40
+Bp. 40
3p. 40
+Dp. 40
Dp. 40
+Hp. 40
Hp. 40
+H2p. 40
+Hp. 40
2p. 40
+H4p. 40
+Hp. 40
4p. 40
+Kp. 40
Kp. 40
+Lp. 40
Lp. 40
+BC 672 EB-2p. 40
BC 672 EB-2p. 40
+3500p. 40
3500p. 40
+3800p. 40
3800p. 40
+3550p. 40
3550p. 40
+3425p. 40
3425p. 40
+1580p. 40
1580p. 40
+4120p. 40
4120p. 40
+3820p. 40
3820p. 40
+1050p. 40
1050p. 40
+600p. 40
600p. 40
+8120p. 40
8120p. 40
+BC 772 EB-2p. 40
BC 772 EB-2p. 40
+3500p. 40
3500p. 40
+3800p. 40
3800p. 40
+3550p. 40
3550p. 40
+3775p. 40
3775p. 40
+1580p. 40
1580p. 40
+4120p. 40
4120p. 40
+3820p. 40
3820p. 40
+1050p. 40
1050p. 40
+600p. 40
600p. 40
+8120p. 40
8120p. 40
+Subject to technical alterations, technical data may deviate for optional equipmentp. 40
Subject to technical alterations, technical data may deviate for optional equipmentp. 41
+Pilot pressure control start at engine speedp. 42
Pilot pressure control start at engine speedp. 42
+6 bar at 1025 rpmp. 42
6 bar at 1025 rpmp. 42
+_Absolute pressure at control startp. 42
_Absolute pressure at control startp. 42
+50 bar at 1025 rpmp. 42
50 bar at 1025 rpmp. 42
+__Corresponds with pump speedp. 42
__Corresponds with pump speedp. 42
+rpmp. 42
rpmp. 42
+1150 ± 50p. 42
1150 ± 50p. 42
+Pilot pressure at control endp. 42
Pilot pressure at control endp. 42
+14 bar at 1700 rpmp. 42
14 bar at 1700 rpmp. 42
+_Absolute pressure at control endp. 42
_Absolute pressure at control endp. 42
+400 bar at 1700 rpmp. 42
400 bar at 1700 rpmp. 42
+Travel motorsp. 42
Travel motorsp. 42
+Manufacturerp. 42
Manufacturerp. 42
+Bosch-Rexrothp. 42
Bosch-Rexrothp. 42
+Typep. 42
Typep. 42
+A6VM 160 HA 2Tp. 42
A6VM 160 HA 2Tp. 42
+Quantityp. 42
Quantityp. 42
+4p. 42
4p. 42
+Systemp. 42
Systemp. 42
+Axial piston – bent axlep. 42
Axial piston – bent axlep. 42
+Displacement (stage 1)p. 42
Displacement (stage 1)p. 42
+cm3/rev.p. 42
+cmp. 42
3p. 42
+160p. 42
160p. 42
+Displacement (stage 2)p. 42
Displacement (stage 2)p. 42
+cm3/rev.p. 42
+cmp. 42
3p. 42
+50p. 42
50p. 42
+Control start change-overp. 42
Control start change-overp. 42
+barp. 42
barp. 42
+280 ± 5p. 42
280 ± 5p. 42
+Control end change-overp. 42
Control end change-overp. 42
+barp. 42
barp. 42
+380 ± 10p. 42
380 ± 10p. 42
+Perm. leak oil ratep. 42
Perm. leak oil ratep. 42
+l/minp. 42
l/minp. 42
+7p. 42
7p. 42
+Wheel drivep. 42
Wheel drivep. 42
+Manufacturerp. 42
Manufacturerp. 42
+Bosch-Rexrothp. 42
Bosch-Rexrothp. 42
+Typep. 42
Typep. 42
+GFT 110 R3p. 42
GFT 110 R3p. 42
+Reduction ratiop. 42
Reduction ratiop. 42
+83p. 42
83p. 42
+Wheel drivep. 42
Wheel drivep. 42
+from serial numberp. 42
from serial numberp. 42
+101 570 591 019 BC 672 RB-2p. 42
101 570 591 019 BC 672 RB-2p. 42
+Manufacturerp. 42
Manufacturerp. 42
+Bonfigliolip. 42
Bonfigliolip. 42
+Typep. 42
Typep. 42
+716 C 3Bp. 42
716 C 3Bp. 42
+Steering/working pumpp. 42
Steering/working pumpp. 42
+Typep. 43
Typep. 43
+A10VO 71 DFRp. 43
A10VO 71 DFRp. 43
+Systemp. 43
Systemp. 43
+Axial piston/swash platep. 43
Axial piston/swash platep. 43
+Max. displacementp. 43
Max. displacementp. 43
+cm3/rev.p. 43
+cmp. 43
3p. 43
+71p. 43
71p. 43
+Max. dozer plate pressurep. 43
Max. dozer plate pressurep. 43
+barp. 43
barp. 43
+230 + 10p. 43
230 + 10p. 43
+Max. steering pressurep. 43
Max. steering pressurep. 43
+barp. 43
barp. 43
+200 + 10p. 43
200 + 10p. 43
+Stand-by pressurep. 43
Stand-by pressurep. 43
+barp. 43
barp. 43
+30 ± 2p. 43
30 ± 2p. 43
+Valve block, working hydraulicsp. 43
Valve block, working hydraulicsp. 43
+Typep. 43
Typep. 43
+2M6-22p. 43
2M6-22p. 43
+Max. steering pressurep. 43
Max. steering pressurep. 43
+barp. 43
barp. 43
+230 + 10p. 43
230 + 10p. 43
+Max. dozer plate pressurep. 43
Max. dozer plate pressurep. 43
+barp. 43
barp. 43
+230 + 10p. 43
230 + 10p. 43
+LS-pressure limitationp. 43
LS-pressure limitationp. 43
+barp. 43
barp. 43
+210 + 10p. 43
210 + 10p. 43
+Tank pre-loading valvep. 43
Tank pre-loading valvep. 43
+barp. 43
barp. 43
+18p. 43
18p. 43
+Charge circuit filterp. 43
Charge circuit filterp. 43
+micronp. 43
micronp. 43
+12p. 43
12p. 43
+Return flow filterp. 43
Return flow filterp. 43
+micronp. 43
micronp. 43
+80p. 43
80p. 43
The following noise and vibration values according to the EC-directive for machines, edition (98/37/EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing o…p. 44
During operation these values may vary because of the existing operating conditions.p. 44
+Noise valuep. 44
Noise valuep. 44
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation isp. 44
sound pressure level at the work place of the operator (with cabin):p. 44
+Lp. 44
pAp. 44
The nose emission value for the machine according to the noise emission regulation 2000/14/EG isp. 44
guaranteed sound capacity level of the machine:p. 44
+Lp. 44
WAp. 44
+Lp. 44
WAp. 44
+These sound values were determined according to ISO 3744 for the sound capacity level (Lp. 44
wAp. 44
pAp. 44
+Vibration valuep. 44
Vibration valuep. 44
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:p. 44
Vibration of the entire body (driver’s seat)p. 44
+The weighted effective acceleration value determined according to ISO 7096 isp. 44
2p. 44
Hand-arm vibration valuesp. 44
+The weighted effective acceleration value determined according to EN 500/ISO isp. 44
2p. 44
+3 Maintenancep. 45
3 Maintenancep. 45
+3.1 General notes on maintenancep. 46
3.1 General notes on maintenancep. 46
+When performing maintenance work always comply with the appropriate safety regulations.p. 46
When performing maintenance work always comply with the appropriate safety regulations.p. 46
Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing t…p. 46
The terms right/left correspond with travel direction forward.p. 46
+l Always clean machine and engine thoroughly before starting maintenance work.p. 46
l Always clean machine and engine thoroughly before starting maintenance work.p. 46
l For maintenance work stand the machine on level ground.p. 46
l Always remove the main battery switch for all maintenance work.p. 46
l Perform maintenance work only with the motor switched off.p. 46
l Relieve hydraulic pressures before working on hydraulic lines.p. 46
l Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 46
l When working in the area of the articulated joint attach the articulation lock (transport lock).p. 46
+During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.p. 46
During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.p. 46
Keep used filters in a separate waste container and dispose of environmentally.p. 46
Catch biodegradable oils separately.p. 46
+Notes on the fuel systemp. 46
Notes on the fuel systemp. 46
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 46
+l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 46
l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 46
l Drums with inside zinc lining are not suitable to store fuel.p. 46
l When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.p. 46
l Do not let the hose stir up the slurry at the bottom of the drum.p. 46
l The fuel drum must rest for a longer period of time before drawing off fuel.p. 46
l The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 46
+Notes on the performance of the enginep. 46
Notes on the performance of the enginep. 46
On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.p. 46
If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.p. 46
+Notes on the cooling systemp. 46
Notes on the cooling systemp. 46
Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 46
Coolant is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water.p. 46
Mixing with cooling system protection agent is necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.p. 46
+Notes on the hydraulic systemp. 46
Notes on the hydraulic systemp. 46
During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles a…p. 46
+l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 46
l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 46
l Seal external leaks immediately. If necessary inform the responsible customer service.p. 46
l Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes.p. 46
l Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.p. 46
l Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 46
l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 46
+Welding work on the refuse compactorp. 46
Welding work on the refuse compactorp. 46
+l Disconnect the main battery switchp. 46
l Disconnect the main battery switchp. 46
+l Pull the plugs off all control units, engine control unit (EMR), travel control (ESX) and additional control (DIOS).p. 46
l Pull the plugs off all control units, engine control unit (EMR), travel control (ESX) and additional control (DIOS).p. 46
+3.2 Fuels and lubricantsp. 47
3.2 Fuels and lubricantsp. 47
+Engine oilp. 47
Engine oilp. 47
Qualityp. 47
For use in DEUTZ engines the lubrication oils are classified in DEUTZ Lubrication Oil Quality Classes (DQC).p. 47
Use only oils complying with DQC III-05 or DQC IV- 05.p. 47
The list of approved lubrication oils is also available in the Internet under the following address:p. 47
+www.deutz.comp. 47
www.deutz.comp. 47
+dep. 47
dep. 47
+>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >> DQC-Release listp. 47
>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >> DQC-Release listp. 47
+enp. 47
enp. 47
+>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >>DQC- release listp. 47
>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >>DQC- release listp. 47
Consult your local service station if in doubt.p. 47
+l Use winter grade engine oil for winter operation!p. 47
l Use winter grade engine oil for winter operation!p. 47
Oil viscosityp. 47
Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class) .p. 47
Too high viscosity can cause starting difficulties, too low ´viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption.p. 47
Fig. 16p. 47
+Optimal operating conditions can be achieved by using the oil viscosity chartp. 47
(Fig. 16)p. 47
At ambient temperatures below -40 °C the lubrication oil must be pre-heated (e.g. by parking the machine indoors).p. 47
The viscosity is classified acc. to SAE. Multi-purpose oils should generally be used.p. 47
Oil change intervalsp. 47
The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operati…p. 47
+DQC III, DQC IVp. 47
DQC III, DQC IVp. 47
500 operating hoursp. 47
+When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10°C and when using biodegradable diesel fuel the oil change intervals must be halved.p. 47
When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10°C and when using biodegradable diesel fuel the oil change intervals must be halved.p. 47
+Fuelsp. 47
Fuelsp. 47
You should only use commercially available brand diesel fuel with a sulphur content of less than 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals.p. 47
The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.p. 48
Qualityp. 48
The following fuel specifications are permitted:p. 48
+l EN 590p. 48
l EN 590p. 48
l DIN 51628p. 48
l ASTM D975 Grade-No. 1-D and 2-D.p. 48
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication properties acc. to EN 590p. 48
Winter fuelp. 48
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.p. 48
In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.p. 48
+Coolantp. 48
Coolantp. 48
For fluid cooled engines the cooling fluid must be prepared by admixing a cooling system protection agent to the fresh water and should be checked within the specified maintenance intervals.p. 48
This prevents damage caused by corrosion, cavitation, freezing and overheating.p. 48
Fresh water qualityp. 48
The correct quality of water is highly important when preparing coolant. Clear and clean water within the boundaries of the following analysis values should generally be used.p. 48
+Fresh water analysis valuesp. 48
Fresh water analysis valuesp. 48
+pH-value at 20 °Cp. 48
pH-value at 20 °Cp. 48
+6.5 – 8.5p. 48
6.5 – 8.5p. 48
+Chloride ion content (mg/l) (ppm)p. 48
Chloride ion content (mg/l) (ppm)p. 48
+max. 100p. 48
max. 100p. 48
+Sulphate ion content (mg/l) (ppm)p. 48
Sulphate ion content (mg/l) (ppm)p. 48
+max. 100p. 48
max. 100p. 48
+Total hardness [°dGH]p. 48
Total hardness [°dGH]p. 48
+3 – 12p. 48
3 – 12p. 48
+corresponds with a potash ion content (mmol/l) ofp. 48
corresponds with a potash ion content (mmol/l) ofp. 48
+0.54 – 3.56p. 48
0.54 – 3.56p. 48
+Carbon hardness proportion of the total hardness (°d)p. 48
Carbon hardness proportion of the total hardness (°d)p. 48
+min. 3p. 48
min. 3p. 48
+corresponds with a content of CaCO3 (mg/l) (ppm)p. 48
+corresponds with a content of CaCOp. 48
3p. 48
+min. 53.4p. 48
min. 53.4p. 48
Information concerning the water quality can be obtained from the waterworks.p. 48
If the fresh water analysis values are unknown, these must be determined with the help of a water analysis.p. 48
If the values of the analysis deviate, the water must be treated accordingly.p. 48
+l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 48
l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 48
l Total hardness or chlorides and/or sulphates too high: Mixing with dehardened water (e.g. distilled water).p. 48
l Total hardness or carbonate hardness too low: Mixing with hardened water (harder water is in most cases available in the form of drinking water).p. 48
+Another analysis must be made after the fresh water has been prepared.p. 48
Another analysis must be made after the fresh water has been prepared.p. 48
Cooling system protection agentp. 48
As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.p. 48
Coolant for fluid cooled engines is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water.p. 48
We therefore highly recommend our BOMAG cooling system protection agent (BOMAG part-no. 009 940 08)..p. 48
If our cooling system protection agent is not available for any important reasons, you may, in exceptional cases, use products that have been approved by the engine manufacturer.p. 48
The list of approved cooling system protection agents can be found in the internet under www.deutz.com >>SERVICE >> Fuels and lubricants and diagnostics >> Collig system protection >>Technical circular Cooling System Protection Agents.p. 48
Products of the same product group (see Deutz Technical Circular Cooling System Protection Agents) can be mixed with each other.p. 48
The BOMAG cooling system protection agent corresponds with product group A.p. 48
+Do not mix different coolants and additives of any other kind.p. 48
Do not mix different coolants and additives of any other kind.p. 48
Before changing the product you must clean the entire cooling system.p. 48
Consult your local service station if in doubt.p. 48
To ensure proper corrosion protection you must use the cooling system protection agent all year around, whereby the following concentration must not be fallen short of or exceeded.p. 48
+Mixing ratiop. 49
Mixing ratiop. 49
+Cooling system protection agentp. 49
Cooling system protection agentp. 49
+Fresh waterp. 49
Fresh waterp. 49
+Cold protection down top. 49
Cold protection down top. 49
+min. 35%p. 49
min. 35%p. 49
+65%p. 49
65%p. 49
+-22 °Cp. 49
-22 °Cp. 49
+40%p. 49
40%p. 49
+60%p. 49
60%p. 49
+-28 °Cp. 49
-28 °Cp. 49
+max. 45%p. 49
max. 45%p. 49
+55%p. 49
55%p. 49
+-35 °Cp. 49
-35 °Cp. 49
+A proportion of more than 45% of cooling system protection agent causes a drop in cooling power.p. 49
A proportion of more than 45% of cooling system protection agent causes a drop in cooling power.p. 49
The use of corrosion protection oils as cooling system protection agents is not permitted.p. 49
+When working at temperature below -35 °C you should consult our local service representative.p. 49
When working at temperature below -35 °C you should consult our local service representative.p. 49
+Coolant must be disposed of environmentally.p. 49
Coolant must be disposed of environmentally.p. 49
+Mineral oil based hydraulic oilp. 49
Mineral oil based hydraulic oilp. 49
+The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mmp. 49
2p. 49
+Bio-degradable hydraulic oilp. 49
Bio-degradable hydraulic oilp. 49
The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.p. 49
The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524.p. 49
In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up.p. 49
When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.p. 49
+Check the filter more frequently after this change.p. 49
Check the filter more frequently after this change.p. 49
Perform regular oil analyses for content of water and mineral oil.p. 49
Replace the hydraulic oil filter element every 500 operating hours.p. 49
+Gear oilp. 49
Gear oilp. 49
Qualityp. 49
+For the gearboxes use only ,ulti-purpose gear oils ISO VG 220 of API-GL5-class with a minimum viscosity of 20 mmp. 49
2p. 49
This is a hypoid lubricant of highest quality class for extremely loaded transmissions.p. 49
The additives in this oil ensure low wear lubrication under all operating conditions.p. 49
+Lubrication greasep. 49
Lubrication greasep. 49
For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G.p. 49
3.3 Table of fuels and lubricantsp. 50
+Assemblyp. 50
Assemblyp. 50
+Fuel or lubricantp. 50
Fuel or lubricantp. 50
+Quantityp. 50
Quantityp. 50
+Summerp. 50
Summerp. 50
+Winterp. 50
Winterp. 50
+Attentionp. 50
+Attentionp. 50
Attentionp. 50
Observe the level marksp. 50
+Enginep. 50
Enginep. 50
+– Engine oilp. 50
– Engine oilp. 50
+DQC III or IVp. 50
DQC III or IVp. 50
+approx. 36 litresp. 50
approx. 36 litresp. 50
+SAE 10W-40 (-20 °C to +40 °C)p. 50
SAE 10W-40 (-20 °C to +40 °C)p. 50
+SAE 10W/40 (-15 °C to +40 °C)p. 50
SAE 10W/40 (-15 °C to +40 °C)p. 50
+SAE 5W-40 (-30 °C to +40 °C)p. 50
SAE 5W-40 (-30 °C to +40 °C)p. 50
+SAE 5W-30 (-30 °C to +30 °C)p. 50
SAE 5W-30 (-30 °C to +30 °C)p. 50
+– Fuelp. 50
– Fuelp. 50
+Dieselp. 50
Dieselp. 50
+Winter diesel fuelp. 50
Winter diesel fuelp. 50
+approx. 500 litresp. 50
approx. 500 litresp. 50
+– Coolantp. 50
– Coolantp. 50
+Mixture of water and anti-freeze agentp. 50
Mixture of water and anti-freeze agentp. 50
(see "Fuels and Lubricants – Colant")p. 50
+approx. 50 litresp. 50
approx. 50 litresp. 50
+Hydraulic systemp. 50
Hydraulic systemp. 50
+Hydraulic oil (ISO), HV46, kinem. Viscosity 46 mm2/s at 40 °C with viscosity index (VI) >150 or biodegradable ester based hydraulic oilp. 50
+The following service work must be performed when taking new machines into operation.p. 51
The following service work must be performed when taking new machines into operation.p. 51
+Up to approx. 250 operating hours check the engine oil level twice every day.p. 51
Up to approx. 250 operating hours check the engine oil level twice every day.p. 51
Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours.p. 51
After a running time of 15 minutes retighten the V- belts for generator and air conditioning compressor.p. 51
Maintenance after 50 operating hoursp. 51
+l Changing engine oil and oil filterp. 51
l Changing engine oil and oil filterp. 51
l Change the oil in the drive gears.p. 51
l Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.p. 51
l Retighten all bolted connections on the machine.p. 51
Maintenance after 500 operating hoursp. 51
+l Change the oil in splitter gear and oil filter.p. 51
l Change the oil in splitter gear and oil filter.p. 51
+l Change the oil in the drive gears.p. 51
l Change the oil in the drive gears.p. 51
Special intervalsp. 51
+l Switch the air conditioning on every month for about 10 minutes.p. 51
l Switch the air conditioning on every month for about 10 minutes.p. 51
3.5 Maintenance tablep. 52
+No.p. 52
No.p. 52
+Maintenance workp. 52
Maintenance workp. 52
+Commentp. 52
Commentp. 52
+every 10 operating hours, dailyp. 52
every 10 operating hours, dailyp. 52
+every 500 oper. hoursp. 52
every 500 oper. hoursp. 52
+every 1000 oper. hoursp. 52
every 1000 oper. hoursp. 52
+every 2000 oper. hoursp. 52
every 2000 oper. hoursp. 52
+every 4000 oper. hoursp. 52
every 4000 oper. hoursp. 52
+every 6000 oper. hoursp. 52
every 6000 oper. hoursp. 52
+as requiredp. 52
as requiredp. 52
+5.6p. 52
5.6p. 52
+Checking the engine oil levelp. 52
Checking the engine oil levelp. 52
+Dipstick markp. 52
Dipstick markp. 52
+Xp. 52
Xp. 52
+5.7p. 52
5.7p. 52
+Check the fuel levelp. 52
Check the fuel levelp. 52
+Instrument clusterp. 52
Instrument clusterp. 52
+Xp. 52
Xp. 52
+5.8p. 52
5.8p. 52
+Check the hydraulic oil levelp. 52
Check the hydraulic oil levelp. 52
+Inspection glassp. 52
Inspection glassp. 52
+Xp. 52
Xp. 52
+5.9p. 52
5.9p. 52
+Check the coolant levelp. 52
Check the coolant levelp. 52
+Instrument clusterp. 52
Instrument clusterp. 52
+Xp. 52
Xp. 52
+5.10p. 52
5.10p. 52
+Check the oil level in the transfer boxp. 52
Check the oil level in the transfer boxp. 52
+Inspection glassp. 52
Inspection glassp. 52
+Xp. 52
Xp. 52
+5.11p. 52
5.11p. 52
+Visual inspection of the machine for damage and leaksp. 52
Visual inspection of the machine for damage and leaksp. 52
+Xp. 52
Xp. 52
+5.12p. 52
5.12p. 52
+Lubricate joints and bearings on the bucket (RS).p. 52
Lubricate joints and bearings on the bucket (RS).p. 52
+Xp. 52
Xp. 52
+5.13p. 52
5.13p. 52
+Change engine oil and oil filterp. 52
+Change engine oil and oil filterp. 52
Running-in instructions: after 50 operating hours change the oil; oil change intervals depend on fuel quality (sulphur content); with a fuel consumption of > 50 l/h the oil must be changed every 250 operating hoursp. 54
+min. 1x per yearp. 52
min. 1x per yearp. 52
see foot notep. 52
+Xp. 52
Xp. 52
+5.14p. 52
5.14p. 52
+Check, clean the water separatorp. 52
Check, clean the water separatorp. 52
+when the "water in fuel" warning light lights upp. 52
when the "water in fuel" warning light lights upp. 52
+Xp. 52
Xp. 52
+5.15p. 52
5.15p. 52
+Service the generator V-beltp. 52
Service the generator V-beltp. 52
+Xp. 52
Xp. 52
+5.16p. 52
5.16p. 52
+Check the V-belt for the air conditioning compressorp. 52
Check the V-belt for the air conditioning compressorp. 52
+Xp. 52
Xp. 52
+5.17p. 52
5.17p. 52
+Service the fan V-beltp. 52
Service the fan V-beltp. 52
+Xp. 52
Xp. 52
+5.18p. 52
5.18p. 52
+Battery service, checking the main battery switchp. 52
Battery service, checking the main battery switchp. 52
+pole greasep. 52
pole greasep. 52
+Xp. 52
Xp. 52
+5.19p. 52
5.19p. 52
+Check the engine mountsp. 52
Check the engine mountsp. 52
+Xp. 52
Xp. 52
+5.20p. 52
5.20p. 52
+Servicing the air conditioningp. 52
Servicing the air conditioningp. 52
+Xp. 52
Xp. 52
+5.21p. 52
5.21p. 52
+Check the condition of radiator, intercooler and hydraulic oil cooler, clean, clean the enginep. 52
Check the condition of radiator, intercooler and hydraulic oil cooler, clean, clean the enginep. 52
+also if the engine temperature or hydraulic oil temperature warning lights light upp. 52
also if the engine temperature or hydraulic oil temperature warning lights light upp. 52
+Xp. 52
Xp. 52
+5.22p. 52
5.22p. 52
+Check the fastening of the scrapersp. 52
Check the fastening of the scrapersp. 52
+Xp. 52
Xp. 52
+5.23p. 52
5.23p. 52
+Check the oil level in the travel gearp. 52
Check the oil level in the travel gearp. 52
+Xp. 52
Xp. 52
+5.24p. 52
5.24p. 52
+Check the central lubrication system, fill upp. 52
Check the central lubrication system, fill upp. 52
+Xp. 52
Xp. 52
+5.25p. 53
5.25p. 53
+Replace the fresh air and circulation air filtersp. 53
Replace the fresh air and circulation air filtersp. 53
+Xp. 53
Xp. 53
+5.26p. 53
5.26p. 53
+Check, adjust the valve clearancep. 53
Check, adjust the valve clearancep. 53
+Intake: 0.25 mmp. 53
Intake: 0.25 mmp. 53
Exhaust: 0.30 mmp. 53
+Xp. 53
Xp. 53
+5.27p. 53
5.27p. 53
+Replace the fuel filter cartridgesp. 53
Replace the fuel filter cartridgesp. 53
+Xp. 53
Xp. 53
+5.28p. 53
5.28p. 53
+Replacing the fuel pre-filter cartridge, bleed the fuel systemp. 53
Replacing the fuel pre-filter cartridge, bleed the fuel systemp. 53
+Xp. 53
Xp. 53
+5.29p. 53
5.29p. 53
+Check the anti-freeze concentration and the condition of the coolantp. 53
Check the anti-freeze concentration and the condition of the coolantp. 53
+Xp. 53
Xp. 53
+5.30p. 53
5.30p. 53
+Intercooler, draining off oil/condensation waterp. 53
Intercooler, draining off oil/condensation waterp. 53
+min. 1x per yearp. 53
min. 1x per yearp. 53
+Xp. 53
Xp. 53
+5.31p. 53
5.31p. 53
+Check fastening of engine/turbo charger/combustion air hosesp. 53
Check fastening of engine/turbo charger/combustion air hosesp. 53
+Xp. 53
Xp. 53
+5.32p. 53
5.32p. 53
+Oil change in travel gearp. 53
+Oil change in travel gearp. 53
Running-in instructions: oil change after 50, 500 and 1000 operating hours, then every 1000 operating hoursp. 54
+see foot notep. 53
see foot notep. 53
+Xp. 53
Xp. 53
+5.33p. 53
5.33p. 53
+Replace the fuel filter for the cabin heater (diesel)p. 53
Replace the fuel filter for the cabin heater (diesel)p. 53
+Xp. 53
Xp. 53
+5.34p. 53
5.34p. 53
+Check, clean the oil bath air filter for the cabin heaterp. 53
Check, clean the oil bath air filter for the cabin heaterp. 53
+Xp. 53
Xp. 53
+5.35p. 53
5.35p. 53
+Change the hydraulic oil fine filterp. 53
+Change the hydraulic oil fine filterp. 53
also after repairs in the hydraulic system.p. 54
+see foot notep. 53
see foot notep. 53
+Xp. 53
Xp. 53
+5.36p. 53
5.36p. 53
+Change hydraulic oil and breather filter **p. 53
Change hydraulic oil and breather filter **p. 53
+at least every 2 yearsp. 53
at least every 2 yearsp. 53
see foot notep. 53
+Xp. 53
Xp. 53
+5.37p. 53
5.37p. 53
+Change the coolantp. 53
Change the coolantp. 53
+Xp. 53
Xp. 53
+5.38p. 53
5.38p. 53
+Change oil and filter in the transfer boxp. 53
+Change oil and filter in the transfer boxp. 53
oil change after 500 and 2000 operating hours, then every 2000 operating hoursp. 54
+see foot notep. 53
see foot notep. 53
+Xp. 53
Xp. 53
+5.39p. 53
5.39p. 53
+Check condition of oscillating articulated jointp. 53
Check condition of oscillating articulated jointp. 53
+Xp. 53
Xp. 53
+5.40p. 53
5.40p. 53
+Change the injection valvesp. 53
Change the injection valvesp. 53
+only by authorized service personnelp. 53
only by authorized service personnelp. 53
+Xp. 53
Xp. 53
+5.41p. 53
5.41p. 53
+Change the crankcase ventilation valvep. 53
Change the crankcase ventilation valvep. 53
+Xp. 53
Xp. 53
+5.42p. 53
5.42p. 53
+Replace the coolant pumpp. 53
Replace the coolant pumpp. 53
+only by authorized service personnelp. 53
only by authorized service personnelp. 53
+Xp. 53
Xp. 53
+5.43p. 53
5.43p. 53
+Replace the pressure retaining valve on the injection pumpp. 53
Replace the pressure retaining valve on the injection pumpp. 53
+only by authorized service personnelp. 53
only by authorized service personnelp. 53
+Xp. 53
Xp. 53
+5.44p. 54
5.44p. 54
+Replace the glow plugsp. 54
Replace the glow plugsp. 54
+only by authorized service personnelp. 54
only by authorized service personnelp. 54
+Xp. 54
Xp. 54
+5.45p. 54
5.45p. 54
+Clean, change the dry air filter cartridgep. 54
Clean, change the dry air filter cartridgep. 54
+when the air filter warning light lights upp. 54
when the air filter warning light lights upp. 54
min. 1x per yearp. 54
+Xp. 54
Xp. 54
+5.46p. 54
5.46p. 54
+Clean the condenserp. 54
Clean the condenserp. 54
+Xp. 54
Xp. 54
+5.47p. 54
5.47p. 54
+Adjust scrapers and edge cuttersp. 54
Adjust scrapers and edge cuttersp. 54
+Xp. 54
Xp. 54
+5.48p. 54
5.48p. 54
+Replace the wheel capsp. 54
Replace the wheel capsp. 54
+Xp. 54
Xp. 54
+5.49p. 54
5.49p. 54
+Check the condition of the cutting blades, replace the cutting blades if necessaryp. 54
Check the condition of the cutting blades, replace the cutting blades if necessaryp. 54
+Xp. 54
Xp. 54
+5.50p. 54
5.50p. 54
+Fill the provision tank for the windscreen washer systemp. 54
Fill the provision tank for the windscreen washer systemp. 54
+Xp. 54
Xp. 54
+5.51p. 54
5.51p. 54
+Drain off dirty fluids from front and rear framep. 54
Drain off dirty fluids from front and rear framep. 54
+Xp. 54
Xp. 54
+5.52p. 54
5.52p. 54
+Tighten all bolted connectionsp. 54
Tighten all bolted connectionsp. 54
+Xp. 54
Xp. 54
+5.53p. 54
5.53p. 54
+Conservationp. 54
Conservationp. 54
+Xp. 54
Xp. 54
+4 Electricsp. 55
+4 Electricsp. 55
4.1 Understanding circuit diagramsp. 56
+Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry logics.p. 56
Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry logics.p. 56
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 56
+l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 56
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 56
l The sequence in which current flows through the individual elements in the electric circuit.p. 56
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.p. 56
l Pin assignment of plug-and-socket connections.p. 56
+Structurep. 56
Structurep. 56
+l Table of contentsp. 56
+l Table of contentsp. 56
(Fig. 17)p. 56
+l Function groupsp. 56
(Fig. 18)p. 56
+l List of componentsp. 56
(Fig. 20)p. 56
+Potential cross referencesp. 57
+Table of contentsp. 57
(Fig. 17)p. 57
The table of contents lists all function groups.p. 57
Fig. 17 Table of contentsp. 57
Example:p. 57
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.p. 57
+Potential cross referencesp. 58
+Function groupsp. 58
(Fig. 18)p. 58
On the individual pages the electric circuits are combined to function groups.p. 58
Arrangement of current pathsp. 58
The individual current paths must be read as follows:p. 58
+l From top (plus potential) to bottom (minus potential).p. 58
l From top (plus potential) to bottom (minus potential).p. 58
l From left to right.p. 58
l From function group to function group.p. 58
l Via cross references for potentials and relays.p. 58
Fig. 18 Function groupsp. 58
+Potential cross referencesp. 58
Potential cross referencesp. 58
+Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 58
Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 58
Example:p. 58
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page no. 8 in current path "1“.p. 58
+Relay cross referencep. 58
Relay cross referencep. 58
+Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 58
Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 58
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally attached to the bottom of each contactor coil.p. 58
Example:p. 58
The coil of relay (K99) is located on page no. 8 in current path "6".p. 58
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is triggered.p. 58
The changeover contact can be found on page no. 8 in current path "3".p. 58
+Current pathsp. 59
Current pathsp. 59
+The pages of a circuit diagram are sub-divided into current pathsp. 59
(Fig. 19)p. 59
Fig. 19 Current pathsp. 59
+Component cross referencesp. 60
+List of componentsp. 60
(Fig. 20)p. 60
Here you find all components used in alphabetical order, related to the name of the component (A01, A02….).p. 60
Fig. 20 List of componentsp. 60
+Component cross referencesp. 60
Component cross referencesp. 60
+Example:p. 60
Example:p. 60
The warning horn "B 11" is located on page no. 8 in current path 3.p. 60
4.2 Designation of components in the wiring diagramp. 61
+The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 61
The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 61
Control lights, warning buzzer, warning lightp. 61
+Kp. 61
Kp. 61
+Relaysp. 61
Relaysp. 61
+Mp. 61
Mp. 61
+Starter, pumps, motorsp. 61
Starter, pumps, motorsp. 61
+Pp. 61
Pp. 61
+Operating hour meter, general gaugesp. 61
Operating hour meter, general gaugesp. 61
+Rp. 61
Rp. 61
+Transducers, resistorsp. 61
Transducers, resistorsp. 61
+Sp. 61
Sp. 61
+Switches, momentary contact switchesp. 61
Switches, momentary contact switchesp. 61
+Vp. 61
Vp. 61
+Diodep. 61
Diodep. 61
+Xp. 61
Xp. 61
+Terminalp. 61
Terminalp. 61
+Yp. 61
Yp. 61
+Solenoid valvesp. 61
Solenoid valvesp. 61
4.3 Terminal designations in wiring diagramp. 62
+l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 62
+l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 62
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 62
+Terminal designationp. 62
Terminal designationp. 62
+Meaningp. 62
Meaningp. 62
+15p. 62
15p. 62
+Switch plus (after battery) : Output of ignition switchp. 62
Switch plus (after battery) : Output of ignition switchp. 62
+15ap. 62
15ap. 62
+Output from dropping resistor to ignition coil and starterp. 62
Output from dropping resistor to ignition coil and starterp. 62
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 62
Battery changeover relay 12V / 24V return line to battery 2 minusp. 62
+31bp. 62
31bp. 62
+Return line to battery minus or ground via switch or relay (switched minus)p. 62
Return line to battery minus or ground via switch or relay (switched minus)p. 62
+31cp. 62
31cp. 62
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 62
Battery changeover relay 12V / 24V return line to battery 1 minusp. 62
+49p. 62
49p. 62
+Input flasher relayp. 62
Input flasher relayp. 62
+49ap. 62
49ap. 62
+Output flasher relayp. 62
Output flasher relayp. 62
+49bp. 62
49bp. 62
+Flasher relay output 2nd flasher circuitp. 62
Flasher relay output 2nd flasher circuitp. 62
+49cp. 62
49cp. 62
+Flasher relay output 3rd flasher circuitp. 62
Flasher relay output 3rd flasher circuitp. 62
+50p. 62
50p. 62
+Starter, starter controlp. 62
Starter, starter controlp. 62
+50ap. 62
50ap. 62
+Battery changeover relay, output for starter controlp. 62
Battery changeover relay, output for starter controlp. 62
+53p. 62
53p. 62
+Wiper motor input (+)p. 62
Wiper motor input (+)p. 62
+53ap. 62
53ap. 62
+Wiper motor (+) end limit shut downp. 62
Wiper motor (+) end limit shut downp. 62
+53bp. 62
53bp. 62
+Wiper shunt windingp. 62
Wiper shunt windingp. 62
+56p. 62
56p. 62
+Head lightp. 62
Head lightp. 62
+56ap. 62
56ap. 62
+Head light, travel light and travel light controlp. 62
Head light, travel light and travel light controlp. 62
+56bp. 62
56bp. 62
+Head lights, dimmed head lightp. 62
Head lights, dimmed head lightp. 62
+56dp. 62
56dp. 62
+Head lights, flash lightp. 62
Head lights, flash lightp. 62
+57p. 62
57p. 62
+Parking light for motor cycles (abroad also for cars and trucks)p. 62
Parking light for motor cycles (abroad also for cars and trucks)p. 62
+57ap. 62
57ap. 62
+Parking lightp. 62
Parking lightp. 62
+57Lp. 62
57Lp. 62
+Parking light leftp. 62
Parking light leftp. 62
+57Rp. 62
57Rp. 62
+Parking light rightp. 62
Parking light rightp. 62
+58p. 62
58p. 62
+Side lights, tail light, number plate light, dashboard lightp. 62
Side lights, tail light, number plate light, dashboard lightp. 62
+58bp. 62
58bp. 62
+Tail light changeover for single axle trailersp. 62
Tail light changeover for single axle trailersp. 62
+58cp. 62
58cp. 62
+Trailer plug for single core wired and trailer fused tail lightp. 62
Trailer plug for single core wired and trailer fused tail lightp. 62
+58dp. 62
58dp. 62
+Adjustable dashboard light, tail light and side lightp. 62
Adjustable dashboard light, tail light and side lightp. 62
+58Lp. 62
58Lp. 62
+Side light, leftp. 62
Side light, leftp. 62
+58Rp. 62
58Rp. 62
+Side light, rightp. 62
Side light, rightp. 62
+61p. 62
61p. 62
+Generator controlp. 62
Generator controlp. 62
+75p. 62
75p. 62
+Radio, cigarette lighterp. 62
Radio, cigarette lighterp. 62
+76p. 62
76p. 62
+Loudspeakerp. 62
Loudspeakerp. 62
+87p. 62
87p. 62
+Relay contact on breaker and two-way contact, inputp. 62
Relay contact on breaker and two-way contact, inputp. 62
+87ap. 63
87ap. 63
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 63
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 63
+87bp. 63
87bp. 63
+Relay contact on breaker and two-way contact, output 2p. 63
Relay contact on breaker and two-way contact, output 2p. 63
+87cp. 63
87cp. 63
+Relay contact on breaker and two-way contact, output 3p. 63
Relay contact on breaker and two-way contact, output 3p. 63
+87zp. 63
87zp. 63
+Relay contact on breaker and two-way contact, input 1p. 63
Relay contact on breaker and two-way contact, input 1p. 63
+87yp. 63
87yp. 63
+Relay contact on breaker and two-way contact, input 2p. 63
Relay contact on breaker and two-way contact, input 2p. 63
+87xp. 63
87xp. 63
+Relay contact on breaker and two-way contact, input 3p. 63
Relay contact on breaker and two-way contact, input 3p. 63
+88p. 63
88p. 63
+Relay contact for makerp. 63
Relay contact for makerp. 63
+88ap. 63
88ap. 63
+Relay contact on maker and two-way contact, (maker side) output 1p. 63
Relay contact on maker and two-way contact, (maker side) output 1p. 63
+88bp. 63
88bp. 63
+Relay contact on maker and two-way contact, (maker side) output 2p. 63
Relay contact on maker and two-way contact, (maker side) output 2p. 63
+88cp. 63
88cp. 63
+Relay contact on maker and two-way contact, (maker side) output 3p. 63
Relay contact on maker and two-way contact, (maker side) output 3p. 63
+88zp. 63
88zp. 63
+Relay contact on maker, input 1p. 63
Relay contact on maker, input 1p. 63
+88yp. 63
88yp. 63
+Relay contact on maker, input 2p. 63
Relay contact on maker, input 2p. 63
+88xp. 63
88xp. 63
+Relay contact on maker, input 3p. 63
Relay contact on maker, input 3p. 63
+B+p. 63
B+p. 63
+Battery positivep. 63
Battery positivep. 63
+B-p. 63
B-p. 63
+Battery minusp. 63
Battery minusp. 63
+D+p. 63
D+p. 63
+Dynamo Plusp. 63
Dynamo Plusp. 63
+D-p. 63
D-p. 63
+Dynamo Minusp. 63
Dynamo Minusp. 63
+DFp. 63
DFp. 63
+Dynamo field (generator excitation current)p. 63
Dynamo field (generator excitation current)p. 63
+DF1p. 63
DF1p. 63
+Dynamo field 1 (generator excitation current)p. 63
Dynamo field 1 (generator excitation current)p. 63
+DF2p. 63
DF2p. 63
+Dynamo field 2 (generator excitation current)p. 63
Dynamo field 2 (generator excitation current)p. 63
4.4 Circuit symbols in the circuit diagramp. 64
+Circuit symbolp. 64
Circuit symbolp. 64
+l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in complianc…p. 64
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in complianc…p. 64
Fig. 1 Example: Circuit symbolp. 64
+1 Current sourcep. 64
1 Current sourcep. 64
2 Conductorp. 64
3 Switchp. 64
4 Groundp. 64
5 Filament lampp. 64
6 Filament lamp with two luminous elementsp. 64
7 Voltmeterp. 64
8 Amperemeterp. 64
9 Resistancep. 64
10 Backupp. 64
11 Line connection (fixed)p. 64
12 Line connection (separable)p. 64
4.5 Battery ground and analog groundp. 65
+GND, battery groundp. 65
GND, battery groundp. 65
The term "ground" (abbreviated GND) describes a conductive body which is normally defined with the potential of "Zero" Volt and represents the reference potential for operating voltages.p. 65
The positive pole of the supply voltage (symbol + ) and all other electric voltages and electical signals in an electrical circuitry refer to the ground potential.p. 65
On motor vehicles and also on motorbikes and bicycles the ground potential is represented by the chassis or the frame. As a conductive part, which covers the entire vehicle, it also serves a return conductor for the vehicle wiring system – the consum…p. 65
Terminal designation for GND = terminale 31p. 65
+AGND, analog groundp. 65
AGND, analog groundp. 65
Apart from the "normal" battery ground there is also the analog ground, which is solely reserved for sensors.p. 65
4.6 Current and voltagep. 65
+Generalp. 65
Generalp. 65
If one wants to describe electric current, this can most simply be accomplished by means of a comparison:p. 65
One simply compares electric current with water.p. 65
+Voltagep. 65
Voltagep. 65
Fig. 1p. 65
+1 (Fig. 1) Chargep. 65
+1 (Fig. 1) Chargep. 65
1 (Fig. 1)p. 65
2 Voltagep. 65
3 Currentp. 65
+The equalization attempt between different electric charges is referred to as electric voltage.p. 65
The equalization attempt between different electric charges is referred to as electric voltage.p. 65
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.p. 65
Fig. 2p. 65
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.p. 65
Plus pole= lack of electronsp. 65
Minus pole = excess of electronsp. 65
The following statements concerning electric voltage can be madep. 66
+l electric voltage is the pressure or force applied to free electrons.p. 66
l electric voltage is the pressure or force applied to free electrons.p. 66
l the electric voltage is the cause of electric currentp. 66
l electric voltage is a result of the equalization attempt of electric charges.p. 66
Voltage is measured with a Voltmeter.p. 66
Unit, Voltp. 66
The electric voltage (U) is measured in Volt (V).p. 66
Currentp. 66
+Electric current generally describes the directed movement of charge carriers.p. 66
Electric current generally describes the directed movement of charge carriers.p. 66
+l The charge carriers may either be electrons or ions.p. 66
l The charge carriers may either be electrons or ions.p. 66
l Electric current can only flow if there is a sufficient amount of free moving charge carriers.p. 66
l The higher the number of electrons flowing through a conductor per second, the higher the amperage.p. 66
Current is measured with an ammeter.p. 66
Unit, Amperep. 66
The electric amperage (I) is measured in Ampere (A).p. 66
The technical flow direction is specified from PLUS to MINUS.p. 66
+Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 66
Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 66
But since this was only discovered after the poles of a current source had already been designated, the assumption that current flows from plus to minus was maintained for historic reasons.p. 66
+Circuitp. 66
Circuitp. 66
Fig. 3 Circuitp. 66
+A simple circuit consists of a current source 1p. 66
(Fig. 3)p. 66
When the circuit is closed, current can flow.p. 66
The circuit can be interrupted or closed with a switch (2).p. 66
The system is protected by a fuse (4).p. 66
Types of currentp. 67
+Direct current (D.C.)p. 67
Direct current (D.C.)p. 67
Fig. 1 Direct current (D.C.)p. 67
Direct current flows with steady voltage and amperage from the plus to the minus pole.p. 67
Pure D.C.-voltages are only delivered by accumulators or batteries.p. 67
The voltage in the vehicle wiring system is no pure D.C.-voltage. Even without the generator running, but the consumers switched on, the voltage is not constant, but drops gradually according to the battery charge condition.p. 67
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off.p. 67
+Alternating current (A.C.)p. 67
Alternating current (A.C.)p. 67
Fig. 2 Alternating current (A.C.)p. 67
Alternating current not only changes its direction, but also its amperage.p. 67
4.7 Resistancep. 67
+Resistance and voltage dropp. 67
Resistance and voltage dropp. 67
+While current flows through a conductor the current flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.p. 67
While current flows through a conductor the current flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.p. 67
Fig. 1 Various size resistorsp. 67
+Each conductor has its specific resistance, which is characteristic for the corresponding material. A good conductor has a low resistance, a poor conductor has a high resistance.p. 67
Each conductor has its specific resistance, which is characteristic for the corresponding material. A good conductor has a low resistance, a poor conductor has a high resistance.p. 67
The resistance can only be measured with a Multimeter.p. 67
Symbol, Rp. 67
+Unit, Ohmp. 67
Wp. 67
+The electric resistance (R) is measured in Ohmp. 67
Wp. 67
Rule of thumb:p. 67
+l The thicker the cable cross-section, the lower the voltage loss.p. 67
l The thicker the cable cross-section, the lower the voltage loss.p. 67
l The shorter the cable, the better the current.p. 67
l The cleaner the contacts, the better the current.p. 68
l The quality of the ground cable is of the same importance as the supply line.p. 68
+Unnecessary resistancesp. 68
Unnecessary resistancesp. 68
+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.p. 68
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.p. 68
Badp. 68
Fig. 1 Screw-type terminalsp. 68
Copper wires are squashed and thus become faulty.p. 68
+Betterp. 68
Betterp. 68
Fig. 2 Spring clampsp. 68
Connecting clamps for flexible conductorsp. 68
BOMAG No. 057 565 72p. 68
Ampacity up to 20 Amp.p. 68
Cable cross-section 0.08 to 2.5 qmmp. 68
Fig. 3p. 68
+In many cases it is better to replace the contact. Soiled or oxidized contacts should be cleaned with Ballistolp. 68
(Fig. 4)p. 68
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.p. 68
Fig. 4 Balistol oilp. 68
Sometimes the flanks of flat plugs bend open. If these are closed again with the help of pliers the flanks will be excessively strained at the bend and will definitely break sooner or later. It is better to place a small nail under the bottom of the …p. 69
Fig. 5p. 69
Hint for practice:p. 69
A tool you cannot buy. The pliers were converted, the nail is permanently present.p. 69
4.8 Series / parallel connectionp. 69
+Series connectionp. 69
Series connectionp. 69
In a series circuit the resistors (consumers) are lined up one after the other and the same current (I) passes through each of the consumers However, series connection of consumers is not suitable in practice, as each resistance causes a voltage drop…p. 69
Fig. 1 Series connectionp. 69
Currentp. 69
In series connection the current is identical at every point.p. 69
Itotal = I1 = I2 = I3p. 69
Voltagep. 69
The sum of all partial voltages is identical with the total voltage.p. 69
Utotal = U1 + U2 + U3p. 69
Resistancep. 69
The sum of all partial resistances is identical with the total resistance.p. 69
Rtotal = R1 + R2 + R3p. 69
+Series connection of batteriesp. 69
Series connection of batteriesp. 69
Fig. 2p. 69
In order to achieve a vehicle voltage of 24 V two batteries of the same type and capacity must be connected in series mode.p. 69
+l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 70
l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 70
l The sum of all individual voltages is applied to the free poles.p. 70
l The total capacity (Ah) is identical with the capacity of the individual battery.p. 70
+Parallel connection of batteriesp. 70
Parallel connectionp. 70
In parallel connection all resistances (consumers) are connected between feed and return line.p. 70
+l All resistances (consumers) are supplied with the same voltage.p. 70
l All resistances (consumers) are supplied with the same voltage.p. 70
l Each of the resistances (consumers) draws as much current as required.p. 70
Fig. 3 Parallel connectionp. 70
Currentp. 70
The total current is the sum of all currents.p. 70
Itotal = I1 + I2 + I3p. 70
Voltagep. 70
The voltage values are identical at every resistance (consumer).p. 70
Utotal = U1 = U2 = U3p. 70
Resistancep. 70
The total resistance is less than the lowest individual resistance.p. 70
+Parallel connection of batteriesp. 70
Parallel connection of batteriesp. 70
Fig. 4p. 70
By connecting 2 batteries of same type and capacity in parallel mode the capacity can be doubled, because the individual capacities add up to the total capacity.p. 70
+l In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 71
l In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 71
l Plus and minus poles have the voltage of the single battery applied.p. 71
l The total capacity (Ah) is identical with the sum of all battery capacities.p. 71
The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of charging.p. 71
4.9 Ohm's lawp. 71
+In a closed electric circuit voltage, current and resistance must always be considered in close relation. This relation is represented by Ohm's Law.p. 71
In a closed electric circuit voltage, current and resistance must always be considered in close relation. This relation is represented by Ohm's Law.p. 71
Fig. 1p. 71
+According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohmp. 71
Wp. 71
Advicep. 71
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger.p. 71
Voltage U = I multiplied with Rp. 71
Resistance R = U divided by Ip. 71
Amperage I = U divided by Rp. 71
U = Voltage in Voltp. 71
I = Current in Amperep. 71
+R = Resistance in OHMp. 71
Wp. 71
4.10 Electrical energyp. 72
Fig. 1p. 72
In a closed electric circuit current and voltage generate energy.p. 72
If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced.p. 72
Advicep. 72
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger.p. 72
Energy P = I multiplied with Up. 72
Amperage I = P divided by Up. 72
Voltage U = P divided by Ip. 72
U = Voltage in Voltp. 72
I = Current in Amperep. 72
P = Power in Wattp. 72
4.11 Formula diagramp. 73
+Description:p. 73
Description:p. 73
+l Select the desired value from the inner circle.p. 73
l Select the desired value from the inner circle.p. 73
l Determine the formula variables in the quarter circlep. 73
l Calculatep. 73
Example:p. 73
P = 150 Wattp. 73
U = 24 Voltp. 73
Sought for = Current in Amperep. 73
I = P : U = 150 W : 24 Volt = 6.25 Amperep. 73
Fig. 1 Formula diagramp. 73
+Resistance, R Ohmp. 73
Wp. 73
Voltage, U Voltp. 73
Current, I Amperep. 73
Power, P Wattp. 73
4.12 Metrologyp. 74
+Test lampsp. 74
Test lampsp. 74
+Test lampp. 74
Test lampp. 74
Fig. 1 Test lampp. 74
+This type of tester must not be used for testing on electronic components. The high power consumption of the test lamp may destroy electronic components in the control units.p. 74
This type of tester must not be used for testing on electronic components. The high power consumption of the test lamp may destroy electronic components in the control units.p. 74
+Diode test lampp. 74
Diode test lampp. 74
This instrument is used for simple voltage measurements. The test lamp consists of two test points. The negative measuring cable is connected to ground and the positive measuring cable to the corresponding measuring location.p. 74
Fig. 2 Diode test lampp. 74
If voltage is present, the corresponding light emitting diode will light up.p. 74
Multimeterp. 74
+This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending on the design it may also be suitable for transistor and frequency.p. 74
This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending on the design it may also be suitable for transistor and frequency.p. 74
Fig. 1 Multimeterp. 74
In order to avoid damage:p. 74
+l the range selector switch must be correctly set for the corresponding measurement.p. 74
l the range selector switch must be correctly set for the corresponding measurement.p. 74
l the test cable must be plugged into the correct socket.p. 74
l the voltage type (AC/DC) must be set.p. 74
l In case of direct voltage the correct polarity must be assured.p. 74
l the measuring range should be chosen higher at the beginning of the test.p. 74
l In order to avoid any influence on the circuitry to be measured, the internal resistance of the voltage tester should be as high as possible.p. 74
Resistance and continuity measurement with multimeterp. 75
Fig. 2p. 75
The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points.p. 75
Fig. 3p. 75
The following information should be observed when measuring resistance and continuity:p. 75
+l The component to be measured must not be connected to the power supply during the measurement.p. 75
l The component to be measured must not be connected to the power supply during the measurement.p. 75
l At least one side of the component to be measured must be disconnected from the circuitry, as otherwise the measuring result may be influenced by parallel components.p. 75
l Polarity is of no significance.p. 75
Voltage and voltage drop measurement with multimeterp. 75
Fig. 4 Measuring voltagep. 75
+l Measurement at the voltage source measures the currently available Voltage.p. 75
l Measurement at the voltage source measures the currently available Voltage.p. 75
l The meter is always connected parallel to consumer, component or power source.p. 75
Fig. 5 Voltage measurementp. 75
+l A measurement at the consumer measures the voltage drop at this component.p. 75
l A measurement at the consumer measures the voltage drop at this component.p. 75
Current measurement with the multimeterp. 76
Fig. 6 Measuring currentp. 76
+l The meter is connected in series with the consumer.p. 76
l The meter is connected in series with the consumer.p. 76
l During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened.p. 76
Fig. 7 Current measurementp. 76
Advicep. 76
If the electric circuit is difficult to access and the internal resistance of the consumer is known, the voltage may also be measured at the consumer.p. 76
The current value can then be calculated with the help of Ohm's law.p. 76
Clip-on measuring instrumentp. 76
+The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 76
The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 76
Fig. 1 Clip-on measuring instrumentp. 76
Fig. 2p. 76
+l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 76
l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 76
Magnet testerp. 77
Fig. 1 Magnet testerp. 77
The magnet tester is used to test solenoid valves and magnetic coils.p. 77
The test lamp responds to the magnetic fields of A.C- voltage, D.C.-voltage and permanent magnets.p. 77
+l The component to be tested does not need to be removed.p. 77
l The component to be tested does not need to be removed.p. 77
l The magnetic coil can also be tested under a protective cap.p. 77
Power measurementp. 77
The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage.p. 77
However, there are also pure power meters with 4 connections available. The power meter has a electro- dynamic measuring mechanism. The current circuit must be opened for measuring. Take care when performing power measurements: Voltage or current pat…p. 77
Fig. 2p. 77
4.13 Diodes, relays, fusesp. 78
+Diodesp. 78
Diodesp. 78
Fig. 1p. 78
A diode consists of two different semi-conductors, which are connected by a separating layer. The max. conducting state current must not be exceeded.p. 78
Plus-voltage on diode:p. 78
+l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 78
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 78
Negative voltage on diode:p. 78
+l The diode does not allow current to pass through.p. 78
l The diode does not allow current to pass through.p. 78
Fig. 2 Marking of the cathodep. 78
Diodes are used:p. 78
+l For rectifying A.C. voltage.p. 78
l For rectifying A.C. voltage.p. 78
l For absorbing voltage peaks (free-wheeling diode).p. 78
l For construction of logical circuits.p. 78
+Diode logics and free-wheeling diodep. 78
Diode logics and free-wheeling diodep. 78
Fig. 3 Diode circuitryp. 78
+l The solenoid valve Y48p. 78
+l The solenoid valve Y48p. 78
(Fig. 3)p. 78
l Solenoid valve Y20 is supplied, if the switch is in position "1".p. 78
l Solenoid valve Y21 is supplied, if the switch is in position "2".p. 78
The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.p. 78
+Light emitting diodesp. 79
Light emitting diodesp. 79
Fig. 4 LEDp. 79
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-conductor crystal thereby emits a light signal, which is converged or scattered by the lenticula…p. 79
Relaysp. 79
Fig. 1 Relaysp. 79
Relays are commonly used to realize switching processes.p. 79
A free-wheeling diode prevents induction voltage from flowing back from the coil into the vehicle wiring system, which would cause interference with electronic components (control units).p. 79
With the possibility of using breaker – maker contacts the effect of an information can be reversed.p. 79
Fig. 2 Relay circuitryp. 79
+The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric currentp. 79
(Fig. 2)p. 79
86 = Positive supply for coilp. 79
85 = Ground supply for coilp. 80
30 = Supply voltagep. 80
87 = Normally open contactp. 80
87a= Normally closed contactp. 80
Fusesp. 80
Fig. 1p. 80
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.p. 80
+Fuses must not be repaired or bridged.p. 80
Fuses must not be repaired or bridged.p. 80
The melting time at 23 °C is:p. 80
+l approx. 1 hour with 1.5 times the rated currentp. 80
l approx. 1 hour with 1.5 times the rated currentp. 80
l approx. 1 minute with 2.5 times the rated current.p. 80
A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours.p. 80
Yellow = 5 Ap. 80
Brown = 7.5 Ap. 80
White = 8 Ap. 80
Red = 16 Ap. 80
Blue = 25 Ap. 80
4.14 Telemecanique switchp. 81
+Example of terminal designationsp. 81
Example of terminal designationsp. 81
Fig. 1 Terminal designationsp. 81
+l Normally open contact 23 located on block 2p. 81
l Normally open contact 23 located on block 2p. 81
l Normally open contact 24 located on block 2p. 81
l Normally closed contact 12 located on block 1p. 81
l Normally closed contact 11 located on block 1p. 81
l Normally open contact 34 located on block 3p. 81
l Normally open contact 33 located on block 3p. 81
l Normally open contact 63 located on block 6p. 81
l Normally open contact 64 located on block 6p. 81
l Normally open contact 43 located on block 4p. 81
l Normally open contact 44 located on block 4p. 81
+If e.g. block 5 is not needed to design a switch, the numbering for blocks 1,2,3,4 and 6 remains unchanged.p. 81
If e.g. block 5 is not needed to design a switch, the numbering for blocks 1,2,3,4 and 6 remains unchanged.p. 81
Disassemblyp. 82
Fig. 2 Disassemblyp. 82
+l Lift up the interlock (5).p. 82
l Lift up the interlock (5).p. 82
Fig. 3 Folding down the switch blockp. 82
+l Fold down the switch block (4).p. 82
l Fold down the switch block (4).p. 82
l Loosen screw (1).p. 82
Fig. 4 Pulling out the front elementp. 82
+l Lift up the interlock (2) and pull out the front element (3).p. 82
l Lift up the interlock (2) and pull out the front element (3).p. 82
Assemblyp. 83
Fig. 5 Assemblyp. 83
+l Insert the front element (3) into the bore in the control panel.p. 83
l Insert the front element (3) into the bore in the control panel.p. 83
Fig. 6 Observe the marks.p. 83
+l Clip the fastening adapter (6) onto the front element (3).p. 83
l Clip the fastening adapter (6) onto the front element (3).p. 83
+Watch the marls on front elementp. 83
+Watch the marls on front elementp. 83
(Fig. 6)p. 83
+l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 83
l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 83
Fig. 7 Assemble the switch blockp. 83
+l Clip on the switch block (4).p. 83
l Clip on the switch block (4).p. 83
+Hook in the switch block at the bottom firstp. 83
+Hook in the switch block at the bottom firstp. 83
(Fig. 7)p. 83
4.15 Plug connectorsp. 84
+Duties and requirementsp. 84
Duties and requirementsp. 84
Electric plug connectors must provide a reliable connection between different system components and thus ensure the safe function of the systems under any operating condition. There design ensures that they will withstand the applied loads throughout…p. 84
+Examples for these loads are:p. 84
Examples for these loads are:p. 84
+l Vibration accelerationp. 84
l Vibration accelerationp. 84
l Temperature fluctuations, high and low temperaturesp. 84
l Dampnessp. 84
l Micro movements of the contact with resulting friction corrosion.p. 84
These loads may increase the transition resistances of the contacts, up to total interruption. Even the insulation resistances may drop and thus cause short circuits in neighbouring lines. Electric plug connectors must therefore have the following pr…p. 84
+l Low transition resistances of the conductive parts.p. 84
l Low transition resistances of the conductive parts.p. 84
l High insulation strength between conductive parts with different voltage potentials.p. 84
l Excellent leak tightness against water and moisture.p. 84
Magnetic coil plugp. 85
+Magnetic coil plug with LED and suppressor diodep. 85
Magnetic coil plug with LED and suppressor diodep. 85
The plug is equipped with a polarized function display and a suppressor diode as protection against overvoltages.p. 85
Fig. 8p. 85
The plug is polarized, it does not matter whether Pin1 or Pin 2 is supplied with current, Pin 3 is not used. The LED lights if voltage is applied to the solenoid valve.p. 85
Fig. 9p. 85
Fig. 10 Switching symbol in circuit diagramp. 85
Magnetic coil plug without LED and without supressor diodep. 85
The plug has no LED and no suppressor diode as protection against overvoltages.p. 85
Assembly of magnetic coil plugsp. 86
These instructions are intended to explain the correct installation of the magnetic coil plug. The objective of the instructions is the correct installation of the plug and to avoid malfunctions in the field caused by moisture and any related corrosi…p. 86
Fig. 11 Solenoid valve plug with pointed cablep. 86
Fig. 12p. 86
+l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 86
l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 86
Fig. 13p. 86
+l Fasten the screw with a suitable screwdriver.p. 86
l Fasten the screw with a suitable screwdriver.p. 86
Fig. 14p. 86
+l Press the plug firmly on again.p. 86
l Press the plug firmly on again.p. 86
Fig. 15p. 86
+l Retighten the screw.p. 86
l Retighten the screw.p. 86
Fig. 16p. 87
+There should be no gap between plug and solenoid coil!p. 87
There should be no gap between plug and solenoid coil!p. 87
Fig. 17 Correctly installed plug without gapp. 87
4.17 Deutsch plug, series DT and DTMp. 87
+Generalp. 87
Generalp. 87
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.p. 87
Fig. 18 Crimp connectionsp. 87
+Do not crimp more than one lead per pin or per socket.p. 87
Do not crimp more than one lead per pin or per socket.p. 87
Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics).p. 87
When connecting sockets and plugs these must engage with a noticeable click when both halves interlock.p. 87
The plug connection should not be separable (without loosening the interlock).p. 87
Pulling testp. 87
This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing.p. 87
+l Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 87
l Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 87
+DT Seriesp. 88
DT Seriesp. 88
Fig. 1 DT plug connectionp. 88
Fig. 2 DT Seriesp. 88
Fig. 3 Sectional drawingp. 88
Installing DT contactsp. 89
Fig. 4p. 89
+l Insert the contacts through the rubber grommet until they click into place.p. 89
l Insert the contacts through the rubber grommet until they click into place.p. 89
l Insert the orange wedge in direction of arrow.p. 89
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 89
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 89
+Use the same method when assembling the socket.p. 89
Use the same method when assembling the socket.p. 89
Disassembling DT contactsp. 90
Fig. 5p. 90
+l Pull the orange wedge out with long nose pliers.p. 90
l Pull the orange wedge out with long nose pliers.p. 90
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 90
l Pull the contact out of the socket.p. 90
+Use the same method when assembling the socket.p. 90
Use the same method when assembling the socket.p. 90
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 90
DTM Seriesp. 91
Fig. 1 DTM plug connectionp. 91
Fig. 2 DTM Seriesp. 91
Fig. 3 Sectional drawingp. 91
Installing DTM contactsp. 92
Fig. 4p. 92
+l Insert the contacts through the rubber grommet until they click into place.p. 92
l Insert the contacts through the rubber grommet until they click into place.p. 92
l Insert the orange wedge, until it clicks into place.p. 92
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 92
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 92
+Use the same method when assembling the socket.p. 92
Use the same method when assembling the socket.p. 92
Disassembling DTM contactsp. 93
Fig. 5p. 93
+l Pull the orange wedge (interlock) out with long nose pliers.p. 93
l Pull the orange wedge (interlock) out with long nose pliers.p. 93
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 93
l Pull the contact out of the socket.p. 93
+Use the same method when assembling the socket.p. 93
Use the same method when assembling the socket.p. 93
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 93
+4.20 Battery service, check the main battery switchp. 94
4.18 Plugs and terminals in spring clamping technologyp. 94
+Generalp. 94
Generalp. 94
Fig. 1p. 94
+The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 94
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 94
+Spring clamp technologyp. 94
(Fig. 1)p. 94
+Connecting terminal for quick repairsp. 94
Connecting terminal for quick repairsp. 94
Fig. 2 That's how it worksp. 94
BOMAG part-no.: 057 565 72p. 94
+The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mmp. 94
2p. 94
2p. 94
2p. 94
(Fig. 2)p. 94
That's how it worksp. 94
+l Strip 9-10 mm of the lead.p. 94
l Strip 9-10 mm of the lead.p. 94
l Open the actuating lever and insert the strand.p. 94
l Return the actuating lever to initial position.p. 94
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 94
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 94
+X-COM plug clampp. 95
Series clampp. 95
Fig. 3 That's how it worksp. 95
That's how it worksp. 95
+l Insert a screw driver into the actuating opening until it bottoms.p. 95
l Insert a screw driver into the actuating opening until it bottoms.p. 95
l Strip 9-10 mm of the lead and insert it into the clamp.p. 95
l Pull out the screw driver.p. 95
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 95
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 95
Measuring signalsp. 95
On these terminal blocks the bridge slot is most suitable 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 …p. 95
Fig. 4 Test adapterp. 95
+X-COM plug clampp. 96
X-COM Systemp. 96
The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit for universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus become pluggable.p. 96
+X-COM plug clampp. 96
X-COM plug clampp. 96
Fig. 5 That's how it worksp. 96
That's how it worksp. 96
+l Insert a screw driver into the actuating opening until it bottoms.p. 96
l Insert a screw driver into the actuating opening until it bottoms.p. 96
l Strip 9-10 mm of the lead and insert it into the plug.p. 96
l Pull out the screw driver.p. 96
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 96
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 96
Fig. 6 X-COM plug with measuring cablep. 96
+l The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 96
l The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 96
Measuring signalsp. 97
Fig. 7 X-COM plug plugged onto the series clampp. 97
+4.20 Battery service, check the main battery switchp. 98
4.19 Batteriesp. 98
+Battery – accumulatorp. 98
Battery – accumulatorp. 98
Fig. 1p. 98
In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries.p. 98
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.p. 98
The basic element of a lead accumulator is the cell. It contains the plate blocks consisting of positive and negative plates. These plates are separated from each other by separators.p. 98
All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.p. 98
Fig. 2p. 98
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.p. 98
Capacityp. 98
is a synonym for the amount of current taken up and discharged by a battery over a specified period of time.p. 98
+Battery maintenancep. 98
Battery maintenancep. 98
+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.p. 98
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.p. 98
If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself.p. 98
The accumulator may only be discharged down to a final 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 ver…p. 98
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.p. 98
The following therefore applies for longer downtimes:p. 98
+l Remove the battery and store it in a cool, dry and frost protected room.p. 98
l Remove the battery and store it in a cool, dry and frost protected room.p. 98
l Check the open circuit voltage on the battery at regular intervals (at least once every month).p. 98
l Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).p. 98
+The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 98
The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 98
+Battery test in generalp. 98
Battery test in generalp. 98
+l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 98
l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 98
l Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar.p. 98
+4.20 Battery service, check the main battery switchp. 99
Batteries with screw plugsp. 99
+Checking the electrolyte levelp. 99
Checking the electrolyte levelp. 99
Fig. 3p. 99
+1 Upper filling level markp. 99
1 Upper filling level markp. 99
2 Lower filling level markp. 99
+l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 99
l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 99
Checking the electrolyte densityp. 99
Fig. 4p. 99
+The cells are filled with diluted sulphuric acid as electrolyte (approx. 25 Vol% sulphuric acid in distilled water), also referred to as accumulator acid, which has a density of 1.285 kg/dmp. 99
3p. 99
3p. 99
With a lead cell the acid density is therefore a measure for the charge condition. This characteristic is used to determine the charge condition of a lead battery. The so-called electrolyte tester (densimeter) is used for this purpose.p. 99
Fig. 5 Checking the electrolyte density:p. 99
1) correctp. 99
2) poorp. 99
3) poorp. 99
+(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 99
(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 99
Do not draw too much electrolyte into the pipe.p. 100
Make sure that the float is not obstructed in its movement and hold the electrolyte tester at eye level.p. 100
The electrolyte tester must be read at the highest electrolyte level.p. 100
+l If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 100
+l If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 100
(reference)p. 100
Referencep. 100
The specific weight varies slightly with temperature. To be exact, the specific weight drops by 0.0007 per 1 °C temperature increase (by 0.0004 per 1 °F) and increases by 0,0007 per 1 °C temperature reduction (by 0,0004 per 1 °F) . If e.g. a temp…p. 100
+l Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 100
l Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 100
l Specific weight at 68 °F = measuring value + 0,0004 × (electrolyte temperature: 68 °F)p. 100
+Acid density at 27 °C in kg/dmp. 100
3p. 100
+l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 100
l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 100
l 1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary.p. 100
l 1.19 and less, open circuit voltage less than 12.3 Volt. Battery is insufficiently charged. The battery needs to be recharged immediately.p. 100
l If there is a deviation of the specific weight of more than 0.05 between any of the cells, the battery needs to be replaced.p. 100
l If the current consumption during charging is not 1/ 20 of the nominal capacity (example 100 Ah battery: 100Ah x 1/20 = 5 A) or full recharging of the battery results in a final electrolyte density of only 1.24 kg/ dm3 or less, the battery shows no…p. 100
+4.20 Battery service, check the main battery switchp. 100
4.20 Battery service, check the main battery switchp. 100
+Danger of cauterisation ! Danger of explosion!p. 100
+Danger of cauterisation ! Danger of explosion!p. 100
Danger of cauterisation ! Danger of explosion!p. 100
When working on the battery do not use open fire, do not smoke!p. 100
The battery contains acid. Do not let acid come in contact with skin or clothes!p. 100
Wear protective clothing!p. 100
Do not lay any tools on the battery!p. 100
For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.p. 100
+Dispose of the old batteries environmentally.p. 100
Dispose of the old batteries environmentally.p. 100
+Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result …p. 100
Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result …p. 100
The following therefore applies for the service life:p. 100
+l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 100
l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 100
l Check open-circuit voltage of the battery at regular intervals. At least once per month.p. 100
Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.p. 100
+l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 100
l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 100
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.p. 100
+l After each charging process allow the battery to rest for one hour before taking it into service.p. 100
l After each charging process allow the battery to rest for one hour before taking it into service.p. 100
l For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.p. 100
+Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 100
Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 100
+Charging voltage recommendationp. 101
Charging voltage recommendationp. 101
Fig. 6p. 101
Fig. 7p. 101
+l Open the access cover in the floor in front of the cabin doorp. 101
+l Open the access cover in the floor in front of the cabin doorp. 101
(Fig. 7)p. 101
l Clean battery poles and pole clamps and grease them with pole grease (Vaseline).p. 101
l Retighten the pole clamps.p. 101
l Check the fastening of the battery.p. 101
l On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.p. 101
+Checking the main battery switchp. 101
Checking the main battery switchp. 101
Fig. 8p. 101
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 101
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 101
+With engine-independent air heating systemsp. 101
Optional equipmentp. 101
+l Turn the main battery switchp. 101
+l Turn the main battery switchp. 101
(Fig. 8)p. 101
+4.21 Starting the engine with jump leadsp. 102
4.21 Starting the engine with jump leadsp. 102
+When using external starting aid two external batteries are required, one for each on-board battery.p. 102
+When using external starting aid two external batteries are required, one for each on-board battery.p. 102
When using external starting aid two external batteries are required, one for each on-board battery.p. 102
+l Open the maintenance door to the battery compartment.p. 102
l Open the maintenance door to the battery compartment.p. 102
Fig. 9p. 102
+A wrong connection will cause severe damage in the electric system.p. 102
A wrong connection will cause severe damage in the electric system.p. 102
+l When starting with external batteries connect the positive polesp. 102
+l When starting with external batteries connect the positive polesp. 102
(Fig. 9)p. 102
+l Start as described under "Starting the engine".p. 102
l Start as described under "Starting the engine".p. 102
+The ignition switch is designed with a re-start lock. For a new starting attempt the ignition key must first be turned back to position "0".p. 102
The ignition switch is designed with a re-start lock. For a new starting attempt the ignition key must first be turned back to position "0".p. 102
+If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.p. 102
If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.p. 102
+l Once the engine is running switch on a powerful consumer (working light, etc.).p. 102
l Once the engine is running switch on a powerful consumer (working light, etc.).p. 102
l After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 102
l Switch off the consumer.p. 102
+Run the engine warm for a short while before starting work. Do not rev up a cold engine to high idle speed/full load speed.p. 102
Run the engine warm for a short while before starting work. Do not rev up a cold engine to high idle speed/full load speed.p. 102
4.22 Main battery switchp. 102
Fig. 10p. 102
Main battery switchp. 102
+Position "I"p. 102
Position "I"p. 102
Normal position, operationp. 102
Position "II"p. 102
Separates batteries from the on- board electrics in case of cable fire and fire in the engine compartment as well as protection against unauthorized use.p. 102
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 102
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 102
+With engine-independent air heating systemsp. 102
Optional equipmentp. 102
4.23 Main fusep. 103
Fig. 11p. 103
Main fuses for batteryp. 103
+(1) 250Ap. 103
(1) 250Ap. 103
(F00) main fuse for batteryp. 103
(2) 80Ap. 103
(F48) Main fuse for pre-heating systemp. 103
+The batteries with the main fuses are located inside the battery compartment under the cover in front of the driver's door.p. 103
The batteries with the main fuses are located inside the battery compartment under the cover in front of the driver's door.p. 103
4.24 Hydraulic oil temperaturep. 103
+Temperature sensor, R04p. 103
Temperature sensor, R04p. 103
The sensor is installed inside the hydraulic oil tank. The analog sensor is a variable resistance to ground.p. 103
Fig. 12 Hydraulic oil tankp. 103
+Temperature gauge, P02p. 103
Temperature gauge, P02p. 103
This gauge shows the temperature of the hydraulic oil.p. 103
Fig. 13 Temperature gauge, old designp. 103
Fig. 14 Temperature gauge (z), new designp. 103
+291 OHMp. 103
+291 OHMp. 103
Þp. 103
+36 OHMp. 103
Þp. 103
New version: If no temperature sensor is connected or the cable is broken, the temperature gauge will go out.p. 104
+Monitoring by ESX-controlp. 104
Temperature switch, B20p. 104
+The temperature switch is installed in the hydraulic oil tank, it switches on at 96°Cp. 104
±3°Cp. 104
±3°Cp. 104
Fig. 15 Hydraulic oil tankp. 104
+Monitoring by ESX-controlp. 104
Monitoring by ESX-controlp. 104
+The signal is evaluated by the ESX-control (Pin X0:50) and displayed 10 seconds later in the display modulep. 104
+The signal is evaluated by the ESX-control (Pin X0:50) and displayed 10 seconds later in the display modulep. 104
(Fig. 16)p. 104
Code "575" appears after 2 minutes, the engine is shut down and the wrning buzzer sounds.p. 104
Fig. 16 Display module in central electricsp. 104
Hydraulic oil temperature warning lightp. 105
+The switch contact connects the monitoring board (A15, terminal X1:117) to ground. The hydraulic oil temperature warning lightp. 105
14p. 105
(Fig. 17)p. 105
qp. 105
(Fig. 18)p. 105
Fig. 17 Monitoring module, old designp. 105
Fig. 18 Monitoring module, new designp. 105
4.25 Pressure switch, hydraulic oil filterp. 105
+Differential pressure switches, B21, B22, B121, B122 and B42p. 105
Differential pressure switches, B21, B22, B121, B122 and B42p. 105
+The differential pressure switches B21, B22, B121 and B122 are installed in the charge circuit filters.p. 105
The differential pressure switches B21, B22, B121 and B122 are installed in the charge circuit filters.p. 105
+Differential pressure switches B121 and B122 are only used in BC 972 RB-2.p. 105
Differential pressure switches B121 and B122 are only used in BC 972 RB-2.p. 105
The pressure switch B42 is installed in the filter of the intermediate gearbox (ground switching).p. 105
+The pressure switches B21, B22, B121 and B122 are parallel connected with the monitoring board (A15) (ground switching). The differential pressure switches switch at a pressure differential ofp. 105
Dp. 105
Fig. 1p. 105
+Monitoring by ESX-controlp. 105
Monitoring by ESX-controlp. 105
+The signals are evaluated by the ESX-control and displayed 10 seconds later in the display modulep. 105
+The signals are evaluated by the ESX-control and displayed 10 seconds later in the display modulep. 105
(Fig. 2)p. 105
Fig. 2 Display module in central electricsp. 106
+Monitoring by ESX-controlp. 106
Warning lamp for differential pressure switches, B21, B22, B121 and B122p. 106
+The switch contacts connect the monitoring board (A15, terminal X1:119) to ground. The warning light for the differential pressure switchesp. 106
13p. 106
(Fig. 3)p. 106
up. 106
(Fig. 18)p. 106
Fig. 3 Monitoring module, old designp. 106
Fig. 4 Monitoring module, new designp. 106
+Monitoring by ESX-controlp. 107
Warning light for differential pressure switch, B42p. 107
+The switch contact connects the monitoring board (A15, terminal X1:120) to ground. The warning light for the differential pressure switchesp. 107
12p. 107
(Fig. 5)p. 107
pp. 107
(Fig. 6)p. 107
Fig. 5 Monitoring module, old designp. 107
Fig. 6 Monitoring module, new designp. 107
+Monitoring by ESX-controlp. 107
Pressure switch in return flow filter block, B25p. 107
+Pressure switch 1p. 107
(Fig. 7)p. 107
±0.5p. 107
Fig. 7p. 107
+Monitoring by ESX-controlp. 107
Monitoring by ESX-controlp. 107
+The signals are evaluated by the ESX-control with a delay of 120 seconds (timing relay K113) and displayed 10 seconds later in the display modulep. 107
+The signals are evaluated by the ESX-control with a delay of 120 seconds (timing relay K113) and displayed 10 seconds later in the display modulep. 107
(Fig. 8)p. 107
Fig. 8p. 107
Warning lamp for return flow filter block, B25p. 108
The timer relay (K113) is activated via the switch contact (ground switching).p. 108
+The monitoring board (A15, terminal X1:118) is connected to ground 120 seconds later. The return flow filter warning lightp. 108
15p. 108
(Fig. 9)p. 108
np. 108
(Fig. 10)p. 108
Fig. 9 Monitoring module, old designp. 108
Fig. 10 Monitoring module, new designp. 108
4.26 Magnetic sensor, hydraulic oilp. 108
+Magnetic sensor, B19p. 108
Magnetic sensor, B19p. 108
+The magnetic sensor is in the return flow filter block. The sensor switches when sensor has picked up metal chips.p. 108
The magnetic sensor is in the return flow filter block. The sensor switches when sensor has picked up metal chips.p. 108
Fig. 1p. 108
+Monitoring by ESX-controlp. 108
Monitoring by ESX-controlp. 108
+The signal is evaluated by the ESX-control and displayed 10 seconds later in the display modulep. 108
+The signal is evaluated by the ESX-control and displayed 10 seconds later in the display modulep. 108
(Fig. 2)p. 108
Fig. 2 Display module in central electricsp. 108
Warning light for magnetic sensor, B19p. 109
+The switch contact connects the monitoring board (A15, terminal X1:121) to ground. The warning light for the magnetic sensorp. 109
9p. 109
(Fig. 3)p. 109
wp. 109
(Fig. 4)p. 109
Fig. 3 Monitoring module, old designp. 109
Fig. 4 Monitoring module, new designp. 109
4.27 Pressure switch for brakep. 109
+Pressure switch, B05p. 109
Pressure switch, B05p. 109
+At a pressure of less than15p. 109
+At a pressure of less than15p. 109
±1.5p. 109
Fig. 1p. 109
Parking brake warning lightp. 110
+The switch contact connects the monitoring board (A15, terminal X1:122) to ground. The parking brake warning lightp. 110
10p. 110
(Fig. 2)p. 110
up. 110
(Fig. 3)p. 110
Fig. 2 Monitoring module, old designp. 110
Fig. 3 Monitoring module, new designp. 110
4.28 Level sensor in diesel tank (R03)p. 110
Fig. 1p. 110
The fluid of the level to be measured carries a float, which lowers or rises with the fluid level. Contact springs mounted on the float thereby slide along two resistor wires arranged parallel to the movement of the float and generate a resistance va…p. 110
+Fuel level gaugep. 110
+Fuel level gaugep. 110
The gauge shows the fuel level.p. 110
Fig. 2 Fuel level gauge, old designp. 111
Fig. 3 Fuel level gauge (j), new designp. 111
+0 OHMp. 111
+0 OHMp. 111
Þp. 111
+81 OHMp. 111
Þp. 111
New version: If no level switch is connected or the cable is broken, the fuel level gauge will go out.p. 111
4.29 Blower monitoring module A53p. 112
Fig. 1 Blower monitoring modulep. 112
Module description blower monitoringp. 112
This module protects the fresh air blower in case of overloads (contamination) against damage and thus the machine against subsequent damage.p. 112
Fig. 1p. 112
The module is located in the right hand cabin flap.p. 112
+The module has the function:p. 112
The module has the function:p. 112
To make a connection from terminal 30 to terminal 87a after 20 seconds if the blower speed drops below a certain limit (1300 rpm) and after 8 seconds if the speed signal fails.p. 112
+In deenerized condition there is no connection between Pins 30 and 87a.p. 112
In deenerized condition there is no connection between Pins 30 and 87a.p. 112
+Switch positionp. 112
Switch positionp. 112
+Dropping resistorp. 112
Dropping resistorp. 112
+Signal frequencyp. 112
Signal frequencyp. 112
+Blower speedp. 112
Blower speedp. 112
+Low speedp. 112
Low speedp. 112
+22 Ohmp. 112
22 Ohmp. 112
+73 Hzp. 112
73 Hzp. 112
+2190 rpmp. 112
2190 rpmp. 112
+Mean speedp. 112
Mean speedp. 112
+10 Ohmp. 112
10 Ohmp. 112
+89 Hzp. 112
89 Hzp. 112
+2670 rpmp. 112
2670 rpmp. 112
+Max.speedp. 112
Max.speedp. 112
+No dropping resistorp. 112
No dropping resistorp. 112
+113 Hzp. 112
113 Hzp. 112
+3390 rpmp. 112
3390 rpmp. 112
Cab electrics
Fig. 1 Dashboard, old designp. 113
+1 P00, fuel gaugep. 113
1 P00, fuel gaugep. 113
2 P12, Volt meter 24Vp. 113
3 P03, engine RPM-meter with (P00) operating hour meterp. 113
4 P14, coolant temperature gaugep. 113
5 P02, hydraulic oil temperature gaugep. 113
6 S00, ignition switchp. 113
7 A15, fault indicator, engine functionsp. 113
8 A15, fault indicator, machine functionsp. 113
9 S70, lever for dozer blade / bucket control controlp. 113
10 H04, warning light for engine controlp. 113
11 H70, control light for water separator in fuel pre-filterp. 113
12 XS, socket 24Vp. 113
13 S02, rotary switch, travel speed rangesp. 113
14 S31, travel lever (forward/0/reverse)p. 113
15 S04, rotary switch for parking brakep. 113
16 S25, rotary switch for seat heatingp. 113
17 E20, cigarette lighterp. 113
18 S27, push button for central lubrication systemp. 113
19 S01, Emergency stop switchp. 113
20 A65, control unit for air conditioningp. 113
21 S44, rotary switch for cabin fresh air ventilatorp. 113
22 S119, travel pedal for throttle controlp. 113
23 S71, steering leverp. 113
24 S03, push button for warning hornp. 113
25 Air distribution nozzlesp. 113
Fig. 2 Dashboard, new designp. 114
+1 A15, instrument cluster leftp. 114
1 A15, instrument cluster leftp. 114
2 A15, instrument cluster rightp. 114
3 S00, ignition switchp. 114
4 Air distribution nozzlesp. 114
5 S70, lever for dozer blade controlp. 114
6 H04, warning light and diagnostic push button for engine controlp. 114
7 H70, warning light water in fuel filterp. 114
8 XS, socket 24Vp. 114
9 S02, rotary switch, travel speed rangesp. 114
10 S31, travel leverp. 114
11 S04, rotary switch for parking brakep. 114
12 S25, rotary switch for seat heatingp. 114
13 Cigarette lighterp. 114
14 S27, push button for central lubrication systemp. 114
+15 A65, control unit for air conditioningp. 114
Optional equipmentp. 114
16 S44, rotary switch for cabin ventilatorp. 114
17 S120, potentiometer for throttle control*p. 114
18 S160, rotary switch for activation of manual throttle/deceleration pedal ON/OFF with indicator light*p. 114
19 S01, Emergency Stop switchp. 114
20 S119, travel pedal for throttle controlp. 114
21 S161, deceleration pedal with emergency braking kick-down*p. 114
22 S71, steering leverp. 114
23 S03, push button for warning hornp. 114
1 Wiring loom, electrics box – engine control unit (A48)p. 115
+1 Wiring loom, electrics box – engine control unit (A48)p. 115
+1 Wiring loom, electrics box – engine control unit (A48)p. 115
1 Wiring loom, electrics box – engine control unit (A48)p. 115
13 Y03, solenoid valve for travel speed range selectionp. 124
14 B75, pressure switch for refrigerant in air conditioningp. 124
15 M26, cyclone separatorp. 124
16 B55, coolant level sensorp. 124
17 B03, air filter vacuum switchp. 124
18 B116, air filter vacuum switchp. 124
19 R04, hydraulic oil temperature sensorp. 124
20 B20, hydraulic oil temperature switchp. 124
21 B19, magnetic dirt sensorp. 124
22 B25, pressure switch in return flow filterp. 124
23 B24, hydraulic oil float switchp. 124
24 B15, sensor wheel motor rear leftp. 124
25 Y111, solenoid valve to close bucketp. 124
26 Y93, solenoid valve steering front leftp. 124
27 Y108, solenoid valve bucket upp. 124
28 Y102, solenoid valve for float positionp. 124
29 Y110, solenoid valve to open bucketp. 124
30 Y92, solenoid valve steering front rightp. 124
31 Y109, solenoid valve bucket downp. 124
1 B88, oil pressure sensorp. 125
+1 B88, oil pressure sensorp. 125
+1 B88, oil pressure sensorp. 125
1 B88, oil pressure sensorp. 125
2 B126, fuel temperature sensorp. 125
3 B133, sensor for charge air temperature and charge air pressurep. 125
4 A48, engine control unitp. 125
5 B113, coolant temperature sensorp. 125
6 not usedp. 125
7 X27.1, central engine plugp. 125
8 B114, crankshaft rotation speed sensorp. 125
9 B130, camshaft rotation speed sensorp. 125
4.34 Electronic control unitsp. 126
+Control unitsp. 126
Control unitsp. 126
+Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i…p. 126
Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i…p. 126
Control units generally work according to the IPO- principle. IPO stands for Input-Processing-Output. Sensors are available for input. Sensors determine a physical characteristic like e.g. rotary speed, pressure, temperature, etc. This value is compa…p. 126
Fig. 1 Electronic control (ESX)p. 126
In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units exchange information about operating states and other relevant data in vehicle across the system. Furthermore, the on-board diagnostic or the d…p. 126
Modulesp. 126
+In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists of a programmable microprocessor with additional circuitry for inputs and outputs.p. 126
In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists of a programmable microprocessor with additional circuitry for inputs and outputs.p. 126
Fig. 2 Modulep. 126
The modules have control lights on inputs and outputs to monitor the applied signals.p. 126
Signalsp. 127
+Analog signalsp. 127
Analog signalsp. 127
Process states are continuous (analog) when they can be mapped by means of a real number, e.g. temperature = 65.5 °C. The sensor converts a continuous process status into an analog signal. If the control unit needs the numerical value of the analog …p. 127
+Binary signalsp. 127
Binary signalsp. 127
Process states are bivalent (binary) if they have only 2 possible states of truth, such as e.g. button pressed/ not pressed, object present/not present. The two states of truth are mapped by means of defined states of an information carrier, e.g. 'no…p. 127
CAN-bus, Controller Area Networkp. 127
+created by Bosch at the end of the eighties for automobile applications.p. 127
created by Bosch at the end of the eighties for automobile applications.p. 127
Development objectives:p. 127
Real-time critical, robust and low price communication of control units, such as transmission and engine control, but also less time critical applications in the field of convenience electronics, such as air conditioning.p. 127
Fig. 3p. 127
Why CAN?p. 127
+l Networking of control units for the realization of complex functions.p. 127
+l Networking of control units for the realization of complex functions.p. 127
l Networking of control units for the realization of complex functions.p. 127
l Reduction of the extend of wiring and plug connections.p. 127
l Better diagnostic possibilities (central diagnostics socket).p. 127
Characteristics of CANp. 127
+It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 127
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 127
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur simultaneously in both lines, the software is thus able to filter out interfering signals more easily.p. 127
Wire (+) = cable colour bluep. 127
Wire (-) = cable colour yellowp. 127
+Measuring on the CANp. 127
Measuring on the CANp. 127
Signals transmitted through the bus line can generally not be measured with simple measuring instruments. Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means of a continuity test. BOMAG displa…p. 127
4.35 Checking the voltage supply for the control unitp. 128
+Power supply for a control unit, generalp. 128
Power supply for a control unit, generalp. 128
All electronic switching and control units require an electric power supply to be able to work. If the plus or minus supply is faulty, the control unit will work incorrectly or fail.p. 128
+The following describes the electric power supply for the ESX-control.p. 128
The following describes the electric power supply for the ESX-control.p. 128
+(Fig. 4) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete representation can be found in the wiring diagram of the machine.p. 128
(Fig. 4)p. 128
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the procedures for line testing are generally the same.p. 128
Fig. 4 Circuitry examplep. 128
+1p. 128
1p. 128
Engine blockp. 128
+ESXp. 128
ESXp. 128
Control unitp. 128
+F00p. 128
F00p. 128
Main fusep. 128
+Fx,Fxxp. 128
Fx,Fxxp. 128
Fuses potential 30p. 128
+Fxxxp. 128
Fxxxp. 128
Fuses potential 15p. 128
+Gp. 128
Gp. 128
Generatorp. 128
+G01p. 128
G01p. 128
Batteryp. 128
+GNDp. 128
GNDp. 128
Housing earthp. 128
+H08p. 128
H08p. 128
Charge control lightp. 128
+S00p. 128
S00p. 128
Ignition switchp. 128
+S01p. 128
S01p. 128
Emergency stop switchp. 128
+Pin 28p. 128
Pin 28p. 128
Voltage supply for controlp. 128
+Pin 54p. 128
Pin 54p. 128
if the signal (12/24 Volt) is applied, the control is switched onp. 128
+Pin 55p. 128
Pin 55p. 128
Ground supply for controlp. 128
+Pin 56 to 60p. 128
Pin 56 to 60p. 128
Voltage supply for outputsp. 128
+GNDp. 128
GNDp. 128
Housing earthp. 128
Fault in current supply, generalp. 129
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides of control units are in most cases connected to the vehicle mains supply via several cables, so that several parallel current branches ex…p. 129
Fig. 5 Circuitry examplep. 129
The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply voltage.p. 129
The following faults may occur:p. 129
+l Line interruption in a plus supply linep. 129
l Line interruption in a plus supply linep. 129
l high voltage drop in a plus supply linep. 129
l line interruption on the minus sidep. 129
Measuring principle for line testingp. 130
+When a line conducts an electric current, a voltage drop will occur in the line (Up. 130
Vp. 130
Vp. 130
+l the available amperage (I) andp. 130
l the available amperage (I) andp. 130
+l the electric resistance (Rp. 130
linep. 130
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Identical marginal conditions are therefore used in all of the following examples:p. 130
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.p. 130
12 V / 21 W – lamp as load in a 12 Volt vehicle network.p. 130
24 V / 21 W – lamp as load in a 24 Volt vehicle network.p. 130
+Test stepsp. 130
Test stepsp. 130
1. Switch off the ignition.p. 130
2. Unplug the control unit from wiring loom.p. 130
+3. If available connect the Pinboxp. 130
(Fig. 6)p. 130
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as necessary. Repeat the measurement.p. 130
+The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 130
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 130
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.p. 130
Fig. 6 Pinbox for 68 pole ESX controlp. 130
General measuring setup to check a supply line (plus side)p. 131
Fig. 7 Measuring arrangement 12 Voltp. 131
+1p. 131
1p. 131
Supply line, plus sidep. 131
+2p. 131
2p. 131
+Plug contact in wiring loom plug on control or Pinboxp. 131
(Fig. 6)p. 131
+Ep. 131
Ep. 131
Lamp, 12V / 21 Wattp. 131
+Pp. 131
Pp. 131
Multimeterp. 131
+G01p. 131
G01p. 131
Battery as voltage source, 12Vp. 131
+Up. 131
+Up. 131
Vp. 131
Voltage drop caused by the lamp currentp. 131
Setpointp. 131
+The voltage drop Up. 131
Vp. 131
Setpointp. 131
£p. 131
General measuring setup to check a return line (minus side)p. 132
Fig. 8 Measuring arrangement 12 Voltp. 132
+1p. 132
1p. 132
Return line, minus sidep. 132
+2p. 132
2p. 132
+Plug contact in wiring loom plug on control or Pinboxp. 132
(Fig. 6)p. 132
+Ep. 132
Ep. 132
Lamp, 12V / 21 Wattp. 132
+Pp. 132
Pp. 132
Multimeterp. 132
+G01p. 132
G01p. 132
Battery as voltage source, 12Vp. 132
+Up. 132
+Up. 132
Vp. 132
Voltage drop caused by the lamp currentp. 132
Setpointp. 132
+The voltage drop Up. 132
Vp. 132
Setpointp. 132
£p. 132
Connection example to check the plus line between battery and plug pin 28p. 133
Fig. 9p. 133
+Xp. 133
Xp. 133
+Wiring loom plug disconnected from control unit or Pinboxp. 133
(Fig. 6)p. 133
+Pp. 133
Pp. 133
Multimeterp. 133
+S00p. 133
S00p. 133
+Ignition switched on. Setpoint : E is bright. Up. 133
Vp. 133
+S00p. 133
S00p. 133
+Ignition switched off. Setpoint : E is dark. Up. 133
Vp. 133
Connection example to check the minus line between battery and plug pin 55p. 134
Fig. 10p. 134
+Pp. 134
Pp. 134
Multimeterp. 134
+Xp. 134
Xp. 134
+Wiring loom plug disconnected from control unit or Pinboxp. 134
(Fig. 6)p. 134
+Ep. 134
Ep. 134
+Setpoint : E is bright. Up. 134
Vp. 134
Test protocol for ESXp. 135
+E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 135
E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 135
E lamp 24V / 21W in 24V vehicle network, to load the current branches.p. 135
G01, batteryp. 135
P multimeter, measuring range: DCp. 135
+Plug pinp. 135
Plug pinp. 135
+Notep. 135
Notep. 135
+Setpointsp. 135
Setpointsp. 135
+28p. 135
28p. 135
+Ignition ONp. 135
Ignition ONp. 135
E between plug pin 28 and battery minusp. 135
P between battery plus and plug pin 28p. 135
E is bright,p. 135
+Up. 135
Vp. 135
+28p. 135
28p. 135
+Ignition OFFp. 135
Ignition OFFp. 135
E between plug pin 28 and battery plusp. 135
P between battery minus and plug pin 28p. 135
E is dark,p. 135
+Up. 135
Vp. 135
+54p. 135
54p. 135
+Ignition OFF, emergency stop not operatedp. 135
Ignition OFF, emergency stop not operatedp. 135
E between plug pin 54 and battery minusp. 135
P between battery plus and plug pin 54p. 135
E is bright,p. 135
+Up. 135
Vp. 135
+54p. 135
54p. 135
+Ignition OFF, emergency stop operatedp. 135
Ignition OFF, emergency stop operatedp. 135
E between plug pin 54 and battery minusp. 135
P between battery plus and plug pin 54p. 135
E is dark,p. 135
+Up. 135
Vp. 135
+55p. 135
55p. 135
+Ignition OFFp. 135
Ignition OFFp. 135
E between plug pin 55 and battery minusp. 135
P between battery plus and plug pin 55p. 135
E is bright,p. 135
+Up. 135
Vp. 135
+56, 57, 58, 59, 60p. 135
56, 57, 58, 59, 60p. 135
+Ignition OFFp. 135
Ignition OFFp. 135
E between plug pin 56, 57, 58, 59, 60 and battery minusp. 135
P between battery plus and plug pin 56, 57, 58, 59, 60p. 135
E is bright,p. 135
+Up. 135
Vp. 135
+If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 135
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 135
Example 1:p. 135
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons. Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.p. 135
Example 2:p. 135
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch and the corresponding plug pin.p. 135
4.36 Diagnostics conceptp. 136
+Introductionp. 136
Introductionp. 136
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble shooting proce…p. 136
+Fault description and questioning of the customerp. 136
Fault description and questioning of the customerp. 136
After the customer has explained his complaint(s) the engineer has to ask further questions to track down the cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examination and a possible test d…p. 136
Fig. 11p. 136
+(1) Fault memorized in error logp. 136
(1) Fault memorized in error logp. 136
+Clear cause?p. 136
Clear cause?p. 136
+l If the fault message leaves no doubt, repair work may be started immediately.p. 136
l If the fault message leaves no doubt, repair work may be started immediately.p. 136
Line or component?p. 137
Fig. 12p. 137
+l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 137
l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 137
l Checking the voltage supply for the control unitp. 137
l Checking the sensor linesp. 137
l Checking the actor linesp. 137
Sequence after the fault is foundp. 137
Fig. 13p. 137
(2) No fault memorized in the error log at the time of initial questioningp. 138
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even gets worse …p. 138
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming sensor information and outgoing command values on a control unit. This requires profound knowledge of system and components.p. 138
+Consideration, when the error log has not recorded a faultp. 138
Consideration, when the error log has not recorded a faultp. 138
+l What could be the cause of the complaint?p. 138
l What could be the cause of the complaint?p. 138
l Which measuring possibilities are available?p. 138
+5 Engine electricsp. 139
+5 Engine electricsp. 139
5.1 Engine control unitp. 140
+Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w…p. 140
+Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w…p. 140
Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w…p. 140
Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged.p. 140
+The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goalsp. 140
The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goalsp. 140
+l excellent exhaust gas characteristics,p. 140
l excellent exhaust gas characteristics,p. 140
l low fuel consumption,p. 140
l smooth running of engine,p. 140
l long lifetime of engine,p. 140
l efficient servicingp. 140
under all operating conditions. For this purpose the engine control unit uses the recorded measuring values and the parameters stored in its data memory to run a number of calculations, which form the basis or all the available functions. The most im…p. 140
+l exact control of the injection process (among others the number, start and duration of injections),p. 140
l exact control of the injection process (among others the number, start and duration of injections),p. 140
l idle speed regulation,p. 140
l regulation of exhaust gas recirculation,p. 140
l optimization of smooth running (by means of injection quantity correction),p. 140
l engine monitoring,p. 140
l system diagnose.p. 140
Fig. 14p. 140
+The EMR3-E (TCD 2015)p. 140
(Fig. 14)p. 140
+l socket D2.1 to connect the vehicle wiring loom,p. 140
l socket D2.1 to connect the vehicle wiring loom,p. 140
l socket D2.2 to connect the engine wiring loom for sensors and actuators,p. 140
l socket D2.3 to connect the engine wiring loom for fuel metering unit and injection valves.p. 140
+Main relayp. 140
Main relayp. 140
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. Meter readings are saved in the non-volatile memory. After approx. 10 seconds the internal main relay switches off and disconnects the control unit fr…p. 140
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. Meter readings are saved in the non-volatile memory. After approx. 10 seconds the internal main relay switches off and disconnects the control unit fr…p. 140
battp. 140
+Replacing the control unitp. 141
Replacing the control unitp. 141
+It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 141
+It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 141
It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 141
Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you mu…p. 141
+The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 141
The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 141
5.2 Pin assignmentp. 142
5.3 System faults indicated by flashing codep. 148
+Engine protection function of the electric engine controller EMR3p. 148
Engine protection function of the electric engine controller EMR3p. 148
+Depending on the design of the monitoring function the EMR3in certain fault situations is able to protect the engine against damages by simply monitoring the compliance with important limit values during operation and by checking the correct function…p. 148
Depending on the design of the monitoring function the EMR3in certain fault situations is able to protect the engine against damages by simply monitoring the compliance with important limit values during operation and by checking the correct function…p. 148
Depending on the engine configuration the flashing fault lamp can have the following meaning:p. 148
+l Shut-down request for the operatorp. 148
l Shut-down request for the operatorp. 148
l Attention: Loss of warranty if disregarded!p. 148
l Automatic engine shut-down after a short pre-warning time, possibly in connection with a restarting prevention.p. 148
l Forced engine operation at low idle speed to cool the engine, possible in connection with automatic shut-down.p. 148
l Start prevention.p. 148
+Indication of system faultp. 148
Indication of system faultp. 148
The diagnostic button provides the possibility to read out existing faults in form of flashing codes. The diagnostics button and the fault lamp are located on the operatorsstandofthemachine.'p. 148
Fig. 15p. 148
+1 Diagnostics button, S118p. 148
1 Diagnostics button, S118p. 148
2 Fault lamp, H04p. 148
3 EMR3 control unitp. 148
If the fault log of the EMR3 engine control unit holds at least one active system fault, an uniformly flashing (in case of severe system faults) or a permanent light (in case of minor system faults) will automatically inform about this condition. In …p. 148
Fig. 16p. 148
The following steps are required to read out the flashing codes for saved system faults:p. 148
+l Hold the diagnostics button depressed (1 to 3 seconds), until the flashing light or the permanent light of the fault lamp goes out.p. 148
l Hold the diagnostics button depressed (1 to 3 seconds), until the flashing light or the permanent light of the fault lamp goes out.p. 148
l After approx. 2 s watch the flashing code or the first or the next active fault.p. 149
l Wait until the fault lamp shows the original flashing or permanent light again after about 5 seconds.p. 149
+Example: 1x short flashing,p. 149
Example: 1p. 149
2p. 149
8p. 149
1-2-8p. 149
(Fig. 16)p. 149
All active and passive system faults can be invoked by repetitive execution of these steps. If this read-out process is continued after the last fault, the output will be restarted with the first fault.p. 149
+The light will go out after the fault has been rectified. With some faults it is necessary to switch off the ignition, then wait for 30 seconds before switching the ignition back on.p. 149
The light will go out after the fault has been rectified. With some faults it is necessary to switch off the ignition, then wait for 30 seconds before switching the ignition back on.p. 149
Deleting the fault logp. 149
+The EMR3 engine control unit has two fault logs.Each system fault is simultaneously saved in both logs. However, fault log 2 is only transmitted after switching off the voltage via terminal 15 and the associated afterrunning. Earlier switching off ma…p. 149
The EMR3 engine control unit has two fault logs.Each system fault is simultaneously saved in both logs. However, fault log 2 is only transmitted after switching off the voltage via terminal 15 and the associated afterrunning. Earlier switching off ma…p. 149
The diagnostics button enables you to delete passive faults from the first fault log. The second fault log can only be cleared with SERDIA.p. 149
The following describes the steps for clearing fault log 1:p. 149
+l Ignition OFF, press and hold the diagnostics button.p. 149
l Ignition OFF, press and hold the diagnostics button.p. 149
l Switch the ignition on.p. 149
l Only release the diagnostics button after approx. 10 seconds.p. 149
l All passive faults in fault log 1 will be deleted.p. 149
l The deleting process is confirmed by three short flashing pulses.p. 149
Flashing codep. 150
+Flashing codep. 150
Flashing codep. 150
+Function / componentp. 150
Function / componentp. 150
+Faultp. 150
Faultp. 150
+Short (0.4s)p. 150
Short (0.4s)p. 150
+Long (0.8s)p. 150
Long (0.8s)p. 150
+Short 0.4sp. 150
Short 0.4sp. 150
+1p. 150
1p. 150
+2p. 150
2p. 150
+3p. 150
3p. 150
+Output to coolant temperature indicator lampp. 150
Output to coolant temperature indicator lampp. 150
Signal implausible, pressure deviation beyond permissible rangep. 150
+2p. 150
2p. 150
+1p. 150
1p. 150
+2p. 150
2p. 150
+Monitoring of camshaft / crankshaftp. 150
Monitoring of camshaft / crankshaftp. 150
+No camshaft signal, no crankshaft signalp. 150
No camshaft signal, no crankshaft signalp. 150
+2p. 150
2p. 150
+1p. 150
1p. 150
+3p. 150
3p. 150
+Monitoring of camshaft / crankshaftp. 150
Monitoring of camshaft / crankshaftp. 150
+Discrepancy between camshaft and crankshaft signalsp. 150
Discrepancy between camshaft and crankshaft signalsp. 150
+2p. 150
2p. 150
+1p. 150
1p. 150
+4p. 150
4p. 150
+Motor protectionp. 150
Motor protectionp. 150
+Status of overspeed/override implausiblep. 150
Status of overspeed/override implausiblep. 150
+2p. 150
2p. 150
+1p. 150
1p. 150
+6p. 150
6p. 150
+Fuel low pressure sensorp. 150
Fuel low pressure sensorp. 150
+Signal faultyp. 150
Signal faultyp. 150
+Fuel low pressure monitoringp. 150
Fuel low pressure monitoringp. 150
+Fuel low pressure outside nominal rangep. 150
Fuel low pressure outside nominal rangep. 150
+2p. 150
2p. 150
+1p. 150
1p. 150
+9p. 150
9p. 150
+Output to actuator for exhaust damper engine brakep. 150
Output to actuator for exhaust damper engine brakep. 150
+Signal faulty, control unit overheatingp. 150
Signal faulty, control unit overheatingp. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+Throttle pedal input 1 (PWM)p. 150
Throttle pedal input 1 (PWM)p. 150
+PWM signal faultyp. 150
PWM signal faultyp. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+3p. 150
3p. 150
+Charge air pressure sensorp. 150
Charge air pressure sensorp. 150
+Signal faultyp. 150
Signal faultyp. 150
+Charge air pressure monitoringp. 150
Charge air pressure monitoringp. 150
+Charge air pressure outside nominal rangep. 150
Charge air pressure outside nominal rangep. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+4p. 150
4p. 150
+Oil pressure sensorp. 150
Oil pressure sensorp. 150
+Signal faulty / implausiblep. 150
Signal faulty / implausiblep. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+5p. 150
5p. 150
+Coolant temperature sensorp. 150
Coolant temperature sensorp. 150
+Signal faulty / implausible in comparison to oil temperature, CAN-signal invalidp. 150
Signal faulty / implausible in comparison to oil temperature, CAN-signal invalidp. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+6p. 150
6p. 150
+Input throttle pedal 1 (analog)p. 150
Input throttle pedal 1 (analog)p. 150
+Signal faulty / implausiblep. 150
Signal faulty / implausiblep. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+7p. 150
7p. 150
+Fuel temperature sensorp. 150
Fuel temperature sensorp. 150
+Signal faultyp. 150
Signal faultyp. 150
+2p. 150
2p. 150
+2p. 150
2p. 150
+8p. 150
8p. 150
+Water level sensor in fuel filterp. 150
Water level sensor in fuel filterp. 150
+Signal faultyp. 150
Signal faultyp. 150
+Fuel filter water level monitoringp. 150
Fuel filter water level monitoringp. 150
+Max. water level exceededp. 150
Max. water level exceededp. 150
+2p. 150
2p. 150
+3p. 150
3p. 150
+1p. 150
1p. 150
+Monitoring of lubrication oil pressurep. 150
Monitoring of lubrication oil pressurep. 150
+Pressure outside the nominal rangep. 150
Pressure outside the nominal rangep. 150
+2p. 150
2p. 150
+3p. 150
3p. 150
+2p. 150
2p. 150
+Monitoring of coolant temperaturep. 150
Monitoring of coolant temperaturep. 150
+Temperature above nominal rangep. 150
Temperature above nominal rangep. 150
+2p. 151
2p. 151
+3p. 151
3p. 151
+3p. 151
3p. 151
+Monitoring of intake air temperaturep. 151
Monitoring of intake air temperaturep. 151
+Temperature above nominal rangep. 151
Temperature above nominal rangep. 151
+2p. 151
2p. 151
+3p. 151
3p. 151
+5p. 151
5p. 151
+Monitoring of coolant levelp. 151
Monitoring of coolant levelp. 151
+Level below nominal rangep. 151
Level below nominal rangep. 151
+2p. 151
2p. 151
+3p. 151
3p. 151
+7p. 151
7p. 151
+Monitoring of fuel temperaturep. 151
Monitoring of fuel temperaturep. 151
+Temperature outside nominal rangep. 151
Temperature outside nominal rangep. 151
+2p. 151
2p. 151
+3p. 151
3p. 151
+8p. 151
8p. 151
+Output to fan actuator 1 / 2p. 151
Output to fan actuator 1 / 2p. 151
+Signal faulty, control unit overheatingp. 151
Signal faulty, control unit overheatingp. 151
+Monitoring of fan speedp. 151
Monitoring of fan speedp. 151
+Speed outside nominal rangep. 151
Speed outside nominal rangep. 151
+2p. 151
2p. 151
+4p. 151
4p. 151
+1p. 151
1p. 151
+Monitoring of combustionp. 151
Monitoring of combustionp. 151
+Misfiring detected in one or several cylindersp. 151
Misfiring detected in one or several cylindersp. 151
+2p. 151
2p. 151
+6p. 151
6p. 151
+1p. 151
1p. 151
+Monitoring of output to actuatorsp. 151
Monitoring of output to actuatorsp. 151
+Relay does not open or is delayed, short circuit to groundp. 151
Relay does not open or is delayed, short circuit to groundp. 151
+2p. 151
2p. 151
+6p. 151
6p. 151
+3p. 151
3p. 151
+Output to cold starting aidp. 151
Output to cold starting aidp. 151
+Signal faulty, relay defective, jammed or incorrectly connected, short circuitp. 151
Signal faulty, relay defective, jammed or incorrectly connected, short circuitp. 151
+2p. 151
2p. 151
+7p. 151
7p. 151
+1p. 151
1p. 151
+CAN-Busp. 151
CAN-Busp. 151
+Time-Out for one or several sent messages, bus inactivep. 151
Time-Out for one or several sent messages, bus inactivep. 151
+2p. 151
2p. 151
+8p. 151
8p. 151
+2p. 151
2p. 151
+Sensor supply voltage 1 / 2 / 3p. 151
Sensor supply voltage 1 / 2 / 3p. 151
+Voltage outside nominal rangep. 151
Voltage outside nominal rangep. 151
+2p. 151
2p. 151
+9p. 151
9p. 151
+2p. 151
2p. 151
+Atmospheric pressure sensorp. 151
Atmospheric pressure sensorp. 151
+Signal faulty / implausiblep. 151
Signal faulty / implausiblep. 151
+3p. 151
3p. 151
+1p. 151
1p. 151
+4p. 151
4p. 151
+Hydraulic oil temperature sensorp. 151
Hydraulic oil temperature sensorp. 151
+Signal faultyp. 151
Signal faultyp. 151
+Hydraulic oil temperature monitoringp. 151
Hydraulic oil temperature monitoringp. 151
+Temperature outside nominal rangep. 151
Temperature outside nominal rangep. 151
+3p. 151
3p. 151
+1p. 151
1p. 151
+8p. 151
8p. 151
+Battery monitoringp. 151
Battery monitoringp. 151
+Voltage outside nominal rangep. 151
Voltage outside nominal rangep. 151
+3p. 151
3p. 151
+2p. 151
2p. 151
+8p. 151
8p. 151
+Output to cold starting aid control lampp. 151
Output to cold starting aid control lampp. 151
+Signal faulty, control unit overheatingp. 151
Signal faulty, control unit overheatingp. 151
+4p. 151
4p. 151
+1p. 151
1p. 151
+4p. 151
4p. 151
+Output to external exhaust gas recirculation actuatorp. 151
Output to external exhaust gas recirculation actuatorp. 151
+Signal faultyp. 151
Signal faultyp. 151
+4p. 151
4p. 151
+1p. 151
1p. 151
+5p. 151
5p. 151
+Output to external exhaust gas recirculation actuatorp. 151
Output to external exhaust gas recirculation actuatorp. 151
+Signal faulty, control unit overheatingp. 151
Signal faulty, control unit overheatingp. 151
+4p. 151
4p. 151
+1p. 151
1p. 151
+6p. 151
6p. 151
+Output to external exhaust gas recirculation actuatorp. 151
Output to external exhaust gas recirculation actuatorp. 151
+Signal faultyp. 151
Signal faultyp. 151
+4p. 151
4p. 151
+1p. 151
1p. 151
+7p. 151
7p. 151
+Lubrication oil wear time meterp. 151
Lubrication oil wear time meterp. 151
+Critical time reachedp. 151
Critical time reachedp. 151
+5p. 151
5p. 151
+1p. 151
1p. 151
+2p. 151
2p. 151
+Output to start relayp. 151
Output to start relayp. 151
+Signal faulty, control unit overheatingp. 151
Signal faulty, control unit overheatingp. 151
+5p. 151
5p. 151
+1p. 151
1p. 151
+3p. 151
3p. 151
+Output to fault lampp. 151
Output to fault lampp. 151
+Signal faulty, control unit overheatingp. 151
Signal faulty, control unit overheatingp. 151
+5p. 151
5p. 151
+1p. 151
1p. 151
+4p. 151
4p. 151
+Monitoring of terminal 15p. 151
Monitoring of terminal 15p. 151
+No signal detectedp. 151
No signal detectedp. 151
+5p. 151
5p. 151
+1p. 151
1p. 151
+5p. 151
5p. 151
+Monitoring of terminal 50p. 151
Monitoring of terminal 50p. 151
+Permanent signal detectedp. 151
Permanent signal detectedp. 151
+5p. 151
5p. 151
+2p. 151
2p. 151
+1p. 151
1p. 151
+Speed measurementp. 151
Speed measurementp. 151
+Travel speed implausiblep. 151
Travel speed implausiblep. 151
+5p. 151
5p. 151
+2p. 151
2p. 151
+8p. 151
8p. 151
+Output to internal engine brakep. 151
Output to internal engine brakep. 151
+Signal faultyp. 151
Signal faultyp. 151
+5.17 Checking the preheating system. Maintenance in case of frost.p. 152
5.5 Diagnose with SERDIAp. 152
+SERDIAp. 152
SERDIAp. 152
+With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 152
With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 152
Fig. 1 Service-Software TCD 2012 / 2013p. 152
The SERDIA software is first choice for any diagnostics task.p. 152
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log.p. 152
This displays information onp. 152
+l Location of fault (e.g. ’coolant temperature sensor’)p. 152
l Location of fault (e.g. ’coolant temperature sensor’)p. 152
l Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)p. 152
l Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)p. 152
l Number of fault locations and frequency of faultp. 152
l Fault status (active – fault present / passive- fault no longer present)p. 152
l Fault messages for non-present / rectified faults can be deleted with SERDIA.p. 152
Function testp. 152
The control outputs can be activated with the engine shut down.p. 152
Assignment of inputs/outputsp. 152
Display of the current input and output assignment of the EMR-control.p. 152
Representation of measuring valuesp. 153
Fig. 2p. 153
There is a vast variety of measuring values available for selection which can even be used if no EMR-fault is present (start behaviour, engine sawing, lack of power).p. 153
Representation of fault logp. 154
Fig. 3p. 154
When looking for the cause of a fault in the EMR3-system examining the fault log of the engine control unit usually provides useful information.p. 154
5.17 Checking the preheating system. Maintenance in case of frost.p. 154
+5.17 Checking the preheating system. Maintenance in case of frost.p. 155
5.6 Diagnose with CAN-busp. 155
+The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 155
The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 155
The display is a compact, robust and integratable modules which enables the user to invoke engine data and to display these in the following formats:p. 155
+l Analog displayp. 155
l Analog displayp. 155
l Digital datap. 155
l Multi data (a combination of analog and digital data)p. 155
l Alarm messages currently presentp. 155
The different diagnostic screens enable detailed examination of the engine data flowp. 155
Fig. 1p. 155
+Display for EMR controlp. 155
(Fig. 1)p. 155
+5.17 Checking the preheating system. Maintenance in case of frost.p. 156
5.7 Diagnostics interfacep. 156
Fig. 1 Control unitp. 156
Fig. 2 Diagnostic interface in electric switchboxp. 156
Fig. 3 Diagnostic linkp. 156
+Ap. 156
Ap. 156
Battery plus (+)p. 156
Bp. 156
Battery minus (-)p. 156
Fp. 156
CAN2 lowp. 156
Gp. 156
CAN1 lowp. 156
Hp. 156
CAN1 highp. 156
Kp. 156
K-Linep. 156
Mp. 156
CAN2 highp. 156
SERDIA connectionp. 157
Fig. 4p. 157
+The KWP-protocol with encrypted dataflow is used via the K-line. For this purpose the PC or laptopp. 157
(Fig. 4)p. 157
Operation of SERDIA is described in a separate operation manual.p. 157
CAN-bus display connectionp. 157
Operation of the display is described in a separate operation manual.p. 157
Fig. 5p. 157
+Display for EMR controlp. 157
(Fig. 5)p. 157
BOMAG part-no.: 057 189 94p. 157
Fig. 6p. 157
The display is connected to the diagnostic interface by means of a special cable.p. 157
+Wiring loom for displayp. 157
(Fig. 6)p. 157
BOMAG part-no.: 079 900 19p. 157
+5.17 Checking the preheating system. Maintenance in case of frost.p. 158
EMR3 List of fault codesp. 158
5.17 Checking the preheating system. Maintenance in case of frost.p. 163
+5.17 Checking the preheating system. Maintenance in case of frost.p. 229
5.9 Sensorsp. 229
+Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged.p. 229
+Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged.p. 229
Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged.p. 229
Sensors must under no circumstances be repaired, but must be replaced if they are defective.p. 229
Fig. 1p. 229
+1 Oil pressure sensorp. 229
1 Oil pressure sensorp. 229
2 Fuel temperature sensorp. 229
3 Sensor for charge air temperature and charge air pressurep. 229
4 Engine control unitp. 229
5 Coolant temperature sensorp. 229
6 Oil level sensor, optionp. 229
7 Central plugp. 229
8 Rotary speed sensor for crankshaftp. 229
9 Rotary speed sensor for camshaftp. 229
10 Wiring loom connecting cablep. 229
Fig. 2p. 230
Fig. 3p. 230
+5.17 Checking the preheating system. Maintenance in case of frost.p. 231
5.10 Oil pressure sensorp. 231
+Pressure sensor, B88p. 231
Pressure sensor, B88p. 231
Fig. 1p. 231
Fig. 2 Oil pressure sensorp. 231
Oil pressure monitoringp. 232
+EMR fault codep. 232
EMR fault codep. 232
Fig. 3p. 232
The operator is warned ifp. 232
+l the oil pressure falls short of the warning limit and/orp. 232
l the oil pressure falls short of the warning limit and/orp. 232
l the power is reduced by the EMR after a pre-warning time, orp. 232
l the oil pressure falls short of the shut-down limit and the engine is shut down after a pre-warning time.p. 232
+permanent lightp. 232
permanent lightp. 232
A fault message is present, the engine can be started and the refuse compactor is still operable with limitations.p. 232
the control light flashes after 2 secondsp. 232
Severe fault, the engine cannot be started.p. 232
+Disassembling the pressure sensorp. 232
Monitoring by ESX-controlp. 232
+The signal is evaluated by the ESX-control (Pin X0:52) and displayed 2 seconds later in the display modulep. 232
+The signal is evaluated by the ESX-control (Pin X0:52) and displayed 2 seconds later in the display modulep. 232
(Fig. 4)p. 232
Fig. 4 Display module in central electricsp. 232
+Disassembling the pressure sensorp. 233
Warning light, engine oil pressurep. 233
+If there is no oil pressure, the EMR-control (PIN XD2.1.20, ground switching) switches, whereby the coil of relay (K60) is excited. The switch contact of relay (K60) supplies the monitoring board (A15, terminal X1:88) with ground potential. The engin…p. 233
3p. 233
(Fig. 5)p. 233
cp. 233
(Fig. 6)p. 233
Fig. 5 Monitoring module, old designp. 233
+3 redp. 233
+3 redp. 233
3p. 233
Engine oil pressure too low.p. 233
Fig. 6 Monitoring module, new designp. 233
+c redp. 233
+c redp. 233
cp. 233
Engine oil pressure too low.p. 233
+Disassembling the pressure sensorp. 233
Removing and installing the pressure sensorp. 233
+Ensure absolute cleanliness when working in the lubrication oil system.p. 233
Ensure absolute cleanliness when working in the lubrication oil system.p. 233
Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 233
Immediately close all connections and openings with new and clean plugs/caps.p. 233
Only remove plugs/caps just before assembling.p. 233
+Catch engine oil and dispose of environmentally.p. 233
Catch engine oil and dispose of environmentally.p. 233
+Disassembling the pressure sensorp. 233
Disassembling the pressure sensorp. 233
Fig. 7p. 233
+l Unlock and pull out the cable plugp. 233
+l Unlock and pull out the cable plugp. 233
(Fig. 7)p. 233
l Unscrew the oil pressure sensor with a socket spanner.p. 233
l Check the component visually.p. 233
+Installing the pressure sensorp. 234
Installing the pressure sensorp. 234
Fig. 8p. 234
+l Insert the oil pressure sensor with a new seal ring and tighten.p. 234
l Insert the oil pressure sensor with a new seal ring and tighten.p. 234
+Tightening torque: 20Nmp. 234
Tightening torque: 20Nmp. 234
Fig. 9p. 234
+l Plug in the cable plug.p. 234
l Plug in the cable plug.p. 234
+Delete the fault entry in the fault log of the engine control unit.p. 234
Delete the fault entry in the fault log of the engine control unit.p. 234
+5.17 Checking the preheating system. Maintenance in case of frost.p. 235
Fuel temperature sensorp. 235
+Temperature senor, B126p. 235
Temperature senor, B126p. 235
Fig. 1p. 235
+l Temperature correction for injection quantityp. 235
l Temperature correction for injection quantityp. 235
Fig. 2p. 235
+5.17 Checking the preheating system. Maintenance in case of frost.p. 236
Charge air temperature – charge air pressure sensorp. 236
+Charge air temperature – charge air pressure sensor, B133p. 236
Charge air temperature – charge air pressure sensor, B133p. 236
Fig. 1p. 236
Fig. 2p. 236
This sensor unites two functions in one housing. The one function measures the charge air pressure in the and adapts the injection quantity in dependence on the measured pressure. On the other hand the EMR now detects the temperature of the passing a…p. 236
+With a faulty pressure sensor the engine continues to run with charge pressure simulation.p. 236
With a faulty pressure sensor the engine continues to run with charge pressure simulation.p. 236
With a defective temperature sensor the engine also carries on running.p. 236
Charge air temperature monitoringp. 236
The operator is warned ifp. 236
+l the temperature exceeds the warning limit and/orp. 236
l the temperature exceeds the warning limit and/orp. 236
l the power is reduced by the EMR 3 after a pre- warning time, orp. 236
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 236
+Disassembling and assembling the sensorp. 237
Disassembling and assembling the sensorp. 237
+Disassembling the sensorp. 237
Disassembling the sensorp. 237
Fig. 3p. 237
+l Unlock and pull out the cable plugp. 237
+l Unlock and pull out the cable plugp. 237
(Fig. 3)p. 237
l Unscrew the screw.p. 237
l Remove the pressure/temperature sensor.p. 237
l Check the component visually.p. 237
+Installing the sensorp. 237
Installing the sensorp. 237
Fig. 4p. 237
+l Assemble a new O-ringp. 237
+l Assemble a new O-ringp. 237
(Fig. 4)p. 237
l Slightly cover the O-ring with grease.p. 237
Fig. 5p. 237
+l Carefully insert the pressure/temperature sensorp. 237
+l Carefully insert the pressure/temperature sensorp. 237
(Fig. 5)p. 237
l Plug on the cable plug and engage the lock.p. 237
l Tighten the screw (1).p. 237
+Delete the fault entry in the fault log of the engine control unit.p. 237
Delete the fault entry in the fault log of the engine control unit.p. 237
+5.17 Checking the preheating system. Maintenance in case of frost.p. 238
5.13 EMR coolant temperature sensorp. 238
+Temperature sensor, B113p. 238
Temperature sensor, B113p. 238
Fig. 1p. 238
Fig. 2p. 238
The coolant temperature has an effect on the calculated injection quantity and the preheating behaviour of the glow plugs.p. 238
Coolant temperature monitoringp. 239
+EMR fault codep. 239
EMR fault codep. 239
Fig. 3p. 239
The operator is warned ifp. 239
+l the temperature exceeds the warning limit and/orp. 239
l the temperature exceeds the warning limit and/orp. 239
l the power is reduced by the EMR after a pre-warning time, orp. 239
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 239
+permanent lightp. 239
permanent lightp. 239
A fault message is present, the engine can be started and the refuse compactor is still operable with limitations.p. 239
the control light flashes after 2 secondsp. 239
Severe fault, the engine cannot be started.p. 239
+Disassembling the temperature sensorp. 239
Monitoring by ESX-controlp. 239
+The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display modulep. 239
+The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display modulep. 239
(Fig. 4)p. 239
Fig. 4 Display module in central electricsp. 239
+Disassembling the temperature sensorp. 240
Warning light, overheating of enginep. 240
+If the coolant temperature is exceeded the EMR-control (PIN XD2.1.39, ground switching) switches, whereby the coil of relay (K146) is excited. The switch contact of relay (K146) supplies the monitoring board (A15, terminal X1:87) with ground potentia…p. 240
6p. 240
(Fig. 5)p. 240
fp. 240
(Fig. 6)p. 240
Fig. 5 Monitoring module, old designp. 240
+6 redp. 240
+6 redp. 240
6p. 240
Coolant temperature too high.p. 240
Fig. 6 Monitoring module, new designp. 240
+f redp. 240
+f redp. 240
fp. 240
Coolant temperature too high.p. 240
+Disassembling the temperature sensorp. 240
Removing and installing the temperature sensorp. 240
+Catch running out fluids in a suitable vessel and dispose of environmentally.p. 240
Catch running out fluids in a suitable vessel and dispose of environmentally.p. 240
+Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 240
Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 240
+Disassembling the temperature sensorp. 240
Disassembling the temperature sensorp. 240
Fig. 7p. 240
+l Unlock and pull out the cable plugp. 240
+l Unlock and pull out the cable plugp. 240
(Fig. 7)p. 240
Fig. 8p. 240
+l Unscrew the coolant temperature sensorp. 240
+l Unscrew the coolant temperature sensorp. 240
(Fig. 8)p. 240
l Check the component visually.p. 240
+Installing the temperature sensorp. 241
Installing the temperature sensorp. 241
Fig. 9p. 241
+l Tighten the coolant temperature sensorp. 241
+l Tighten the coolant temperature sensorp. 241
(Fig. 9)p. 241
+Make sure that the seal rings are present .p. 241
Make sure that the seal rings are present .p. 241
+Tightening torque: 22p. 241
±2p. 241
Fig. 10p. 241
+l Push on the cable plugp. 241
+l Push on the cable plugp. 241
(Fig. 10)p. 241
+Delete the fault entry in the fault log of the engine control unit.p. 241
Delete the fault entry in the fault log of the engine control unit.p. 241
+5.17 Checking the preheating system. Maintenance in case of frost.p. 242
Rotary speed sensor for crankshaftp. 242
+Rotary speed sensor, B130p. 242
+Rotary speed sensor, B130p. 242
Fig. 1p. 242
+l Inductive sensorp. 242
l Inductive sensorp. 242
l Exact determination of engine speedp. 242
l Limp-home function in case of camshaft sensor failurep. 242
+5.17 Checking the preheating system. Maintenance in case of frost.p. 243
Rotary speed sensor for camshaftp. 243
+Rotary speed sensor, B114p. 243
Rotary speed sensor, B114p. 243
Fig. 1p. 243
+l Inductive sensorp. 243
l Inductive sensorp. 243
l Determination of TDCp. 243
l Limp-home function in case of crankshaft sensor failurep. 243
+5.17 Checking the preheating system. Maintenance in case of frost.p. 244
5.16 Preheating systemp. 244
+Glow plugs, R02p. 244
Glow plugs, R02p. 244
+The engines are fitted with glow plugs as cold starting aids by standard.p. 244
The engines are fitted with glow plugs as cold starting aids by standard.p. 244
Fig. 1 Glow plug R02p. 244
Once the preheating temperature is reached, a solenoid valve (Y02) directs fuel into the evaporation zones of the glow plug. This generates a flame which sustainably heats up the intake air and thus enables reliably, comfortable and environmentally f…p. 244
Fig. 2 Solenoid valve Y02p. 244
Fig. 3p. 244
+1 Main battery fuse (F00), 250Ap. 244
1 Main battery fuse (F00), 250Ap. 244
2 Fuse for preheating system (F48), 80Ap. 244
+Removing and installing the glow plugp. 244
Removing and installing the glow plugp. 244
+Follow the safety regulations and country specific regulations concerning the handling of fuel.p. 244
Follow the safety regulations and country specific regulations concerning the handling of fuel.p. 244
Ensure absolute cleanliness when working in the fuel system. Remove any existing paint and dirt particles before disassembling. Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 244
Immediately close all connections and openings with new and clean plugs/caps. Only remove plugs/caps just before assembling.p. 244
+Catch running out fluids in a suitable vessel and dispose of environmentally.p. 244
Catch running out fluids in a suitable vessel and dispose of environmentally.p. 244
+Disassembling the glow plugp. 245
Disassembling the glow plugp. 245
Fig. 4p. 245
+l Remove the fuel lines 1p. 245
+l Remove the fuel lines 1p. 245
(Fig. 4)p. 245
Fig. 5p. 245
+l Unscrew the nut 1p. 245
+l Unscrew the nut 1p. 245
(Fig. 5)p. 245
l Disconnect the cable.p. 245
Fig. 6p. 245
+l Loosen counter nut 1p. 245
+l Loosen counter nut 1p. 245
(Fig. 6)p. 245
l Unscrew the glow plug.p. 245
Fig. 7p. 245
+l Remove the seal 1p. 245
+l Remove the seal 1p. 245
(Fig. 7)p. 245
l Check the component visually.p. 245
Installing the glow plugp. 246
Fig. 8p. 246
+l Install the new gasket.p. 246
l Install the new gasket.p. 246
l Screw in the glow plug.p. 246
+Observe measurement (X)p. 246
+Observe measurement (X)p. 246
(Fig. 8)p. 246
+Measurement (X) = 60p. 246
– 3p. 246
Fig. 9p. 246
+l Install the fuel lines 1p. 246
+l Install the fuel lines 1p. 246
(Fig. 9)p. 246
+l Tighten the counter nut (2).p. 246
l Tighten the counter nut (2).p. 246
+Tightening torque of counter nut 25 Nmp. 246
Tightening torque of counter nut 25 Nmp. 246
Fig. 10p. 246
+l Push on the cable lugp. 246
+l Push on the cable lugp. 246
(Fig. 10)p. 246
l Install the washer.p. 246
l Tighten the nut.p. 246
+Tightening torque of nut = 5 Nm.p. 246
Tightening torque of nut = 5 Nm.p. 246
+5.17 Checking the preheating system. Maintenance in case of frost.p. 247
5.17 Checking the preheating system. Maintenance in case of frost.p. 247
+Fire hazard!p. 247
+Fire hazard!p. 247
Fire hazard!p. 247
When working on the fuel system do not use open fire, do not smoke, do not spill any fuel.p. 247
+Catch running out fuel.p. 247
Catch running out fuel.p. 247
Fig. 11p. 247
+If the system works correctly suction pipe 3p. 247
+If the system works correctly suction pipe 3p. 247
(Fig. 11)p. 247
+Test step 1p. 247
Test step 1p. 247
Fig. 12p. 247
+l Turn the ignition key to position "I", the control light "preheating" 1p. 247
+l Turn the ignition key to position "I", the control light "preheating" 1p. 247
(Fig. 12)p. 247
Otherwise the glow plug is defective or the line is interrupted.p. 247
+Test step 2p. 247
Test step 2p. 247
+Danger of injury!p. 247
Danger of injury!p. 247
Keep clear of rotating parts.p. 247
+l Loosen the pipe fitting (2) on the glow plug for a few turns.p. 247
l Loosen the pipe fitting (2) on the glow plug for a few turns.p. 247
Fig. 13p. 247
+l Press the button of the emergency stop switch inp. 247
+l Press the button of the emergency stop switch inp. 247
(Fig. 13)p. 247
+l Hold the ignition key in position „I“, until the „preheating“ control light goeas out.p. 247
l Hold the ignition key in position „I“, until the „preheating“ control light goeas out.p. 247
+l Turn the ignition key further to position "II" against the resistance and crank the engine with the starter.p. 247
l Turn the ignition key further to position "II" against the resistance and crank the engine with the starter.p. 247
l Fuel must run out of the loosened pipe fitting. Otherwise have the system (solenoid valve) checked.p. 247
+Test step 3p. 247
Test step 3p. 247
+l Remove the glow plug and connect the fuel line.p. 247
l Remove the glow plug and connect the fuel line.p. 247
l Crank the engine with the starter, see test step 2.p. 247
l Fuel must run out of the glow plug. Otherwise replace the clogged glow plug.p. 247
l Reinstall the disassembled parts.p. 247
5.18 Sensor, water in fuelp. 248
+Sensor, B124p. 248
Sensor, B124p. 248
Fig. 14p. 248
+1 Water separator sensor (B124)p. 248
1 Water separator sensor (B124)p. 248
+Warning light water in fuel filterp. 248
Warning light water in fuel filterp. 248
+In case of water in the fuel, the EMR-control will switch (Pin XD2.1.38 ground) The water in fuel warning lightp. 248
(Fig. 15)p. 248
Fig. 15p. 248
+lightsp. 248
lightsp. 248
Lights when the water content in the fuel pre-cleaner reaches the sensor contacts.p. 248
+EMR fault codep. 248
EMR fault codep. 248
Fig. 16p. 248
+Fault light is permanently on.p. 248
Fault light is permanently on.p. 248
+permanent lightp. 248
permanent lightp. 248
A fault message is present, the engine can be started and the refuse compactor is still operable with limitations.p. 248
5.19 Air filter vacuum switchp. 249
+Vacuum switches, B03 and B116p. 249
Vacuum switches, B03 and B116p. 249
+The signal is not monitored by the engine control unit.p. 249
+The signal is not monitored by the engine control unit.p. 249
The signal is not monitored by the engine control unit.p. 249
The signal is monitored by the ESX-control.p. 249
The pressure switches are connected in parallel.p. 249
Fig. 17p. 249
+Air filter warning lightp. 249
Monitoring by ESX-controlp. 249
+The signal is evaluated by the ESX-control (Pin X0:11) and displayed 2 seconds later in the display modulep. 249
+The signal is evaluated by the ESX-control (Pin X0:11) and displayed 2 seconds later in the display modulep. 249
(Fig. 18)p. 249
Fig. 18 Display module in central electricsp. 249
+Air filter warning lightp. 249
Air filter warning lightp. 249
The vacuum switches operate at a vacuum of > 50 mbar.p. 249
+The switch contacts connect the monitoring board (A15, terminal X1:86) to ground. The air filter warning lightp. 249
5p. 249
(Fig. 19)p. 249
gp. 249
(Fig. 20)p. 249
Fig. 19 Monitoring module, old designp. 249
+5 yellowp. 249
+5 yellowp. 249
5p. 249
Air filter warning light Lights when the combustion air filter is contaminated. Clean or replace, as necessary.p. 249
Fig. 20 Monitoring module, new designp. 250
+g yellowp. 250
+g yellowp. 250
gp. 250
Air filter warning light Lights when the combustion air filter is contaminated. Clean or replace, as necessary.p. 250
5.20 Coolant temperature sensorp. 250
+Temperature sensor, B53p. 250
Temperature sensor, B53p. 250
+The temperature sensor is not monitored by the engine control unit.p. 250
The temperature sensor is not monitored by the engine control unit.p. 250
The temperature sensor is installed inside the engine. The analog sensor is a variable resistance switched rto ground.p. 250
Fig. 21 Diesel enginep. 250
+Temperature gauge, P14p. 250
Temperature gauge, P14p. 250
This gauge shows the temperature of the coolant.p. 250
Fig. 22 Temperature gauge, old designp. 251
Fig. 23 Temperature gauge (y), new designp. 251
+480 OHMp. 251
+480 OHMp. 251
Þp. 251
+36 OHMp. 251
Þp. 251
New version: If no temperature sensor is connected or the cable is broken, the temperature gauge will go out.p. 251
5.21 Float switch, coolant tankp. 251
+Float switch, B55p. 251
Float switch, B55p. 251
+The signal is not monitored by the engine control unit.p. 251
+The signal is not monitored by the engine control unit.p. 251
The signal is not monitored by the engine control unit.p. 251
The signal is monitored by the ESX-control.p. 251
Fig. 1p. 251
+Monitoring by ESX-controlp. 251
Monitoring by ESX-controlp. 251
+The signal is evaluated in the ESX-control (Pin X0:19).p. 251
The signal is evaluated in the ESX-control (Pin X0:19).p. 251
+After 2 seconds the display modulep. 251
(Fig. 2)p. 251
Code "525" appears after 20 seconds, the engine is shut down and the warning buzzer sounds.p. 251
Fig. 2 Display module in central electricsp. 252
+Coolant level warning lightp. 252
Coolant level warning lightp. 252
+The float switch switches if the coolant level is too low. The switch contact connects the monitoring board (A15, terminal X1:85) to ground. The coolant level warning lightp. 252
7p. 252
(Fig. 3)p. 252
dp. 252
(Fig. 4)p. 252
Fig. 3 Monitoring module, old designp. 252
Fig. 4 Monitoring module, new designp. 252
5.22 Charge control light, engine RPM-meterp. 252
+The generator is not monitored by the engine control unit.p. 252
+The generator is not monitored by the engine control unit.p. 252
The generator is not monitored by the engine control unit.p. 252
Fig. 1 Generatorp. 252
+1 Terminal Wp. 252
1 Terminal Wp. 252
2 Terminal D+p. 252
3 Terminal B+p. 252
+Charge control lightp. 252
Charge control lightp. 252
+Charge control light, old designp. 252
Charge control light, old designp. 252
+If the battery is not being charged, a ground signal is applied to D+ terminal 2p. 252
(Fig. 1)p. 252
2, yellowp. 252
(Fig. 2)p. 252
Fig. 2 Monitoring module, old designp. 253
+Charge control light, new designp. 253
Charge control light, new designp. 253
+If the battery is not being charged, a ground signal is applied to D+ terminal 2p. 253
(Fig. 1)p. 253
e, yellowp. 253
(Fig. 3)p. 253
Fig. 3 Monitoring module, new designp. 253
+Engine PRM-meterp. 253
Engine PRM-meterp. 253
Terminal "W" on the generator delivers a pulsating direct voltage, which is utilized to determine the rotary speed of the engine.p. 253
5.23 Generatorp. 253
+Generalp. 253
Generalp. 253
The generator should be of light weight, have a high rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already at idling speed.p. 253
Terminal designationsp. 253
+l B61, L = charge controlp. 253
l B61, L = charge controlp. 253
l B+, B = battery plus, also with the designation "30"p. 253
l B- = battery minus, also with the designation "31"p. 253
l D+ = dynamo plus corresponds with terminal "61" and "L"p. 253
l D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed)p. 253
l DF = dynamo field (this designation is only found on D.C. generators or A.C. generators with regulator removed). Note: The designation DF is also found on older alternators with externally arranged regulator on the connection of the exciting coil t…p. 253
l DF1 = dynamo field 1p. 253
l DF2 = dynamo field 2p. 253
l IG = "15" ignition switchp. 253
Three-phase generatorp. 254
+The AC-generator first of all produces AC-voltage / AC-current.p. 254
The AC-generator first of all produces AC-voltage / AC-current.p. 254
Why does AC-current need to be rectified?p. 254
There are a few components for which can either be operated with alternating current or direct current, because they work independently from the current flow direction.p. 254
This includes :p. 254
+l Incandescent lampsp. 254
l Incandescent lampsp. 254
l Fluorescent lampsp. 254
l Glow lampsp. 254
l Electric heating elements.p. 254
There are also a few components that could be operated either with alternating current, direct current or three-phase current, if the components were designed accordingly.p. 254
This includes :p. 254
+l Electric motorsp. 254
l Electric motorsp. 254
l Relays.p. 254
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.p. 254
This includes :p. 254
+l Accumulatorsp. 254
l Accumulatorsp. 254
l Control unitsp. 254
l All electronicsp. 254
l Communication equipment.p. 254
+Design and functionp. 254
Design and functionp. 254
Fig. 4p. 254
+1 Fanp. 254
1 Fanp. 254
2 Holding platep. 254
3 Stator corep. 254
4 Stator windingp. 254
5 Brushp. 254
6 Brush holderp. 254
7 Rectifierp. 254
8 Bearing coverp. 254
9 Rotor windingp. 254
10 Rotorp. 254
11 V-belt pulleyp. 254
Fig. 5 Rotor with claw polesp. 254
+In the generator the armature windings are located inside the stationary statorp. 254
(Fig. 6)p. 254
(Fig. 5)p. 254
Fig. 6 Statorp. 254
+The three stator windingsp. 254
(Fig. 6)p. 254
Fig. 7 3-phase currentp. 255
+The wiring diagramp. 255
(Fig. 7)p. 255
The diodes D1, D2, D3 are also referred to as minus diodes, because they have B- as common connection (minus plate). The other diodes are the plus diodes.p. 255
The rectifier diodes have the effect that the negative half-wave is suppressed and only the positive section of the wave is allowed to pass, resulting in a pulsating D.C. voltage.p. 255
Charge control lightp. 255
The charge control light has two duties:p. 255
+l Indication of the correct generator functionp. 255
l Indication of the correct generator functionp. 255
l External excitation of the generator during the starting phasep. 255
Fig. 8 plus controlled charging regulatorp. 255
+(Fig. 8) shows the current flow with the ignition switched on, engine stopped.p. 255
(Fig. 8)p. 255
Fig. 9 plus controlled charging regulatorp. 255
+(Fig. 9) shows the current flow with the ignition switched on, engine running.p. 255
(Fig. 9)p. 255
+1 Batteryp. 255
1 Batteryp. 255
2 Charge controllerp. 255
3 Ignition switchp. 255
4 Charge control lightp. 255
5 Rectifierp. 255
6 Rotorp. 255
7 Sliprings / carbon brushp. 255
8 Auxiliary rectifierp. 255
Normally the charge control light lights with the engine stopped and the ignition switched on and goes out at low engine speed, but at the latest after a single, short-term increase in engine speed from idle speed, because there is no longer a voltag…p. 255
Any other behaviour would indicate a defect on the generator (rectifier, carbon brushes, regulator) or a defect on the lamp, presumed the on-board battery is not discharged.p. 256
A far more important function of the lamp is the transition and provision of field current. At standstill there is no magnetic field in the de-energized generator. Since this is necessary for the generation of electric current, the rotor must be supp…p. 256
The current flows from the ignition switch via the charge control light through the generator winding against ground (terminal 31) and is limited to approx. 300 mA by the light bulb (4 W) (without the lamp the current flow would be 2 to 5 A). While t…p. 256
With used, older generators a weak permanent magnetic field may have developed over the lifetime, which does even exist when no voltage is applied. This type of machines can even start without charge control light and produce current during operation…p. 256
Charge controllerp. 256
The charge controller has the following functionsp. 256
+l To regulate the voltage generated by the generatorp. 256
l To regulate the voltage generated by the generatorp. 256
l To protect against overloads caused by too high output currentp. 256
l Protection against reverse currentp. 256
If the output voltage or the output current of the generator exceeds the determined maximum values, the field current and thus the electric power is reduced.p. 256
+Electronic charge regulatorp. 256
Electronic charge regulatorp. 256
Fig. 10p. 256
In AC-generators the electrically generated exciter field of the generator rotor is influenced by an attached electronic charge regulator. Together with the holder for the carbon brushes this regulator forms a unit, which transfers the field current …p. 256
Fig. 11 plus controlled regulatorp. 257
Fig. 12 minus controlled regulatorp. 257
Checking the generatorp. 257
+First one must check whether the generator is actually defective.p. 257
First one must check whether the generator is actually defective.p. 257
+l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 257
l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 257
l When the engine is at rest, the charge control light must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously also possible.p. 257
The following points allow to contain faults in the voltage supply within certain limits.p. 257
+l Cable connections on the generator OK?p. 257
l Cable connections on the generator OK?p. 257
l V-belt OK?p. 257
l Generator ground (engine ground) OK?p. 257
l Pre-excitation from vehicle electronics OK?p. 257
Only if all criteria mentioned above are OK, the fault must be in the generator itself. In this case it must be replaced or the following trouble shooting procedure must be performed.p. 257
Checking the pre-exciter circuit, D+ generatorp. 258
The most common reason for a 3-phase alternator not charging is a too low pre-excitation current. The pre- excitation current through connection D+ depends on the connected consumer (resistance), e.g. charge control light or relay of a MD+ engine con…p. 258
The pre-excitation current should be approx. 250 mA at 12 Volt. This corresponds with a 3 Watt light bulb or an equivalent combination of light bulb + resistance or an LED + resistance.p. 258
The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm.p. 258
In case of faults likep. 258
+l charge control light stays onp. 258
l charge control light stays onp. 258
l no voltage increase, e.g. from 12 V to 14 Vp. 258
one should check that the correct resistance is assured.p. 258
Fig. 13 Connections on the three-phase alternator (exemplary design)p. 258
If the charge control light or LED stays on when the engine is running, you should proceed as follows:p. 258
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 258
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 258
(Fig. 13)p. 258
If this measure does not clear the fault, the alternator must be defective.p. 258
+Measuring the charge currentp. 258
Measuring the charge currentp. 258
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 258
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 258
l The generator ground connection must be OK.p. 258
l During the measurement switch on as many consumers as possible.p. 258
+1 Attach the clip-on ammeter around the B+ line.p. 258
1 Attach the clip-on ammeter around the B+ line.p. 258
2 Gradually increase the engine speed.p. 258
3 The generator current must be at least as high as the total current of all switched on consumers.p. 258
Checking the rotorp. 259
+The rotor coils can only be measured in disassembled state.p. 259
The rotor coils can only be measured in disassembled state.p. 259
Fig. 14p. 259
+l Measure the resistance between the sliprings.p. 259
l Measure the resistance between the sliprings.p. 259
l If the resistance does not comply with the factory specification, replace the rotor.p. 259
l Use the resistance range of the continuity tester to check the continuity between slipring and core.p. 259
l Replace the rotor if no infinite value is indicated.p. 259
+Factory specification for resistance: 2.8 to 5 OHM.p. 259
Factory specification for resistance: 2.8 to 5 OHM.p. 259
Checking the statorp. 259
+The stator coils can only be measured in disassembled state.p. 259
The stator coils can only be measured in disassembled state.p. 259
Fig. 15p. 259
+l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 259
l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 259
l If the measuring value does not comply with the factory specification, replace the stator.p. 259
l Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core.p. 259
l Replace the stator if no infinite value is indicated.p. 259
+Factory specification for resistance: Less than 1 OHM.p. 259
Factory specification for resistance: Less than 1 OHM.p. 259
Checking the bearingsp. 260
Fig. 16p. 260
+l Check whether the bearing rotates without obstruction.p. 260
l Check whether the bearing rotates without obstruction.p. 260
l Replace the bearing if it does not rotate properly.p. 260
Checking the regulator voltage with the generator testerp. 260
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.p. 260
Fig. 17p. 260
The generator test assesses the regulator voltage and the ripple factor of the generator voltage.p. 260
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 260
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 260
l The generator ground connection must be OK.p. 260
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 260
l If possible switch off all consumers.p. 260
l Perform the measurement at raised engine speed.p. 260
Checking the regulator voltage with the multimeterp. 261
Fig. 18p. 261
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 261
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 261
l The generator ground connection must be OK.p. 261
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 261
l If possible switch off all consumers.p. 261
l Perform the measurement at raised engine speed.p. 261
l The voltage (B+) should adjust itself at 13 to 14 Volt.p. 261
Checking the regulator in disassembled statep. 261
+On ap. 261
Bosch generatorp. 261
+Thep. 261
Delco-Remy generatorp. 261
+When testing the regulator one should be aware that there are 2 different types of regulators:p. 261
When testing the regulator one should be aware that there are 2 different types of regulators:p. 261
+l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon …p. 261
l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon …p. 261
D+ (vehicle wiring system)p. 261
D- (ground contact, mostly located on one of the fastening screws)p. 261
DF (Dynamo Field)p. 261
Fig. 19p. 261
+l If the carbon brush is connected to ground the regulator 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 i…p. 261
l If the carbon brush is connected to ground the regulator 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 i…p. 261
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).p. 261
Fig. 20p. 262
E.g minus controlled regulatorp. 262
+One connects the regulatorp. 262
(Fig. 20)p. 262
With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-.p. 262
Fig. 21p. 262
Fig. 22p. 262
+The illustrationsp. 262
(Fig. 21)p. 262
(Fig. 22)p. 262
Replacing carbon brushesp. 262
+l On ap. 262
+l On ap. 262
Bosch generatorp. 262
5 mmp. 262
+l For replacing the carbon brushes in thep. 262
Delco- Remy generatorp. 262
5.24 Replacing the voltage regulatorp. 263
+Disassembling the regulatorp. 263
Disassembling the regulatorp. 263
Fig. 1p. 263
+l Unscrew the hexagon nut M5 from terminal Wp. 263
+l Unscrew the hexagon nut M5 from terminal Wp. 263
(Fig. 1)p. 263
l Remove hexagon nut, washer and flat-pin plug.p. 263
Fig. 2p. 263
+l Unscrew the fastening nuts M5 from the protective coverp. 263
+l Unscrew the fastening nuts M5 from the protective coverp. 263
(Fig. 2)p. 263
Fig. 3p. 263
+l Lift off the plastic protective cover using a screwdriverp. 263
+l Lift off the plastic protective cover using a screwdriverp. 263
(Fig. 3)p. 263
l Remove the protective cover.p. 263
Fig. 4p. 263
+l Slacken the screws M3 (A)p. 263
+l Slacken the screws M3 (A)p. 263
(Fig. 4)p. 263
l Loosen the screws M5 (B).p. 263
l Remove the screws, lift off the voltage regulator.p. 263
+Assembling the voltage regulatorp. 264
Assembling the voltage regulatorp. 264
Fig. 1p. 264
+Check the correct alignment of the gasket before placing it on the brush holderp. 264
+Check the correct alignment of the gasket before placing it on the brush holderp. 264
(Fig. 1)p. 264
Fig. 2p. 264
+The gasket must be pushed fully against the brush holderp. 264
+The gasket must be pushed fully against the brush holderp. 264
(Fig. 2)p. 264
Fig. 3p. 264
+l Attach the voltage regulatorp. 264
+l Attach the voltage regulatorp. 264
(Fig. 3)p. 264
+The gasket must be inserted into the rectifier plate.p. 264
The gasket must be inserted into the rectifier plate.p. 264
l Tighten the screw M3 (A).- Tightening torque 0.7- 1.0 Nm.p. 264
l Tighten the screw M5 (B).- Tightening torque 3.5- 4.5 Nm.p. 264
Fig. 4p. 264
+l Attach the protective cover and fasten it with washers and hexagon nuts 1p. 264
+l Attach the protective cover and fasten it with washers and hexagon nuts 1p. 264
(Fig. 4)p. 264
l Attach flat-pin plug, washer and hexagon nut to terminal (W) and tighten.- Tightening torque 2.7-3.8 Nm.p. 264
5.25 Electric starterp. 265
+Generalp. 265
Generalp. 265
Combustion engines need to be started by means of a special device, because they are not able to start by themselves. Considerable resistances caused by compression and friction must thereby be overcome.p. 265
The starter converts the electric energy stored in the battery into mechanical energy. The starter can only generate its power when a battery with appropriate capacity is available.p. 265
Duties of the starter:p. 265
+l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 265
l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 265
l establish the gear connection between starter and combustion engine.p. 265
l to maintain this connection.p. 265
l to switch on the starter current.p. 265
After starting the engine:p. 265
+l to return the starter pinion to initial position.p. 265
l to return the starter pinion to initial position.p. 265
l to switch off the starter current.p. 265
Directly acting electric starterp. 265
+This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 265
This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 265
Fig. 5p. 265
+1 Magnetic switchp. 265
1 Magnetic switchp. 265
2 Armaturep. 265
3 Actuating leverp. 265
4 Freewheeling clutchp. 265
5 Resetting springp. 265
6 Brushp. 265
7 Exciting windingp. 265
8 Armaturep. 265
9 Collectorp. 265
+Ignition switch in position "START"p. 265
Ignition switch in position "START"p. 265
Fig. 6 Magnetic switch openp. 265
With the ignition switch (5) in "START" position current flows from the battery (10) through the holding winding (2) and the pick-up winding (3).p. 265
The armature (1) is magnetically picked up and forces the pinion (8) with the actuating lever (6) to engage with the ring gear (7).p. 265
+1 Armaturep. 265
1 Armaturep. 265
2 Holding windingp. 265
3 Pick-up windingp. 265
4 Magnetic switchp. 265
5 Ignition switchp. 266
6 Actuating leverp. 266
7 Ring gearp. 266
8 Pinionp. 266
9 Freewheeling clutchp. 266
10 (Batteryp. 266
+Pinion meshes with the ring gearp. 266
Pinion meshes with the ring gearp. 266
Fig. 7 Magnetic switch closedp. 266
When the pinion (3) meshes with the flywheel mounted ring gear (4) and the magnetic switch (2) is closed, a strong current flows from the battery (7) directly into the exciting winding (6) and the armature winding, but not into the pick-up winding.p. 266
This causes the armature (5) to rotate with high speed and drives the pinion, which in turn drives the ring gear (4) with a speed of 200 to 300 rpmp. 266
+1 Pick-up windingp. 266
1 Pick-up windingp. 266
2 Magnetic switchp. 266
3 Pinionp. 266
4 Ring gearp. 266
5 Armaturep. 266
6 Exciting windingp. 266
7 Batteryp. 266
+Engine runningp. 266
Engine runningp. 266
Fig. 8p. 266
Once the engine is running and drives the pinion (1) via the ring gear (2), the freewheeling clutch (3) will open and prevent the armature (4) from being driven by the engine.p. 266
+1 Pinionp. 266
1 Pinionp. 266
2 (Ring gearp. 266
3 Freewheeling clutchp. 266
4 Armaturep. 266
+Ignition switch releasedp. 266
Ignition switch releasedp. 266
Fig. 9p. 266
When releasing the ignition switch (6) it will return from position "START" to "ON" and interrupt the starter current circuit. Current will now flow from the battery (9) through the contact plate in the pick-up winding (3) and the holding winding (2)…p. 266
This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops.p. 266
+1 Armaturep. 266
1 Armaturep. 266
2 Holding windingp. 266
3 Pick-up windingp. 266
4 Resetting springp. 267
5 Magnetic switchp. 267
6 Ignition switchp. 267
7 Pinionp. 267
8 Ring gearp. 267
9 Batteryp. 267
Magnetic switchp. 267
Fig. 10 Direct acting electric motorp. 267
Fig. 11 Geared motorp. 267
Armature (4), contact plate (3) and armature guide (6) form a closed unit. When the ignition switch is turned to "START", the armature is picked up and causes the pinion of the clutch to disengage.p. 267
This causes the pinion and the ring gear to mesh, while the contact plate establishes a connection between the contacts, which enable the main current to flow into the armature. Once the ignition switch is opened, the resetting spring (5) will pull t…p. 267
+1 Holding windingp. 267
1 Holding windingp. 267
2 Pick-up windingp. 267
3 Contact platep. 267
4 Armaturep. 267
5 Resetting springp. 267
6 Armature guidep. 267
Freewheeling clutchp. 268
Fig. 12 Freewheeling clutchp. 268
The freewheeling clutch is designed in such a way, that the flow of force is automatically interrupted if the pinion (5) of the clutch rotates faster than the freewheeling ring (1) at higher engine speeds.p. 268
This makes sure that the armature will only drive the ring gear, but can never be driven by the engine.p. 268
+1 Freewheeling ringp. 268
1 Freewheeling ringp. 268
2 Rollerp. 268
3 Roller springp. 268
4 Splined shaftp. 268
5 Pinionp. 268
6 Pinionp. 268
Trouble shooting "Starter"p. 268
+The most frequent fault is definitely a fully discharged battery.p. 268
+The most frequent fault is definitely a fully discharged battery.p. 268
The most frequent fault is definitely a fully discharged battery.p. 268
+If the starter rotates too slowly, either the brushes are partly worn off, or parts of the exciter or armature winding is shorted. In some cases oxidized electric contacts or a soiled ground connection causing extremely high voltage losses in the overalp. 268
If the starter rotates too slowlyp. 268
+If the starter only emits a clicking sound,- either the magnetic switch is defect / soiled (dismantle and clean))- the main contacts on the magnetic switch are worn off / soiled (scrape off carefully with a file and clean)- the starter motor is defectivp. 268
If the starter only emits a clicking soundp. 268
Frequently a jammed return mechanism is the reason for a starter failure.p. 268
Occasionally worn contacts are found on the magnetic return switchp. 268
Defects on the actual starter motor including pinion and carbon brushes are very rare.p. 268
With a trouble shooting chart the faults in the starter system can be narrowed down. The starter system can only work when many conditions are fulfilled at the same time.p. 268
+l Immobilizer deactivated?p. 268
l Immobilizer deactivated?p. 268
l Ignition switch OK?p. 268
l Travel lever in correct position?p. 268
l Emergency stop not actuated?p. 268
l Battery sufficiently charged?p. 268
l Battery poles OK?p. 268
l Main battery fuse OK?p. 268
l Main battery switch closed?p. 268
l Main starter cable (terminal 30) OK?p. 268
l Starter control cable (terminal 50) OK, voltage drop?p. 268
l Ground cable OK?p. 268
l Switching of magnetic switches OK?p. 268
The sequence of these tests is generally of no significance. It mainly depends on:p. 268
+l the experience of the specialistp. 268
l the experience of the specialistp. 268
l the failure probability of the component to be tested and the testing effort for the respective part.p. 268
Only if all criteria mentioned above are OK, the fault must be in the starter itself. In this case it can be repaired or replaced.p. 268
Testing and measuring the starterp. 269
+Function control with the starter removedp. 269
Function control with the starter removedp. 269
+Fasten the starter to make sure that it will not come loose during the test.p. 269
Fasten the starter to make sure that it will not come loose during the test.p. 269
Fig. 13p. 269
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 269
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 269
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 269
+If the motor does not start, the starter is defective. Repair or replace the starter.p. 269
If the motor does not start, the starter is defective. Repair or replace the starter.p. 269
+Checking the magnetic switchp. 269
Checking the magnetic switchp. 269
Fig. 14p. 269
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 269
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 269
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 269
+If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 269
If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 269
+Continuity test for the magnetic switchp. 269
Continuity test for the magnetic switchp. 269
Fig. 15p. 269
+l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 269
l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 269
l Replace the magnetic switch if no continuity is detected.p. 269
+6 Electronic controlp. 271
6 Electronic controlp. 271
+Installation location ESX-controlp. 272
Installation location ESX-controlp. 272
Bild 16 BC 972/1172p. 272
+Installation location ESX-controlp. 273
6.1 ESX controlp. 273
Installation location ESX-controlp. 274
+Installation location ESX-controlp. 274
Installation location ESX-controlp. 274
Bild 17 BC 972/1172p. 274
+7 Trouble shootingp. 343
+7 Trouble shootingp. 343
Notes on trouble shootingp. 344
+General notes on trouble shooting in hydraulic systemsp. 344
General notes on trouble shooting in hydraulic systemsp. 344
The following description of trouble shooting steps contains a small selection of possible faults that may occur during the operation of the machine. The fault lists are by no means complete, but the fault tables were compiled according to the experi…p. 344
Procedure:p. 344
On machines with electronic control (ESX) you should first of all check the CAN-Bus module, to find out if there is a error code and thus an electric fault present. If a fault code is present, continue trouble shooting by following the description of…p. 344
If no fault code is present, the fault may still be caused by an electrical problem or an operating error. The control will only report a fault if the current/voltage values are out of the nominal range. If e.g. a contact in a switch is defective, th…p. 344
+Important points for trouble shooting and fault rectificationp. 344
Important points for trouble shooting and fault rectificationp. 344
+Danger of injury!p. 344
Danger of injury!p. 344
Do not touch rotating parts of the engine.p. 344
When working on the travel pump and performing tests in the travel circuit block the wheels with suitable wheel chocks.p. 344
Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. Before repressurizing the system make sure that all line connections and por…p. 344
When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.p. 344
+It is not recommended to open or repair hydraulic units and components without comprehensive knowledge.p. 344
It is not recommended to open or repair hydraulic units and components without comprehensive knowledge.p. 344
Risk of damage to pressure gauges if incorrectly connected.p. 344
When performing trouble shooting it is assumed that the machine is correctly equipped and connected, that connections and hoses are free of faults and that setscrews have not been deadjusted without permission.p. 344
Progressive tests drawn up in the trouble shooting diagram lead to the detection of faults and their rectification by trained personnel.p. 344
+l Ensure strict cleanliness, clean ports and fittings before disconnecting.p. 344
l Ensure strict cleanliness, clean ports and fittings before disconnecting.p. 344
l Cover all openings and ports or close with plugs.p. 344
l Check the hydraulic oil level before and after the work.p. 344
l Use only clean oil according to specification.p. 344
l Check the hydraulic system for leaks, find and rectify the cause.p. 344
l Ensure strict cleanliness, clean ports and fittings before disconnecting.p. 344
l Fill new hydraulic units with hydraulic oil before starting operation.p. 344
l After changing a component thoroughly flush and bleed the hydraulic system.p. 344
l As far as possible conduct all measurements at operating temperature 40 … 50 °C.p. 344
l After changing a component check charge and high pressure, if necessary check the rotational speed.p. 344
+Hydraulic hosesp. 344
Hydraulic hosesp. 344
+Danger of injuryp. 344
Danger of injuryp. 344
Hydraulic hoses must be visually inspected at regular intervals.p. 344
Hydraulic hoses must be immediately replaced if:p. 344
+l the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks, etc.)p. 344
l the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks, etc.)p. 344
l the outer layer is brittle (formation of cracks in the hose material)p. 344
l the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hosep. 344
l the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blistersp. 344
l the hose is leakingp. 344
l the hydraulic hose has separated from the fittingp. 344
l the fitting shows corrosion that impairs both function and strengthp. 344
l the fitting is deformed in a way that both function and strength are affectedp. 344
l the storage time and utilization period has expired.p. 344
The machine drives with the travel lever in „NEUTRAL“p. 345
The machine does not drivep. 347
Machine travels to one direction only or to one travel direction with reduced powerp. 349
Hydraulic oil overheatingp. 352
Insufficient travel power, max speed is not reachedp. 353
No steering function / steering stiff, end stops are not reachedp. 358
Failure of central lubrication system (grease emerges from relief valve)p. 359
Trouble shooting travel systemp. 361
+Travel drivep. 361
Travel drivep. 361
+The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.p. 361
The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.p. 361
The specified numbers in the table indicate the probability of the fault cause and thus the recommended trouble shooting sequence, based on our previous experience.p. 361
+Trouble shootingp. 361
Trouble shootingp. 361
Travel drivep. 361
+Symptomsp. 361
Symptomsp. 361
+Machine does not travel (forward and reverse)p. 361
Machine does not travel (forward and reverse)p. 361
+Machine travels to one direction onlyp. 361
Machine travels to one direction onlyp. 361
+Left or right hand side blocked in 1 directionp. 361
Left or right hand side blocked in 1 directionp. 361
+1 wheel blockedp. 361
1 wheel blockedp. 361
+Machine moves with travel direction switch in neutralp. 361
Machine moves with travel direction switch in neutralp. 361
+The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.p. 363
The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.p. 363
The specified numbers in the table indicate the probability of the fault cause and thus the recommended trouble shooting sequence, based on our previous experience.p. 363
+Trouble shootingp. 363
Trouble shootingp. 363
Working hydraulicsp. 363
+Symptomsp. 363
Symptomsp. 363
+No steering function (dozer blade/bucket function OK)p. 363
No steering function (dozer blade/bucket function OK)p. 363
+No dozer blade/bucket function (steering OK)p. 363
No dozer blade/bucket function (steering OK)p. 363
+No steering and dozer blade/bucket functionp. 363
No steering and dozer blade/bucket functionp. 363
+Steering function only to one sidep. 363
Steering function only to one sidep. 363
+Dozer blade/bucket function only to one directionp. 363
Dozer blade/bucket function only to one directionp. 363
+all work functions too slow / fast / jerkyp. 363
all work functions too slow / fast / jerkyp. 363
+individual work functions too slow / fast / jerkyp. 363
individual work functions too slow / fast / jerkyp. 363
41 Pilot pressure connection, travel range selectorp. 371
42 Plug, travel range selectorp. 371
43 Plug, brakep. 371
44 Charge pressure switch (5 bar), right hand tandem pump, normally closedp. 371
45 Connection from left hand charge pumpp. 371
46 Charge pressure switch (5 bar), left hand tandem pump, normally closedp. 371
47 Filter outlet, to the charge oil supply port on left hand tandem pumpp. 371
48 Port X, pilot pressurep. 371
49 Port G, synchronous controlp. 371
50 Port T, leak oilp. 371
Measuring and adjustment points on control valve blockp. 372
+Measuring and adjustment pointsp. 372
Measuring and adjustment pointsp. 372
Fig. 2 Control valve blockp. 372
+Pos.p. 373
Pos.p. 373
+Designationp. 373
Designationp. 373
+Pos. ii electric wiring diagramp. 373
Pos. ii electric wiring diagramp. 373
+Pos. in hydraulic diagramp. 373
Pos. in hydraulic diagramp. 373
+Measuring valuep. 373
Measuring valuep. 373
+1p. 373
1p. 373
+Proportional solenoid, steering rightp. 373
Proportional solenoid, steering rightp. 373
+Y92p. 373
Y92p. 373
+0 – 1000 mAp. 373
0 – 1000 mAp. 373
+1ap. 373
1ap. 373
+Proportional solenoid, steering leftp. 373
Proportional solenoid, steering leftp. 373
+Y93p. 373
Y93p. 373
+0 – 1000 mAp. 373
0 – 1000 mAp. 373
+2p. 373
2p. 373
+Switching solenoid, float positionp. 373
Switching solenoid, float positionp. 373
+Y102p. 373
Y102p. 373
+0 / 24Vp. 373
0 / 24Vp. 373
+2ap. 373
2ap. 373
+2. Switching solenoid, float positionp. 373
2. Switching solenoid, float positionp. 373
+Y102p. 373
Y102p. 373
+0 / 24Vp. 373
0 / 24Vp. 373
+3p. 373
3p. 373
+Proportional solenoid, blade downp. 373
Proportional solenoid, blade downp. 373
+Y109p. 373
Y109p. 373
+0 – 1000 mAp. 373
0 – 1000 mAp. 373
+3ap. 373
3ap. 373
+Proportional solenoid, blade up (on opposite side)p. 373
Proportional solenoid, blade up (on opposite side)p. 373
+Y108p. 373
Y108p. 373
+0 – 1000 mAp. 373
0 – 1000 mAp. 373
+4p. 373
4p. 373
+Pressure test port, pilot pressure steering leftp. 373
Pressure test port, pilot pressure steering leftp. 373
+Map. 373
Map. 373
+20 -30 barp. 373
20 -30 barp. 373
+4ap. 373
4ap. 373
+Proportional solenoid, pilot pressure steering right (on opposite side)p. 373
Proportional solenoid, pilot pressure steering right (on opposite side)p. 373
+Mbp. 373
Mbp. 373
+20 -30 barp. 373
20 -30 barp. 373
+5p. 373
5p. 373
+Pressure test port, pilot pressure blade upp. 373
Pressure test port, pilot pressure blade upp. 373
+Map. 373
Map. 373
+10 -30 barp. 373
10 -30 barp. 373
+5ap. 373
5ap. 373
+Proportional solenoid, pilot pressure blade down (on opposite side)p. 373
Proportional solenoid, pilot pressure blade down (on opposite side)p. 373
+Mbp. 373
Mbp. 373
+10 -30 barp. 373
10 -30 barp. 373
+6p. 373
6p. 373
+Pressure test port, tank pre-tensioning valvep. 373
Pressure test port, tank pre-tensioning valvep. 373
+Mtp. 373
Mtp. 373
+10 -15 barp. 373
10 -15 barp. 373
+7p. 373
7p. 373
+Pressure test port, working pressurep. 373
Pressure test port, working pressurep. 373
+Mpp. 373
Mpp. 373
+0 -230 +10 barp. 373
0 -230 +10 barp. 373
+8p. 373
8p. 373
+LS-pressure limitationp. 373
LS-pressure limitationp. 373
+0-210 + 10 barp. 373
0-210 + 10 barp. 373
+9p. 373
9p. 373
+Tank pre-loading valvep. 373
Tank pre-loading valvep. 373
+15 bar (dozer blade in top position, drop with floating position)p. 373
15 bar (dozer blade in top position, drop with floating position)p. 373
+10p. 373
10p. 373
+Pressure test port, steering leftp. 373
Pressure test port, steering leftp. 373
+M18p. 373
M18p. 373
+0 -230 +10 barp. 373
0 -230 +10 barp. 373
+11p. 373
11p. 373
+Pressure test port, steering rightp. 373
Pressure test port, steering rightp. 373
+M19p. 373
M19p. 373
+0 -230 +10 barp. 373
0 -230 +10 barp. 373
+12p. 373
12p. 373
+Pressure test port, blade downp. 373
Pressure test port, blade downp. 373
+M31p. 373
M31p. 373
+0 -230 +10 barp. 373
0 -230 +10 barp. 373
+13p. 373
13p. 373
+Pressure test port, blade upp. 373
Pressure test port, blade upp. 373
+M32p. 373
M32p. 373
+0 -230 +10 barp. 373
0 -230 +10 barp. 373
+14p. 373
14p. 373
+mechanical endstopp. 373
mechanical endstopp. 373
+15p. 373
15p. 373
+Shock valvep. 373
Shock valvep. 373
+260 barp. 373
260 barp. 373
+9 Air conditioning systemp. 375
+9 Air conditioning systemp. 375
9.1 Physical basicsp. 376
+In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system.p. 376
In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system.p. 376
The four well known physical conditions of water apply also for the refrigerant in the air conditioning system.p. 376
1. gaseous (invisible)p. 376
2. vaporousp. 376
3. liquidp. 376
4. solidp. 376
Fig. 1p. 376
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 reversible. When withdrawing…p. 376
+A – heat absorptionp. 376
A – heat absorptionp. 376
B- Heat dissipationp. 376
Fig. 2p. 376
+Heat always flows from the warmer to the colder matter. Any matter consists of a mass of moving molecules. The rapidly moving molecules or a warmer matter dissipate part of their energy to the slower moving molecules with less heat. The movement of t…p. 376
Pressure and boiling pointp. 377
The boiling point is the temperature at which fluid changes to gaseous state.p. 377
Changing the pressure above a fluid also changes the boiling point. It is a well known fact, that e.g. the lower the pressure applied to water, the lower the boiling point.p. 377
When looking at water, the following values do apply:p. 377
+l Atmospheric pressure, boiling point 100°Cp. 377
l Atmospheric pressure, boiling point 100°Cp. 377
l Overpressure 0.4 bar, boiling point 126°Cp. 377
l Vacuum -0.6 bar, boiling point 71°Cp. 377
For an optimal exchange of heat, liquid refrigerants must have a low boiling point, so that they can absorb and dissipate heat quickly.p. 377
Fig. 3 Steam pressure curvep. 377
Steam pressure curve for refrigerant R134ap. 377
The steam pressure curve is a means for explaining the operation principle of an air conditioning system.p. 377
A- liquidp. 377
B- gaseousp. 377
The diagram shows the evaporation curve of R134a. The diagram for example shows, that R134a is liquid at 0°C and a pressure of 5 bar, but becomes gaseous at 40°C and 5 bar.p. 377
For better understanding one must also be aware of the following:p. 377
1. A gas heats up when being compressed (e.g. air pump, turbo charger, …).p. 377
2. When relieving gas it will cool down (e.g. white frost forms on the valve when relieving air pressure from a car tire).p. 377
3. Condensing gas dissipates a lot of heat energy.p. 377
4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby cools down the surrounding environment (e.g. alcohol on skin)p. 377
+At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated …p. 377
At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated …p. 377
Fig. 4 Pressure – Temperature Diagramp. 377
In the pressure – temperature diagram for the refrigerant the drawn in closed curve shows the cycle of the refrigerant. This cycle permanently continues in direction of the arrow.p. 377
The characters A, B, C, D stand for:p. 377
A – compressionp. 377
B- condensationp. 377
C- relaxationp. 377
D- evaporation.p. 377
+Excerpt from the wet steam tablep. 378
+Excerpt from the wet steam tablep. 378
This table is used for the determination of evaporation and condensation temperature.p. 378
+Saturation temperaturep. 378
Saturation temperaturep. 378
+Overpressure (pressure gauge reading Pe in bar)p. 378
Overpressure (pressure gauge reading Pe in bar)p. 378
+Absolute pressure (pamb = 1 bar P in bar)p. 378
Absolute pressure (pamb = 1 bar P in bar)p. 378
+-20p. 378
-20p. 378
+0,33p. 378
0,33p. 378
+1,33p. 378
1,33p. 378
+-10p. 378
-10p. 378
+1,01p. 378
1,01p. 378
+2,01p. 378
2,01p. 378
+0p. 378
0p. 378
+1,93p. 378
1,93p. 378
+2,93p. 378
2,93p. 378
+10p. 378
10p. 378
+3,15p. 378
3,15p. 378
+4,15p. 378
4,15p. 378
+20p. 378
20p. 378
+4,72p. 378
4,72p. 378
+5,72p. 378
5,72p. 378
9.2 Refrigerant R134ap. 379
+Generalp. 379
Generalp. 379
The evaporation and condensation process is the method commonly used in mobile air conditioning systems. The system in this case works with a substance that boils at low temperature, a substance referred to a refrigerant. The refrigerant used is tetr…p. 379
Although the refrigerant circuit is a hermetically closed loop, the system loses approx. 100g of refrigerant over the course of 1 year by diffusion through hoses, pipes and seals, even though the system is free of leaks. If too much refrigerant is lo…p. 379
Physical data of the refrigerant R134ap. 379
Chemical formula:p. 379
CH2F-CF3 or CF3-CH2Fp. 379
Chemical designation:p. 379
Tetrafluoroethanep. 379
Boiling point at 1 bar:p. 379
– 26.5 °Cp. 379
Solidification point:p. 379
-101.6 °Cp. 379
Critical temperature:p. 379
100,6 °Cp. 379
Critical pressure:p. 379
40.56 bar (absolute)p. 379
Critical point:p. 379
Critical point (critical temperature and critical pressure) means that above this point there is no separating interface between liquid and gas. Above its critical point any substance is gaseous. At temperatures below the critical point all refrigera…p. 379
Characteristics of the refrigerant R134a:p. 379
Refrigerant R134a is currently available under the following trade marks. H-FKW 134a SUVA 134a KLEA 134ap. 379
Colour:p. 379
Refrigerant in form of vapour or liquid is colourless as water. The gas is invisible. Only the bordering layer between gas and liquid is visible. (Fluid level in rising pipe of filling cylinder or bubbles in inspection glass). In the inspection glass…p. 379
Steam pressure:p. 379
In an incompletely filled, closed container, vaporous 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 pressure and is frequently refer…p. 379
Physical properties of R134a:p. 379
The steam pressure curves of R134a and other refrigerants are partly very similar, making a clear differentiation solely by pressure impossible. With R 134a the compressor is lubricated by special synthetic refrigeration oils, e.g. PAG-oils (polyalky…p. 379
Behaviour with metals:p. 379
In pure condition refrigerant R134a is chemically stable and does not attack iron and aluminium. However, contamination of the refrigerant, e.g. with chlorine compounds, leads to aggressiveness against certain metals and plastics. This can cause clog…p. 379
Critical temperature / critical pressure:p. 379
Up to a gas pressure of 39.5 bar overpressure (this corresponds with a temperature of 101 °C) the refrigerant R134a remains chemically stable, above this temperature the refrigerant decomposes (see combustibility).p. 379
Water content:p. 379
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 liquid container has absorbed approx. 8 gr. of water, the refrigerant circuit tra…p. 379
Inflammability:p. 380
Refrigerant is not inflammable. On the contrary, it has fire inhibiting or fire extinguishing properties. Refrigerant is decomposed by flames or glowing surfaces. Ultraviolet light also cracks refrigerant (caused by electric welding). This results in…p. 380
Filling factor:p. 380
In a container there must be a steam space above the liquid space. The liquid expands with increasing temperature. The steam filled space becomes smaller. From a certain time on the container will be filled with just liquid. After this only a minor t…p. 380
+Environmental aspectsp. 380
Environmental aspectsp. 380
The contribution of R134a to the greenhouse effect is by factor 10 smaller than the contribution of R12.p. 380
Since approx. 1992 the air conditioning systems for newly produced construction equipment were successively converted to refrigerant R134a. This refrigerant does not contain any chlorine and is thus harmless for the ozone layer. Until approx. 1992 ai…p. 380
9.3 Compressor oil / refrigeration oilp. 380
+The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up.p. 380
The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up.p. 380
Part of the compressor oil dissolves in the refrigerant until saturation is reached, so that a gas mixture of refrigerant, water steam, compressor oil and contrast agent circulates through the system.p. 380
Compressor oil (the oil quantity should be 10 % of the refrigerant weight) mixes with the refrigerant and circulates permanently through the system.p. 380
In connection with R134a- air conditioning systems special synthetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are used. This is necessary, because e.g. mineral oil does not mix with R134a. Apart from this, the materials in the R134a air …p. 380
Properties of compressor oil / refrigeration oil:p. 380
The most important properties are high solvency in connection with refrigerants, good lubrication characteristics, that they are free of acids and their low water content. For this purpose only certain oils can be used. PAG-oils suitable for use with…p. 380
9.4 Working principle of the air conditioning systemp. 381
+All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri…p. 381
All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri…p. 381
Fig. 1 Principle sketch of an air conditioning systemp. 381
An engine driven compressor (1) draws in gaseous refrigerant from the evaporator (5) and compresses it. During this process the temperature of the refrigerant increases tremendously.p. 381
The refrigerant vapour is then pumped to the condenser (2). This condenser is arranged directly in front of the vehicle radiator, so that a sufficient air flow is assured. In the condenser (2) the gas is cooled down and consequently liquefied.p. 381
In the dryer / liquid container (3) the refrigerant is then collected and freed of moisture and contaminants.p. 381
The expansion valve (4) regulates the flow rate from the dryer / liquid container (3) back to the evaporator (5) and the circuit starts again.p. 381
+9.5 Monitoring devicesp. 381
+Pressure switchp. 381
Pressure switchp. 381
The pressure switch (8) is used as monitoring feature for too high and too low pressures. The switching contacts (4 and 5) effect the magnetic clutch of the compressor via a relay (6).p. 381
If the system pressure increases excessively, e.g. because of a excessively soiled condenser, a failed fan or a defective expansion valve, the high pressure contact (5) will cut off the electric power supply to the magnetic clutch when the set pressu…p. 381
The low pressure contact (4) interrupts the electric power supply to the magnetic clutch when the set pressure is fallen short of (possible causes: lack of refrigerant, defective expansion valve, too low heat load, defective evaporator fan, …). Sin…p. 381
+Thermostatp. 381
Thermostatp. 381
A frost protection thermostat (3) protects the evaporator against icing. Similar to the pressure switch, the thermostat activates or deactivates the magnetic clutch for the compressor. Depending on the design, the feeler of the temperature control is…p. 381
With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature.p. 381
+Monitoring chainp. 382
Monitoring chainp. 382
Fig. 2 Monitoring chain consisting of:p. 382
+l 1 Switchp. 382
l 1 Switchp. 382
l 2 Fusep. 382
l 3 Thermostatp. 382
l 4 Low pressure switch contactp. 382
l 5 High pressure switch contactp. 382
l 6 Relayp. 382
l 7 Connection for magnetic clutchp. 382
l 8 Pressure switchp. 382
9.6 Description of componentsp. 383
+Compressorp. 383
Compressorp. 383
Fig. 1 Refrigerant compressorp. 383
The compressor is mounted to the engine and has the duty to build up the refrigerant pressure required for the function of the system. Coupling and decoupling is accomplished by an electromagnetically controlled mechanical clutch (Y15), which is inte…p. 383
The refrigerant compressor is a 7-cylinder compressor in swash plate design.p. 383
The gaseous refrigerant enters into the compressor through the cylinder heads at the end of the compressor and is delivered to the condensers in desnified state.p. 383
The oil sump of the compressor is filled with refrigeration oil up to level of the filler and level inspection bore. An internal gear pump at the end of the drive shaft delivers this oil to the bearing locations inside the compressor for lubrication.p. 383
Compressor datap. 383
Displacement: 155 cm²p. 383
Weight: 6,9 kgp. 383
max. rpm: 6000p. 383
Sense of rotation: cwp. 383
Refrigerant: R134ap. 383
Oil quantity (scope of delivery): 207 grp. 383
Oil: PAG SP-20 (H14-003-404)p. 383
Fig. 2 Compressor mounting, bottom viewp. 384
+Pos.p. 384
Pos.p. 384
+Designationp. 384
Designationp. 384
+Pos. ii electric wiring diagramp. 384
Pos. ii electric wiring diagramp. 384
+Measuring valuep. 384
Measuring valuep. 384
+1p. 384
1p. 384
+Pressure side filling portp. 384
Pressure side filling portp. 384
+2p. 384
2p. 384
+Suction side filling portp. 384
Suction side filling portp. 384
+3p. 384
3p. 384
+Plug connectionp. 384
Plug connectionp. 384
+X14p. 384
X14p. 384
+0-24 Voltp. 384
0-24 Voltp. 384
+4p. 384
4p. 384
+Magnetic clutchp. 384
Magnetic clutchp. 384
+Y15p. 384
Y15p. 384
+24 Volt, 1.75 Amp.p. 384
24 Volt, 1.75 Amp.p. 384
The service valves are installed directly on the compressor. These are used to e.g. evacuate and fill the system.p. 384
Two manual shut-off valves are also installed here. These valves can be used e.g. in case of a compressor failure. The compressor can be replaced after closing the valves. After completion of all repair work the valves must be reopened, so that the s…p. 384
+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).p. 384
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).p. 384
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.p. 384
The actual quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 384
+Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 384
Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 384
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.p. 384
+Reason of oil lossp. 385
Reason of oil lossp. 385
+Amount of oil lostp. 385
Amount of oil lostp. 385
+Loss when emptyingp. 385
Loss when emptyingp. 385
+approx. 15 grp. 385
approx. 15 grp. 385
+Defective A/C hosep. 385
Defective A/C hosep. 385
+approx. 30 grp. 385
approx. 30 grp. 385
+Hose changep. 385
Hose changep. 385
+approx. 15 grp. 385
approx. 15 grp. 385
+Replacement of condenserp. 385
Replacement of condenserp. 385
+approx. 30 grp. 385
approx. 30 grp. 385
+Replacement of evaporatorp. 385
Replacement of evaporatorp. 385
+approx. 30 grp. 385
approx. 30 grp. 385
+Replacement of liquid containerp. 385
Replacement of liquid containerp. 385
+approx. 30 grp. 385
approx. 30 grp. 385
+Replacement of expansion valvep. 385
Replacement of expansion valvep. 385
+approx. 15 grp. 385
approx. 15 grp. 385
+Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A/C-system and thus a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly.p. 385
Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A/C-system and thus a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly.p. 385
The quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 385
The compressor oil quantity must be 10% of the refrigerant quantity in the complete system.p. 385
With a refrigerant filling of 1100 gr. the system requires a compressor oil / refrigerant oil filling of 100 gr.p. 385
Procedure:p. 385
Drain and measure the compressor oil from the old compressor.p. 385
Drain the compressor oil from the new compressor and only fill in the exact quantity that had been drained out of the old compressor. The compressor oil from the new compressor can be used for this purpose.p. 385
+Topping up compressor oil / refrigeration oil is possible 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…p. 385
Topping up compressor oil / refrigeration oil is possible 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…p. 385
Condenserp. 385
Fig. 1 Condensersp. 385
The 2 condensers are mounted on a foldable frame in front of the combustion air intake opening on the ROPS. They dissipate heat energy from the system into the surrounding air and liquefiy the gaseous refrigerant.p. 385
+The fins must be free of dirt and damage.p. 385
The fins must be free of dirt and damage.p. 385
+When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 385
When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 385
The fluid container collects the fluid drops and passes these then as a constant flow to the expansion valve. Moisture that has entered during assembly of the refrigerant circuit is absorbed by a dryer in the fluid container.p. 386
At evaporation temperatures below zero the refrigerant will deposit previously absorbed moisture on the expansion valve, where this water turns into ice and thus adversely affects the controllability of the expansion valve. Moreover, moisture in the …p. 386
Inside the refrigerant container the heavy liquid refrigerant collects in the lower part of the container, flows through a rising pipe to the outlet marked "A" and thus ensures bubble free operation of the expansion valve.p. 386
+Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years, before the start of the season.p. 386
Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years, before the start of the season.p. 386
+The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 386
The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 386
This requires emptying the air conditioning system!p. 386
Installation position:p. 386
The arrow marks on the filter/dryer must point in flow direction, i.e. towards the expansion valve.p. 386
Filter/dryer cannot be treated for further use!p. 386
+Safety valvep. 386
Safety valvep. 386
Fig. 2p. 386
The fluid container is equipped with a safety valve.p. 386
Response pressure 32 +/- 4 barp. 386
Tightening torque 10 – 15 Nmp. 386
+Inspection glassp. 386
Inspection glassp. 386
Fig. 3p. 386
During operation the refrigerant must flow through the inspection glass without air bubbles. In most cases the presence of air bubbles is a sign for a too low refrigerant level in the system. Apart from this, the refrigerant may not sufficiently cond…p. 386
However, incorrect evacuation or filling may also be the reason for air entering into the system and since air cannot be condensed, one will not be able to get rid of these bubbles by topping up refrigerant. In this case the air conditioning system n…p. 386
+Air in the system is characterized by high pressures and temperatures.p. 387
Air in the system is characterized by high pressures and temperatures.p. 387
On R134a refrigeration systems from KONVEKTA the inspection glasses are equipped with moisture indicators. In addition to the float, the dryer/collector/inspection glass combination has an indicator pearl integrated in the inspection glass, which cha…p. 387
The refrigerant level should be inside the inspection glass and should only be checked after approx. 5 minutes continuous operation, because the refrigerant must first evenly distribute all over the system.p. 387
+In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 387
In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 387
Pressure switchp. 387
Fig. 1p. 387
After a minimum pressure is reached in the low pressure side or a maximum pressure in the high pressure side, the pressure switch (B75) will switch of the magnetic clutch of the compressor, thus to avoid destruction of system components by excessive …p. 387
Working pressure:p. 387
Low pressure off: 1,5 ±0,5 barp. 387
Low pressure on: 3.5 barp. 387
Overpressure off: 25,0 ±1,5 barp. 387
Overpressure on: 18,0 ±1,5 barp. 387
Expansion valvep. 388
Fig. 1 Expansion valvep. 388
The expansion valve (1) is located inside the cab on the blower box. The expansion valve always allows a small amount of the high pressure liquefied refrigerant to flow into the evaporator, which has a much lower pressure. This lower pressure causes …p. 388
The thermostatic expansion valve operates with an external pressure compensation. This type of expansion valve works with high accuracy, because it uses pressure and temperature at the evaporator outlet and adjusts and overheating of approx. 7 K. The…p. 388
+In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 388
In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 388
Evaporatorp. 388
Fig. 1 Evaporatorp. 388
The evaporator is located inside the cab in the blower box. It consists of a heat exchanger (inside air – refrigerant), with refrigerant flowing to a pipe system with cooling flanges.p. 388
As with the condenser, correct operation of all fans and cleanliness of the fins must be assured.p. 388
Air conditioning systems have a circulation air filter mounted in the air flow in front of the evaporator, which should be cleaned or changed by the operator, depending on the amount of dirt.p. 388
Fig. 2 Changing the circulation air filterp. 388
+l Remove the slotted cover from the console behind the driver’s seat.p. 388
l Remove the slotted cover from the console behind the driver’s seat.p. 388
+l Remove both circulation air filters and insert the new circulation air filtersp. 388
(Fig. 2)p. 388
l Fasten the slotted cover to the console.p. 388
A condensation water filter is mounted in the air flow after the evaporator. This filter has the function to collect the water that has condensed from the air in the evaporator block and to discharge this water into the water pan With a defective con…p. 388
+When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 389
When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 389
Defroster thermostatp. 389
Fig. 1 Defroster thermostatp. 389
The feeler of a defroster thermostat (B117) to switch off the magnetic clutch in case of icing up or to switch the clutch back on after defrosting, is mounted on the evaporator. The correct adjustment of the defroster thermostat as well as the correc…p. 389
Switching point on: + 1°C (± 1°C)p. 389
Switching point off: + 5,5°C (± 1°C)p. 389
+It is very important that the feeler is mounted downstream of the evaporator, but before the pressure sensor, in countercurrent direction, with full length and insulated against the outside temperature.p. 389
It is very important that the feeler is mounted downstream of the evaporator, but before the pressure sensor, in countercurrent direction, with full length and insulated against the outside temperature.p. 389
Blower with rotary speed modulep. 390
Fig. 1 Radial twin blowerp. 390
The radial twin blower (E37) draws in air from inside the cabin through the circulation air filter. The drawn in air is cooled down in the evaporator fins and guided through air ducts and nozzles back into the cabin.p. 390
The rotary speed module (blower module, A53) is mounted on the blower housing. This module serves the purpose of converting the PWM current signals from the Climatronic control into corresponding voltage signals for the blower motor. The fan voltage …p. 390
Solenoid valve, heatingp. 390
The heating valve (Y138) is a black/white valve and is opened by the Climatronic control with 24V. When the voltage supply is switched off, the applied water pressure will close the valve as a pilot controlled valve. It is thus very important to main…p. 390
Fig. 2p. 390
Intended intermediate positions are realized via temporal cycling. The length of the total interval is approx. 10 seconds. The temporal proportion of "open" is between 30-100%.p. 390
Fig. 3 Solenoid valve for heating Y138p. 390
Pipes and hosesp. 391
+Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug…p. 391
Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug…p. 391
O-rings are made of a special type of chloroprene rubber (neoprene). Before assembly of the air conditioning system these O-rings must be lubricated with compressor oil / refrigeration oil. The O-rings must always be replaced when assembling A/C-comp…p. 391
Recommended tightening torques for O-ring sealed fittingsp. 391
+Threadp. 391
+Threadp. 391
Threadp. 391
+Spanner widthp. 391
Spanner widthp. 391
+Torquep. 391
Torquep. 391
+5/8“p. 391
5/8“p. 391
+17 or 19p. 391
17 or 19p. 391
+13,6 – 20,3 Nmp. 391
13,6 – 20,3 Nmp. 391
+3/4“p. 391
3/4“p. 391
+32,5 – 39,3 Nmp. 391
32,5 – 39,3 Nmp. 391
+7/8“p. 391
7/8“p. 391
+27p. 391
27p. 391
+35,3 – 42,0 Nmp. 391
35,3 – 42,0 Nmp. 391
+1 1/16“p. 391
1 1/16“p. 391
+32p. 391
32p. 391
+40,7 – 47,5 Nmp. 391
40,7 – 47,5 Nmp. 391
+M30X2p. 391
M30X2p. 391
+36p. 391
36p. 391
+105,0 – 115,0 Nmp. 391
105,0 – 115,0 Nmp. 391
+M36X2p. 391
M36X2p. 391
+41p. 391
41p. 391
+165,0 – 175,0 Nmp. 391
165,0 – 175,0 Nmp. 391
Bending radii for air conditioning hosesp. 391
+Hose typep. 391
Hose typep. 391
+Nominal widthp. 391
Nominal widthp. 391
+Bending radiusp. 391
Bending radiusp. 391
+GH 134p. 391
GH 134p. 391
+NW8p. 391
NW8p. 391
+min. 50 mmp. 391
min. 50 mmp. 391
+GH 134p. 391
GH 134p. 391
+NW10p. 391
NW10p. 391
+min. 65 mmp. 391
min. 65 mmp. 391
+GH 134p. 391
GH 134p. 391
+NW12p. 391
NW12p. 391
+min. 75 mmp. 391
min. 75 mmp. 391
+GH 134p. 391
GH 134p. 391
+NW16p. 391
NW16p. 391
+min. 100 mmp. 391
min. 100 mmp. 391
+GH 494p. 391
GH 494p. 391
+NW20p. 391
NW20p. 391
+min. 160 mmp. 391
min. 160 mmp. 391
+GH 494p. 391
GH 494p. 391
+NW25p. 391
NW25p. 391
+min. 194 mmp. 391
min. 194 mmp. 391
+GH 494p. 391
GH 494p. 391
+NW32p. 391
NW32p. 391
+min. 225 mmp. 391
min. 225 mmp. 391
+9.11 Servicing the air conditioningp. 392
9.7 Climatronic controlp. 392
+The Climatronic control is integrated in the housing of the control unit.p. 392
The Climatronic control is integrated in the housing of the control unit.p. 392
Fig. 1 Front view of Climatronic controlp. 392
Fig. 2 Backside with connection terminalp. 392
+When the ignition is switched on the Climatronic control is supplied with vehicle voltage via terminal X26:1 and can be switched on.p. 392
When the ignition is switched on the Climatronic control is supplied with vehicle voltage via terminal X26:1 and can be switched on.p. 392
As long as the engine is not running, no signal is applied to terminal X26:4 on the control. After a period of 10 minutes without the engine running the Climatronic limits the blower speed to 30% to prevent unnecessary discharging of the battery.p. 392
In automatic mode the control regulates the cabin temperature. This is accomplished with the help of the two sensors:p. 392
+l Room temperature sensor B29p. 392
+l Room temperature sensor B29p. 392
(Fig. 3)p. 392
+l Blow out temperature sensor B118p. 392
(Fig. 3)p. 392
The two sensor signals are fault monitored, i.e. in case of cable breakage, short circuit or disconnected sensors a fault will be displayed and the Climatronic will be out of servise.p. 392
The digital output signals for:p. 392
+l the magnetic clutch of the compressor (Y15) andp. 392
l the magnetic clutch of the compressor (Y15) andp. 392
l the solenoid valve for heating (Y138)p. 392
as well as the analog PWM-signalp. 392
+l for the blower speed modulep. 392
l for the blower speed modulep. 392
are generated from the sensor signals.p. 392
Fig. 3 Sensorsp. 392
The two sensors are technically identical, they only differ by their colour identification:p. 392
Room temperature sensor (B29): blue colour mark,p. 392
Blow out temperature sensor (B119): yellow colour mark.p. 392
These sensors are NTC-elements, i.e. the electric resistance drops with increasing temperature.p. 392
+Designationp. 392
Designationp. 392
+Measuring valuep. 392
Measuring valuep. 392
+Blow out temperature sensorp. 392
Blow out temperature sensorp. 392
+B118p. 392
B118p. 392
+55kW at -10°Cp. 392
+55kp. 392
Wp. 392
+32kp. 392
Wp. 392
+19kp. 392
Wp. 392
+12kp. 392
Wp. 392
+10kp. 392
Wp. 392
+Room temperature sensorp. 392
Room temperature sensorp. 392
+B29p. 392
B29p. 392
+55kW at -10°Cp. 392
+55kp. 392
Wp. 392
+32kp. 392
Wp. 392
+19kp. 392
Wp. 392
+12kp. 392
Wp. 392
+10kp. 392
Wp. 392
Various functions of control logicp. 393
This point deals with special control steps, which are not self explanatory, and with technical backgrounds of Climatronic functions, which are worth knowing.p. 393
+Automatic operationp. 393
Automatic operationp. 393
Fig. 4p. 393
+(LED under the hand 7p. 393
(Fig. 4)p. 393
Fig. 5p. 393
+Air conditioning operation: In order to achieve a cooling effect, the compressor outlet of the control must be manually released also in automatic operation by pressing button 3p. 393
Air conditioning operation:p. 393
(Fig. 5)p. 393
Manual operation of heatingp. 394
Fig. 6p. 394
+The automatic control of the heating valve can be switched off with push button 12p. 394
(Fig. 6)p. 394
Manual blower speed settingp. 394
Fig. 7p. 394
+Automatic blower speed control can be disabled with button 10p. 394
(Fig. 7)p. 394
REHEAT function (dehumidification function)p. 395
Fig. 8p. 395
+When pressing button 11p. 395
(Fig. 8)p. 395
Circulation air operationp. 395
Fig. 9p. 395
+Button 9p. 395
(Fig. 9)p. 395
Error messagesp. 396
+Faulty room temperature sensorp. 396
Faulty room temperature sensorp. 396
Fig. 10p. 396
’F0’ flashes in display. The Climatronic is unable to work without the actual temperature value and is therefore out of function when this error message is displayed. The Climatronic is only operable again after this fault (cable breakage, short …p. 396
Faulty blow out temperature sensorp. 396
Fig. 11p. 396
’F1’ flashes in the display. The Climatronic is unable to work without the blow out temperature value and is therefore out of function when this error message is displayed. The Climatronic is only operable again after this fault (cable breakage, …p. 396
+9.11 Servicing the air conditioningp. 397
9.8 Measuring the compressor oil levelp. 397
+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 / refrigeration oil PAG SP-20 (H14-003-404).p. 397
+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 / refrigeration oil PAG SP-20 (H14-003-404).p. 397
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 / refrigeration oil PAG SP-20 (H14-003-404).p. 397
+l Run the compressor for 10 minutes at engine idle speed.p. 397
l Run the compressor for 10 minutes at engine idle speed.p. 397
l remove the refrigerant from the air conditioning system.p. 397
Fig. 1p. 397
+l Turn the compressor, as shown inp. 397
+l Turn the compressor, as shown inp. 397
(Fig. 1)p. 397
l Remove the oil plug.p. 397
+The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 397
The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 397
+l Close the oil plug again.p. 397
l Close the oil plug again.p. 397
+The contact area must be clean and should be free of damage.p. 397
The contact area must be clean and should be free of damage.p. 397
Tightening torque 15 to 25 Nmp. 397
+l Refill the air conditioning system.p. 397
l Refill the air conditioning system.p. 397
+9.11 Servicing the air conditioningp. 397
9.9 Checking the magnetic clutchp. 397
+l Measure the voltage.p. 397
+l Measure the voltage.p. 397
l Measure the voltage.p. 397
+Nominal value = vehicle voltagep. 397
Nominal value = vehicle voltagep. 397
+l Check the magnetic coil locking ring for secure fit.p. 397
l Check the magnetic coil locking ring for secure fit.p. 397
l Check the current consumption.p. 397
Fig. 1p. 397
+at 12 Volt vehicle voltage approx. 3.5 Amp.p. 397
at 12 Volt vehicle voltage approx. 3.5 Amp.p. 397
at 24 Volt vehicle voltage approx. 1.75 Amp.p. 397
Overcurrent indicates a short circuit inside the magnetic coil.p. 397
No current indicates an interrupted electric circuit.p. 397
Fig. 2 Measuring the air gapp. 397
+l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 397
l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 397
+The gap should be 0.4 to 0.8 mm.p. 398
The gap should be 0.4 to 0.8 mm.p. 398
+l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 398
l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 398
+In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 398
In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 398
+Cross-section of magnetic clutchp. 398
Cross-section of magnetic clutchp. 398
Fig. 3 shows a cross-section of the magnetic clutch. If the coil (7) is not supplied with operating voltage, there is no contact between the front plate of the clutch (1) and the V-belt pulley (2). A spring presses the front plate away from the belt …p. 398
Fig. 3 Cross-section of magnetic clutchp. 398
+9.11 Servicing the air conditioningp. 398
9.10 Inspection and maintenance workp. 398
+l Visual inspection of the complete system for damage.p. 398
+l Visual inspection of the complete system for damage.p. 398
l Visual inspection of the complete system for damage.p. 398
l Check the compressor mounting bracket on the vehicle engine for tight fit and damage.p. 398
l Check the condition, alignment and tightness of the V-belt.p. 398
l Check the routing of refrigerant hoses and cables in the area of the vehicle engine and transmission, as well as on the chassis for chafing and rectify any detected faults. Ensure sufficient clearance to hot parts, such as the exhaust; install a pr…p. 398
l Check the routing of hoses and hoses on the attachment box or in the cabin.p. 398
l Check all hose and screw fittings for leaks.p. 398
l Check the fastening of the condenser unit.p. 398
l Clean the condenser fins, replace the condenser block if damaged fins are found.p. 398
l Check the fastening of the evaporator unit.p. 398
l Check the function of evaporator and condenser fans.p. 398
l Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays.p. 398
l Switch on the cooling system and check the refrigerant level.p. 398
l Filter/dryer and filter/dryer/fluid container combinations must always be replaced after opening the refrigerant circuit. If these are in service for more than 1 year, there is a risk that they may be clogged by excessive absorption of moisture! Th…p. 398
l Measure the temperature on the evaporator: Measure the intake air temperature – Measure the blow out air temperature – The temperature difference should be at least 8-10 K.p. 398
+l Measuring the pressure in the refrigerant circuitp. 398
l Measuring the pressure in the refrigerant circuitp. 398
+9.11 Servicing the air conditioningp. 399
9.11 Servicing the air conditioningp. 399
+The air conditioning unit is attached to the ROPS and can be access from outside for service work.p. 399
The air conditioning unit is attached to the ROPS and can be access from outside for service work.p. 399
+Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system.p. 399
Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system.p. 399
+Danger of accident!p. 399
Danger of accident!p. 399
Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.p. 399
+Clean the condenserp. 399
Clean the condenserp. 399
Fig. 4p. 399
+l Fold the air intake gridp. 399
+l Fold the air intake gridp. 399
(Fig. 4)p. 399
Fig. 5p. 399
+l Clean the condenser fins on front and back with compressed air or cold waterp. 399
+l Clean the condenser fins on front and back with compressed air or cold waterp. 399
(Fig. 5)p. 399
+During cleaning work do not damage the cooling fins and realign bent fins.p. 399
During cleaning work do not damage the cooling fins and realign bent fins.p. 399
+Checking the refrigerant levelp. 399
Checking the refrigerant levelp. 399
+l Start the engine.p. 399
l Start the engine.p. 399
Fig. 6p. 399
+l Switching on the control unitp. 399
+l Switching on the control unitp. 399
(Fig. 6)p. 399
Fig. 7p. 399
+l Start operation of the air conditioningp. 399
+l Start operation of the air conditioningp. 399
(Fig. 7)p. 399
Fig. 8p. 399
+l Open the air outlet nozzlesp. 399
+l Open the air outlet nozzlesp. 399
(Fig. 8)p. 399
l Check, whether the out flowing air is noticeably cooler.p. 399
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 399
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 399
Fig. 9p. 400
+l Check whether the white floatp. 400
+l Check whether the white floatp. 400
(Fig. 9)p. 400
+The refrigerant level is correct.p. 400
The refrigerant level is correct.p. 400
Fig. 10p. 400
+l If the white floatp. 400
+l If the white floatp. 400
(Fig. 10)p. 400
+The refrigerant level is not correct.p. 400
The refrigerant level is not correct.p. 400
+l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 400
l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 400
+Checking the moisture level of the drying agentp. 400
Checking the moisture level of the drying agentp. 400
Fig. 11p. 400
+l Check the moisture indication pearlp. 400
+l Check the moisture indication pearlp. 400
(Fig. 11)p. 400
+orangep. 400
orangep. 400
Drying agent o.k.p. 400
colourlessp. 400
moisture level of drying agent too high.p. 400
+l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 400
l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 400
+Have the drier/collector unit replaced by the service department every year before the operating season.p. 400
Have the drier/collector unit replaced by the service department every year before the operating season.p. 400
+Checking the condition of the drier/collector unitp. 400
Checking the condition of the drier/collector unitp. 400
+According to the regulation for pressure reservoirs 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 t…p. 400
According to the regulation for pressure reservoirs 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 t…p. 400
+Danger of injury!p. 400
Danger of injury!p. 400
In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.p. 400
Fig. 12p. 401
+l Check the drier/collector unitp. 401
+l Check the drier/collector unitp. 401
(Fig. 12)p. 401
+9.12 Check condition and tension of refrigerant compressor V- belt, replace the V-beltp. 401
9.12 Check condition and tension of refrigerant compressor V- belt, replace the V-beltp. 401
+Danger of injury!p. 401
+Danger of injury!p. 401
Danger of injury!p. 401
Work on the V-belt must only be performed with the engine shut down.p. 401
+Checking the V-beltp. 401
Checking the V-beltp. 401
Fig. 13p. 401
+l Inspect the entire circumference of the V-beltp. 401
+l Inspect the entire circumference of the V-beltp. 401
(Fig. 13)p. 401
l Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary.p. 401
+Retightening the V-beltp. 401
Retightening the V-beltp. 401
Fig. 14p. 401
+l Slacken the bearing screw 2p. 401
+l Slacken the bearing screw 2p. 401
(Fig. 14)p. 401
l Slightly loosen the hexagon screw (1) on the slot for the compressor bracket.p. 401
l Loosen the counter nut (3).p. 401
l Turn down tensioning screw (4) in direction of arrow, until the correct V-belt tension is reached.p. 402
l Retighten screws and counter nut.p. 402
+Changing the V-beltp. 402
Changing the V-beltp. 402
Fig. 15p. 402
+l Remove the V-belt of the fan drive.p. 402
l Remove the V-belt of the fan drive.p. 402
+l Slacken the bearing screw 2p. 402
(Fig. 15)p. 402
l Slightly loosen the hexagon screw (1) on the slot for the compressor bracket.p. 402
l Loosen the counter nut (3).p. 402
l Turn tensioning screw (4) in direction of arrow to the stop.p. 402
l Take the old V-belt off the V-belt pulley.p. 402
l Fit the new V-belt to the V-belt pulleys.p. 402
l Tension the V-belt as previously described.p. 402
l Reinstall and tension the fan drive V-belt.p. 402
+Retighten new V-belts after a running time of 15 minutes.p. 402
Retighten new V-belts after a running time of 15 minutes.p. 402
9.13 Drying and evacuationp. 402
+Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t…p. 402
Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t…p. 402
Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage.p. 402
Vacuum pumps with a capacity of more than 100 l/min and a final pressure of less than 30 micron, i.e. 0.039 mbar should be used to evacuate the refrigeration system.p. 402
The refrigerant compressor is not suitable for the purpose of evacuation, because it is not able to achieve a sufficient final vacuum and, apart from this, may be mechanically damaged because of a lack of lubrication when running empty during evacuationp. 402
It is common practice to evacuate the refrigeration system to a final vacuum of 1 Torr, i.e. 1.33 mbar.p. 402
Function drying:p. 402
Under normal ambient pressure (1.013 mbar) evaporates absolute at 100° C. If the pressure is reduced, water will already evaporate, e.g. under a pressure of 10 mbar, at an ambient temperature of almost 7°C, but the water will not evaporate all at o…p. 402
9.14 Emptying in case of repairp. 403
+For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 403
For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 403
Especially with expensive refrigerants and larger amounts of oil it may be necessary to keep the refrigerant for later use.p. 403
For later use these refrigerants must be drawn out with suitable equipment and intermediately stored in collecting containers.p. 403
+Contaminated refrigerant must be disposed of environmentallyp. 403
Contaminated refrigerant must be disposed of environmentallyp. 403
Releasing refrigerant into the atmosphere is prohibited (see restrictive injunction concerning CFC, day of enforcement 01. 08. 1991, § 8)p. 403
+For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive.p. 403
For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive.p. 403
When transferring refrigerant you must make sure that the bottle does not contain more than the permitted amount of refrigerant in litres and has sufficient gas space for expansion (filling factor: 0,7).p. 403
In order to reduce the evacuation period in case of short repairs, you may fill the refrigerant circuit with approx. 0.5 bar nitrogen when opening. This ensures that nitrogen will flow out of the refrigerant circuit while it is open and no air or moi…p. 403
9.15 Leak testp. 403
+The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 403
+The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 403
The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 403
Before starting the evacuation process, the refrigerant circuit is filled with nitrogen through a pressure reducer valve (approx. 22 bar). After this all connections in the air conditioning system are checked with the help of a suitable leak detectio…p. 403
A leak test is required if a pressure drop is noticed.p. 403
The leak test must be repeated after filling the air conditioning system with refrigerant.p. 403
Leak test with electronic leak testerp. 403
Fig. 1 Electronic leak testerp. 403
Small leaks with only very low amounts of refrigerant escaping can be detected, e.g. with an electronic leak tester. Such equipment is able to detect leaks of less than 5 gr. per year.p. 403
The leak tester used must be specially designed for the refrigerant composition in the air conditioning system. For example, leak detectors for refrigerant R12 are not suitable for R134a, because the refrigerant R134a is free of chlorine atoms, meani…p. 403
+Leak test with soap bubblesp. 403
Leak test with soap bubblesp. 403
Fig. 2 Soap bubble testp. 403
Points susceptible for leakage are sprayed with a soapy solution. Bubbles indicate the leak. The detection limit for R 134a is 250 g/year.p. 403
9.16 Filling instructionsp. 404
+Filling instructionsp. 404
+Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 404
Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 404
In most large series production facilities highly complicated equipment is available for this purpose, whereas individual machines at the place of installation must be filled directly from the refrigerant container.p. 404
Liquid refrigerant is only used to pre-fill the pressure side of the evacuated refrigeration system (protective filling).p. 404
After switching the refrigeration system on and watching the inspection glass, gaseous refrigerant can be filled into the system while the engine is running, if the refrigerant level is found to be too low (gas bubbles in the inspection glass).p. 404
+Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor..p. 404
Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor..p. 404
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 fi…p. 404
With correct operation of the air conditioning the refrigerant container should be about 1/3 filled with liquid refrigerant, the evaporator should be maximally filled at the calculated evaporation temperature, i.e. the suction line should only be a f…p. 404
+White frost on the suction line is no measure for assessing the filling.p. 404
White frost on the suction line is no measure for assessing the filling.p. 404
Fig. 1p. 405
+1 High pressure – gaseousp. 405
+1 High pressure – gaseousp. 405
1 High pressure – gaseousp. 405
2 High pressure – liquidp. 405
3 Low pressure – gaseousp. 405
4 Compressorp. 405
5 Compressor pressure switch (not used)p. 405
6 not usedp. 405
7 Evaporatorp. 405
8 Expansion valvep. 405
9 Inspection glassp. 405
10 Filter dryerp. 405
11 Fluid containerp. 405
12 Condenserp. 405
13 Manual shut-off valve (not used)p. 405
14 Pressure switch with high and low pressure contactsp. 405
15 Defroster thermostatp. 405
16 Vacuum meterp. 405
17 Low pressure gaugep. 405
18 High pressure gaugep. 405
19 Pressure reducing valvep. 406
20 Vacuum pumpp. 406
21 Nitrogen bottlep. 406
22 Refrigerant bottlep. 406
23 Pressure gauge barp. 406
+Filling instructionsp. 406
Filling instructionsp. 406
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 406
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 406
1 Connect the service adapter with the blue hand wheel in the suction side.p. 406
2 Connect the service adapter with the red hand wheel in the pressure side (the hand wheels on the service adapters must be fully backed out – left hand stop)p. 406
3 Connect the blue suction hose below the blue hand wheel on the pressure gauge bar to the blue service adapter.p. 406
4 Connect the red pressure hose below the red hand wheel on the pressure gauge bar to the red service adapter.p. 406
5 Connect the yellow hose below the yellow hand wheel on the manometer bar to the 2-stage vacuum pump.p. 406
6 Connect the last hose below the black hand wheel on the nitrogen bottle via the pressure reducing valve.p. 406
7 Check on the pressure gauge bar that all hand wheels are closed.p. 406
8 Turn the hand wheels on both service adapter clockwise. This opens the valves (right hand stop).p. 406
9 Open the valve on the nitrogen bottle (only via pressure reducer); pressure approx. 20 bar.p. 406
10 Open the black and red hand wheels on the pressure gauge bar and fill nitrogen into the system, until a pressure of approx. 3.5 to 5.0 bar is indicated on the suction side.p. 406
11 Then open the blue hand wheel and raise the pressure in the suction side (max. 10 bar). Check for leaks with a leak detection fluid or soapsuds.p. 406
12 If the system is leak tight, release the nitrogen from the system. For this purpose disconnect the hose from the nitrogen bottle and open the red, blue and black hand wheels on the pressure gauge bar.p. 406
13 Then connect the hose to the refrigerant bottle.p. 406
14 Switch on the vacuum pump and open all hand wheels on the pressure gauge bar. In case of a leak no or only an insufficient vacuum will be reached. In this case proceed as described under point 9-12. Once the leak is sealed continue with point 14.p. 406
15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the pressure gauge bar.p. 406
16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained.p. 406
17 Open the valve on the refrigerant bottle and open the black and red hand wheels on the pressure gauge bar. Fill refrigerant into the system, until a pressure equilibrium between suction and pressure side is reached (reading of pressure gauges).p. 406
18 Close the red hand wheel.p. 406
19 Perform a leak test with the electronic leak detector.p. 406
20 Start the engine and switch on the system.p. 406
21 Open the blue hand wheel and continue filling in refrigerant until the inspection glass is free or air bubbles (in fluid container/dryer combinations the white pearl should float in the upper third of the inspection glass). Then close the refriger…p. 406
22 Close the blue hand wheel on the pressure gauge bar.p. 406
23 Preparing the test run: -Close windows and doors -Fan on full speed stage -Mount measuring feelers to air discharge and air intake.p. 406
24 Run the system for approx. 20 minutes with medium engine speed.p. 406
25 The temperature difference between air discharge and air intake should be (depending on type of air condition) 8-10°C. The ambient temperature thereby is approx. 20°C. (These data are only reference values, which may be influenced by possible in…p. 406
26 Switch off system and engine and check for leaks again.p. 406
27 Turn out (left hand stop) and remove the hand wheels on both service adapters.p. 406
28 Fit all valves with dust caps.p. 406
29 Perform a leak test.p. 406
30 Mark the system with the corresponding type plates and information decals, such as type of oil and refrigerant.p. 406
9.17 Trouble shooting in refrigerant circuit, basic principlesp. 407
+Basic principlesp. 407
Basic principlesp. 407
+Requirementsp. 407
Requirementsp. 407
For trouble shooting two requirements must be fulfilled:p. 407
+l Expert knowledgep. 407
l Expert knowledgep. 407
l technical equipmentp. 407
+Technical equipmentp. 407
Technical equipmentp. 407
The most important aids for trouble shooting are pressure gauges and thermometer. The refrigerant conditions, like overheating and excessive cooling provide important Information when searching for faults. Even your own senses are important aids for …p. 407
The following tools and auxiliary materials should be available for trouble shooting:p. 407
+l Service stationp. 407
l Service stationp. 407
l Pressure gaugep. 407
l Thermometerp. 407
l dry nitrogenp. 407
l Refrigerant bottle for new refrigerantp. 407
l Container for old oilp. 407
l Vacuum pumpp. 407
l Hosesp. 407
l Scalesp. 407
l Suction stationp. 407
l Leak detectorp. 407
The measuring equipment must be checked at regular intervals. Calibration can only be made by an approved testing authority.p. 407
+Pressure gaugep. 407
Pressure gaugep. 407
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 …p. 407
+Pp. 407
absp. 407
ambp. 407
ep. 407
+Pp. 407
absp. 407
+Pp. 407
ambp. 407
+Pp. 407
ep. 407
Fig. 2 Pressure gaugep. 407
Example:p. 407
+A totally empty air conditioning system holds an atmospheric pressure of approx. Pp. 407
ampp. 407
+Filling the system with refrigerant causes an excess pressure of Pp. 407
ep. 407
+Pp. 407
absp. 407
ambp. 407
ep. 407
+Evacuating the system down to Pp. 407
ep. 407
+Pp. 407
absp. 407
ambp. 407
ep. 407
+Pressure gauge with saturation temperature scalep. 408
Pressure gauge with saturation temperature scalep. 408
Fig. 3 Absolute pressure gaugep. 408
Temperature scales on the pressure gauges always refer to the absolute pressures Pabs. Please note that it is not possible to measure a temperature directly with a pressure gauge. The indicated temperatures are just reference values. Only the saturat…p. 408
If the refrigerant is fluid, the temperature is below the saturation temperature.p. 408
If the refrigerant is gaseous, the temperature is above the saturation temperature.p. 408
Pressure gauges must indicate 0 bar when not connected to the system.p. 408
Low pressure gauges have a blue, high pressure gauges a red border.p. 408
+Thermometerp. 408
Thermometerp. 408
Normally digital thermometers with surface or contact feelers are used. Especially for high temperature differences excellent heat insulation of the measuring location is of utmost importance. The sparing use of a heat conducting paste is highly reco…p. 408
+Overheatingp. 408
Overheatingp. 408
+Common overheating valuesp. 408
Due to its design a refrigerant compressor can only deliver gaseous or vaporous substances. Fluids are not compressible and must therefore not enter into the compression chamber of the compressor.p. 408
If the suction condition of the compressor is directly on the dew line, an e.g. incorrect evaporator load can cause "wet suction". This can lead to two processes, which are destructive for the compressor. The liquid refrigerant washes off the lubrica…p. 408
Apart from protecting the compressor against fluid, overheating has further advantages. Since the fluid proportions in the drawn in steam reduces the flow rate of the compressor, it may be increased by a overheating. Overheating also improves the oil…p. 408
+Common overheating valuesp. 408
Common overheating valuesp. 408
The optimal overheating value is approx. 5 – 8 Kelvin. With this overheating the maximum system power is reached. However, the thermostatic expansion valve is unable to regulate this value exactly. Depending on design and operating conditions overhea…p. 408
+Overheating is calculated as follows:p. 408
Overheating is calculated as follows:p. 408
+D tp. 408
Dp. 408
o2hp. 408
o2hp. 408
op. 408
+D tp. 408
Dp. 408
o2hp. 408
+tp. 408
o2hp. 408
+tp. 408
op. 408
+„p. 408
hp. 408
+Supercoolingp. 408
Supercoolingp. 408
+Common supercooling valuesp. 408
It is the function of the expansion valve to reduce the refrigerant to a lower pressure level (evaporation pressure) after it has been liquefied. For an optimal function of the valve pure fluid must be applied to its inlet port.p. 408
The refrigerant must "squeeze" (literally speaking) through a throttle gap inside the expansion valve. When comparing a certain mass of refrigerant in fluid and in vaporous state (with constant pressure), the vaporous refrigerant requires a much high…p. 408
Vaporous refrigerant in front of the expansion valve reduces the flow rate and results in an undersupply of the evaporator with refrigerant. Evaporation pressure and evaporator power will drop.p. 408
If the refrigeration system is operated with the "expansion valve inlet" condition directly on the boiling curve, slightest fluctuations in operating condition may cause a formation of bubbles in front of the expansion element.p. 408
For this reason one shifts the condition "Expansion Valve Inlet" away from the boiling curve into the fluid area and refers to this condition as Supercooling. This supercooling ensures a fluid supply in front of the expansion valve.p. 409
+Common supercooling valuesp. 409
Common supercooling valuesp. 409
In systems with fluid container the supercooling at the fluid container outlet is approx. Zero "0" Kelvin (assumed that the system is filled with the correct refrigerant quantity). In this case the fluid container provides the required fluid supply.p. 409
+Supercooling is calculated as follows:p. 409
Supercooling is calculated as follows:p. 409
+D tp. 409
Dp. 409
c2up. 409
cp. 409
c2up. 409
+D tp. 409
Dp. 409
c2up. 409
+tp. 409
c2up. 409
+tp. 409
cp. 409
+„p. 409
up. 409
Fig. 1 Refrigerant circuit with t, h- diagramp. 410
9 Pressure switch with high and low pressure contactsp. 411
10 Dryerp. 411
11 Fluid containerp. 411
12 Hot airp. 411
13 Compressorp. 411
14 Condenserp. 411
15 Cooling airp. 411
16 Pressure gauge, low pressurep. 411
9.19 Trouble shooting procedurep. 412
+Procedurep. 412
Procedurep. 412
+Knowledgep. 412
Knowledgep. 412
Trouble shooting is not possible with exact knowledge about the system design, the installed components and their function in the system trouble shooting is not possible:p. 412
+Visual inspectionp. 412
Visual inspectionp. 412
With the appropriate experience some faults can be visually detected or felt. Frequently occurring condenser soiling or formation of steam bubbles in the inspection glass can be quickly detected.p. 412
In case of unusual formation of hoarfrost on the evaporator the hoarfrost pattern provides useful information. Hoarfrost only occurring at the inlet side is a clear indication of insufficient refrigerant feed, which in turn indicates an incorrectly w…p. 412
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.p. 412
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.p. 412
Unusually cold pressure lines indicate "wet" intake of the compressor.p. 412
The oil level in the compressor sight glass provides information about the oil quantity and the oil recirculation in the system. However, the oil level may also be considerably influenced by condensing refrigerant. Discoloration informs about the sta…p. 412
Water in the system can simply be detected through the inspection glass with moisture indicator.p. 412
+The dangerous part of common rules is that they apply 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.p. 412
The dangerous part of common rules is that they apply 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.p. 412
+Test prerequisitesp. 412
Test prerequisitesp. 412
+l Cooler and condenser are clean, clean if necessary.p. 412
l Cooler and condenser are clean, clean if necessary.p. 412
l The ribbed belt for compressor and generator is correctly tightened.p. 412
l All air ducts, covers and seals are OK and correctly fitted. Flaps reach their end positions.p. 412
l The engine has operating temperature.p. 412
l Evaporator and heating (with highest fresh air fan speed) do not draw leak air.p. 412
l The fresh air fan runs when the engine is running and the air conditioning system is set to max. cooling power.p. 412
l Ambient temperature above 15 °C.p. 412
l The thermostat is correctly installed and the switching temperatures are correct.p. 412
+Example: Measurement of overheatingp. 413
Measuring points and measurementsp. 413
Fig. 2 Flow diagram with measuring pointsp. 413
+l C, condenser measuring pointsp. 413
l C, condenser measuring pointsp. 413
l E, expansion valve measuring pointsp. 413
l O, evaporator measuring pointsp. 413
l V, compressor measuring pointsp. 413
The flow diagram contains "Minimum Requirements" which must be fulfilled to be able to check the system or perform trouble shooting.p. 413
+Example: Measurement of overheatingp. 413
Example: Measurement of overheatingp. 413
+l a) Which measuring equipment is required?p. 413
l a) Which measuring equipment is required?p. 413
l b) Where to measure with which size?p. 413
+l c) A pressure gauge connected to the evaporator indicates "Pp. 413
eo2p. 413
op. 413
+l d) How high is the evaporator temperature "tp. 413
op. 413
+l e) A thermal sensor attached to the evaporator outlet measures the temperature "tp. 413
o2hp. 413
Dp. 413
o2hp. 413
l f) Evaluation of the measured overheating.p. 413
+Solution:p. 414
Solution:p. 414
+l a) Pressure gauge, thermometer, steam tablep. 414
l a) Pressure gauge, thermometer, steam tablep. 414
+l b) Evaporation pressure "Pp. 414
eo2p. 414
o2hp. 414
+l c) Pp. 414
op. 414
eo2p. 414
ambp. 414
+l d) "Pp. 414
cp. 414
op. 414
+l e)p. 414
Dp. 414
o2hp. 414
o2hp. 414
op. 414
l f) The determined overheating is within the usual range of 4 – 12 Kelvin.p. 414
+Example: Measuring supercoolingp. 414
Example: Measuring supercoolingp. 414
+l a) Which measuring equipment is required?p. 414
l a) Which measuring equipment is required?p. 414
l b) Where to measure with which size?p. 414
+l c) A pressure gauge connected to the condenser indicates "Pp. 414
ec2p. 414
cp. 414
+l d) How high is the condensing temperature "tp. 414
cp. 414
+l e) A thermal sensor attached to the condenser outlet measures the temperature "tp. 414
c2up. 414
Dp. 414
c2up. 414
l f) Evaluation of the measured supercooling.p. 414
+Solution:p. 414
Solution:p. 414
+l a) Pressure gauge, thermometer, steam tablep. 414
l a) Pressure gauge, thermometer, steam tablep. 414
+l b) Condensing pressure "Pp. 414
ec2p. 414
c2up. 414
+l c) Pp. 414
cp. 414
ec2p. 414
ambp. 414
+l d) "Pp. 414
cp. 414
cp. 414
+l e)p. 414
Dp. 414
c2up. 414
cp. 414
c2up. 414
l f) The determined overheating is within the usual range of approx. "0" Zero Kelvin.p. 414
+Typical faults and possible causesp. 414
Typical faults and possible causesp. 414
Most faults in the refrigerant side of the system can be clearly assigned with the help a checklist. r Occurring faults frequently have a similar appearance, but different causes. An evaporator showing hoarfrost may be quite normal. However, there ma…p. 414
The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds).p. 414
Suction pressure (low pressure gauge)p. 414
+Ambient temperature in °Cp. 414
Ambient temperature in °Cp. 414
+Excess pressure in barp. 414
Excess pressure in barp. 414
+25p. 414
25p. 414
+approx. 2,0p. 414
approx. 2,0p. 414
+30p. 414
30p. 414
+approx. 2,5p. 414
approx. 2,5p. 414
+35p. 414
35p. 414
+approx. 3p. 414
approx. 3p. 414
High pressure (high pressure gauge)p. 414
+Ambient temperature in °Cp. 414
Ambient temperature in °Cp. 414
+Excess pressure in barp. 414
Excess pressure in barp. 414
+25p. 414
25p. 414
+approx. 8,0p. 414
approx. 8,0p. 414
+35p. 414
35p. 414
+approx. 13p. 414
approx. 13p. 414
+40p. 414
40p. 414
+approx. 16p. 414
approx. 16p. 414
+45p. 414
45p. 414
+approx. 18p. 414
approx. 18p. 414
+Noise in systemp. 415
Values effecting the operating pressuresp. 415
Since the pressures occurring in a refrigeration system are highly dependent on environmental conditions, it is mandatory to know these dependencies. The following table contains some of these dependencies.p. 415
+Measuring valuep. 415
Measuring valuep. 415
+Suction pressurep. 415
Suction pressurep. 415
+High pressurep. 415
High pressurep. 415
+increasesp. 415
increasesp. 415
+dropsp. 415
dropsp. 415
+increasesp. 415
increasesp. 415
+dropsp. 415
dropsp. 415
+Compressor speedp. 415
Compressor speedp. 415
+increasesp. 415
increasesp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+dropsp. 415
dropsp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+Vehicle interior temperaturep. 415
Vehicle interior temperaturep. 415
+increasesp. 415
increasesp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+dropsp. 415
dropsp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+Ambient temperaturep. 415
Ambient temperaturep. 415
+increasesp. 415
increasesp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+dropsp. 415
dropsp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+Humidityp. 415
Humidityp. 415
+increasesp. 415
increasesp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+dropsp. 415
dropsp. 415
+Xp. 415
Xp. 415
+Xp. 415
Xp. 415
+Noise in systemp. 416
Suction pressure too low (1), high pressure too low to normal (2)p. 416
Fig. 3p. 416
+Causep. 416
Causep. 416
+Possible effectp. 416
Possible effectp. 416
+Remedyp. 416
Remedyp. 416
+Lack of refrigerantp. 416
Lack of refrigerantp. 416
+no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 416
no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 416
+Check for leaks, refillp. 416
Check for leaks, refillp. 416
+Evaporator fins or air filter soiledp. 416
Evaporator fins or air filter soiledp. 416
+Cooling power too lowp. 416
Cooling power too lowp. 416
+cleanp. 416
cleanp. 416
+Evaporator fan failedp. 416
Evaporator fan failedp. 416
+Low pressure shut offp. 416
Low pressure shut offp. 416
+Repair the fanp. 416
Repair the fanp. 416
+Expansion valve defectivep. 416
Expansion valve defectivep. 416
+Suction pressure gauge shows vacuum, because the valve has closedp. 416
Suction pressure gauge shows vacuum, because the valve has closedp. 416
+Replace the valvep. 416
Replace the valvep. 416
+Screen or nozzle in expansion valve cloggedp. 416
Screen or nozzle in expansion valve cloggedp. 416
+high overheatingp. 416
high overheatingp. 416
+cleanp. 416
cleanp. 416
+Filter dryer cloggedp. 416
Filter dryer cloggedp. 416
+Bubbles in inspection glass, high overheating, filter dryer coldp. 416
Bubbles in inspection glass, high overheating, filter dryer coldp. 416
Suction pressure normal (1), high pressure too high (2)p. 417
Fig. 4p. 417
+Causep. 417
Causep. 417
+Possible effectp. 417
Possible effectp. 417
+Remedyp. 417
Remedyp. 417
+Condenser dirtyp. 417
Condenser dirtyp. 417
+high hot gas temperature, low cooling powerp. 417
high hot gas temperature, low cooling powerp. 417
+cleanp. 417
cleanp. 417
+Condenser fan failedp. 417
Condenser fan failedp. 417
+high hot gas temperature, high pressure shut downp. 417
high hot gas temperature, high pressure shut downp. 417
+repairp. 417
repairp. 417
+overfilledp. 417
overfilledp. 417
+high hot gas temperature, low supercooling, low cooling powerp. 417
high hot gas temperature, low supercooling, low cooling powerp. 417
+Correct the filling capacityp. 417
Correct the filling capacityp. 417
+Leak gas (air)p. 417
Leak gas (air)p. 417
+high hot gas temperature, low measured supercooling, low cooling powerp. 417
high hot gas temperature, low measured supercooling, low cooling powerp. 417
+renew fillingp. 417
renew fillingp. 417
+Restriction between compressor and condenserp. 417
Restriction between compressor and condenserp. 417
+high hot gas temperature, low cooling powerp. 417
high hot gas temperature, low cooling powerp. 417
+Check lines and valvesp. 417
Check lines and valvesp. 417
+Noise in systemp. 418
Suction pressure too high (1), high pressure too low to normal (2)p. 418
Fig. 5p. 418
+Causep. 418
Causep. 418
+Possible effectp. 418
Possible effectp. 418
+Remedyp. 418
Remedyp. 418
+Compressor defectivep. 418
Compressor defectivep. 418
+Cooling power too lowp. 418
Cooling power too lowp. 418
+Replace the compressorp. 418
Replace the compressorp. 418
+Noise in systemp. 419
Suction pressure too high (1), high pressure too high (2)p. 419
Fig. 6p. 419
+Causep. 419
Causep. 419
+Possible effectp. 419
Possible effectp. 419
+Remedyp. 419
Remedyp. 419
+Expansion valve defectivep. 419
Expansion valve defectivep. 419
+overheating too low, wet operation of compressorp. 419
overheating too low, wet operation of compressorp. 419
+Replace the valvep. 419
Replace the valvep. 419
+Noise in systemp. 420
Other faultsp. 420
+Symptomp. 420
Symptomp. 420
+Causep. 420
Causep. 420
+Possible effectp. 420
Possible effectp. 420
+Remedyp. 420
Remedyp. 420
+Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 420
Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 420
+Lack of refrigeration oilp. 420
Lack of refrigeration oilp. 420
+increased compressor wearp. 420
increased compressor wearp. 420
+Refill refrigeration oilp. 420
Refill refrigeration oilp. 420
+Compressor does not startp. 420
Compressor does not startp. 420
+Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 420
Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 420
+System stoppedp. 420
System stoppedp. 420
+Check the control units, check cause for switching and rectifyp. 420
Check the control units, check cause for switching and rectifyp. 420
+Compressor switches continuouslyp. 420
Compressor switches continuouslyp. 420
+Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 420
Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 420
+Cycling of compressor, increased wear, too low cooling powerp. 420
Cycling of compressor, increased wear, too low cooling powerp. 420
+Check the control units, check cause for switching and rectifyp. 420
Check the control units, check cause for switching and rectifyp. 420
+Excessive overheatingp. 420
Excessive overheatingp. 420
+Expansion valve deadjusted or screen blocked, lack of refrigerantp. 420
Expansion valve deadjusted or screen blocked, lack of refrigerantp. 420
+low cooling power, hot gas temperatures too highp. 420
low cooling power, hot gas temperatures too highp. 420
+Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 420
Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 420
+Hoarfrost on inlet side of evaporatorp. 420
Hoarfrost on inlet side of evaporatorp. 420
+incorrectly working expansion valve, lack of refrigerantp. 420
incorrectly working expansion valve, lack of refrigerantp. 420
+too low infeed of refrigerant into the evaporatorp. 420
too low infeed of refrigerant into the evaporatorp. 420
+Check the expansion valve, check the refrigerant fillingp. 420
Check the expansion valve, check the refrigerant fillingp. 420
+Evaporator fully covered with hoarfrostp. 420
Evaporator fully covered with hoarfrostp. 420
+Load problem, too low air flow volumep. 420
Load problem, too low air flow volumep. 420
+low cooling power of systemp. 420
low cooling power of systemp. 420
+Clean the evaporator, check the evaporator fanp. 420
Clean the evaporator, check the evaporator fanp. 420
+Fluid line is warm and shows condensationp. 420
Fluid line is warm and shows condensationp. 420
+Pressure drop in fluid line, filter dryer cloggedp. 420
Pressure drop in fluid line, filter dryer cloggedp. 420
+low cooling powerp. 420
low cooling powerp. 420
+Eliminate the pressure drop, replace the filter dryerp. 420
Eliminate the pressure drop, replace the filter dryerp. 420
+Exceptionally cold pressure linesp. 420
Exceptionally cold pressure linesp. 420
+"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 420
"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 420
+low cooling power, excessive wear of compressorp. 420
low cooling power, excessive wear of compressorp. 420
+Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 420
Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 420
+Noise in systemp. 420
Noise in systemp. 420
+Faultsp. 420
Faultsp. 420
+Possible causep. 420
Possible causep. 420
+Remedyp. 420
Remedyp. 420
+V-belt loose or excessively wornp. 420
V-belt loose or excessively wornp. 420
+V-belt slips and generates noisep. 420
V-belt slips and generates noisep. 420
+Retention or renew the V-beltp. 420
Retention or renew the V-beltp. 420
+Magnetic clutch loudp. 420
Magnetic clutch loudp. 420
+Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 420
Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 420
+Repair or replace the magnetic clutchp. 420
Repair or replace the magnetic clutchp. 420
+Refrigerant compressor is loudp. 420
Refrigerant compressor is loudp. 420
+Mounting bracket is loose, internal parts worn, low oil level in compressorp. 420
Mounting bracket is loose, internal parts worn, low oil level in compressorp. 420
+Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 420
Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 420
+Fan is loud, fan motor excessively wornp. 420
Fan is loud, fan motor excessively wornp. 420
+Replace the fan motorp. 420
Replace the fan motorp. 420
+Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 420
Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 420
+V-belt pulley and bearing wornp. 420
V-belt pulley and bearing wornp. 420
+Replace the bearing, check V-belt pulley for wearp. 420
Replace the bearing, check V-belt pulley for wearp. 420
+Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 420
Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 420
+System overfilledp. 420
System overfilledp. 420
+Draw out refrigerantp. 420
Draw out refrigerantp. 420
+Expansion valve loudp. 420
Expansion valve loudp. 420
+excessive moisture in systemp. 420
excessive moisture in systemp. 420
+Replace the dryerp. 420
Replace the dryerp. 420
+Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 420
Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 420
+refrigerant level in system too lowp. 420
refrigerant level in system too lowp. 420
+Perform a leak test, fill up the systemp. 420
Perform a leak test, fill up the systemp. 420
+Inspection glassp. 421
Inspection glassp. 421
+Faultsp. 421
Faultsp. 421
+Possible causep. 421
Possible causep. 421
+Remedyp. 421
Remedyp. 421
+Steam bubbles in inspection glassp. 421
Steam bubbles in inspection glassp. 421
+No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 421
No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 421
+Fill up the system, replace the filter dryer, perform a leak testp. 421
Fill up the system, replace the filter dryer, perform a leak testp. 421
+Discolouration of inspection glass (black from inside)p. 421
Discolouration of inspection glass (black from inside)p. 421
+Lubricant destroyed by excessive operating temperaturesp. 421
Lubricant destroyed by excessive operating temperaturesp. 421
+Replace the refrigeration oil, examine the temperature increasep. 421
Replace the refrigeration oil, examine the temperature increasep. 421
+Moisture indicator changes to pinkp. 421
Moisture indicator changes to pinkp. 421
+Moisture level of drying agent too highp. 421
Moisture level of drying agent too highp. 421
+Replace the filter dryerp. 421
Replace the filter dryerp. 421
+Ball floats at bottomp. 421
Ball floats at bottomp. 421
+lack of refrigerantp. 421
lack of refrigerantp. 421
+Fill the systemp. 421
Fill the systemp. 421
+Monitoring devicesp. 421
Monitoring devicesp. 421
+Faultsp. 421
Faultsp. 421
+Possible causep. 421
Possible causep. 421
+Remedyp. 421
Remedyp. 421
+The high pressure contact has switched off the magnetic clutchp. 421
The high pressure contact has switched off the magnetic clutchp. 421
System pressure exceeded, condenser excessively soiled, condenser fan defective, expansion valve defectivep. 421
+Clean the condenser, replace the expansion valve, check the condenser fanp. 421
Clean the condenser, replace the expansion valve, check the condenser fanp. 421
+The low pressure contact has switched off the magnetic clutchp. 421
The low pressure contact has switched off the magnetic clutchp. 421
+System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 °Cp. 421
System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 °Cp. 421
+Clean the evaporator, replace the expansion valve, check the evaporator fanp. 421
Clean the evaporator, replace the expansion valve, check the evaporator fanp. 421
+The thermostat has switched off the magnetic clutchp. 421
The thermostat has switched off the magnetic clutchp. 421
+Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 421
Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 421
+Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 421
Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 421
Steam table for R134a
+Temperaturep. 422
Temperaturep. 422
+Pressurep. 422
Pressurep. 422
+Densityp. 422
Densityp. 422
+spec. volumep. 422
spec. volumep. 422
+spec. enthalpyp. 422
spec. enthalpyp. 422
+Evaporation heatp. 422
Evaporation heatp. 422
+of the fluidp. 422
of the fluidp. 422
+of the steamp. 422
of the steamp. 422
+of the fluidp. 422
of the fluidp. 422
+of the steamp. 422
of the steamp. 422
+of the fluidp. 422
of the fluidp. 422
+of the steamp. 422
of the steamp. 422
+10 Central lubrication systemp. 427
10 Central lubrication systemp. 427
+Control lights for central lubrication systemp. 428
10.1 System layoutp. 428
+The sanitary landfill compactors are equipped with an automatically working central lubrication system.p. 428
The sanitary landfill compactors are equipped with an automatically working central lubrication system.p. 428
Fig. 1 Lubrication system RB machinep. 428
Fig. 2 Lubrication system RS machinep. 428
+1 Ignition switchp. 428
1 Ignition switchp. 428
2 Fuse F16p. 428
3 Push button with control lightp. 428
4 Lubrication pump with integrated controlp. 428
5 Main distributorp. 428
6 Main distributor in rear framep. 428
7 Piston detector, monitors and ends duty cyclep. 428
8 Sub-distributor in front framep. 428
+Control lights for central lubrication systemp. 429
10.2 Technical descriptionp. 429
+The system is equipped with an electronic control and a monitoring device for the function of the lubricant distributor. The electronic control is integrated in the pump case and controls the lubrication cycle automatically.p. 429
The system is equipped with an electronic control and a monitoring device for the function of the lubricant distributor. The electronic control is integrated in the pump case and controls the lubrication cycle automatically.p. 429
When switching the ignition on, the automatic lubrication system is supplied with voltage via fuse (F16) At the same time the system performs a function test for drive motor and control light.p. 429
During this function test the motor is activates for 1 seconds (short movement of stirring blade), at the same time a 2 second voltage pulse is sent to the monitoring board.p. 429
+Control lights for central lubrication systemp. 429
Control lights for central lubrication systemp. 429
+The control light 11p. 429
(Fig. 3)p. 429
(Fig. 4)p. 429
Faults are indicated by flashing frequencies of different lengths.p. 429
Old designp. 429
Fig. 3 Monitoring module, old designp. 429
+11 yellowp. 429
+11 yellowp. 429
11p. 429
lights during the lubrication process and flashes in case of functional disturbances.p. 429
New versionp. 429
Fig. 4 Monitoring module, new designp. 429
+m yellowp. 429
+m yellowp. 429
mp. 429
lights during the lubrication process and flashes in case of functional disturbances.p. 429
+The control light indicates the same operating states as the function displayp. 429
+The control light indicates the same operating states as the function displayp. 429
(Fig. 5)p. 429
Fig. 5 Function display on control boardp. 429
+10.5 Progressive distributorp. 430
Function controlp. 430
Fig. 6 Push buttonp. 430
+To check the function of the system you can perform a test run. For this purpose press the push buttonp. 430
(Fig. 6)p. 430
+Start an additional lubrication cycle.p. 430
Start an additional lubrication cycle.p. 430
Press the push button longer than 2 seconds (> 2 s).p. 430
Short pressing of button acknowledges the fault signal, i.e the flashing control lamp changes to a permanent light.p. 430
+Acknowledging a faultp. 430
Acknowledging a faultp. 430
Press the push button for short moment (< 1 s).p. 430
+An acknowledged fault also remains stored after switching off the ignition. When switching on again the control lamp flashes again, according to the respective fault.p. 430
An acknowledged fault also remains stored after switching off the ignition. When switching on again the control lamp flashes again, according to the respective fault.p. 430
Fig. 7 Operating statesp. 430
+Ap. 430
Ap. 430
Fault indicatorp. 430
Bp. 430
Function display or acknowledged faultp. 430
+in case of a faultp. 430
in case of a faultp. 430
Switch the pump on again by pressing the button (> 2 s).p. 430
+The fault can also be acknowledge or reset by triggering an additional lubrication cycle by pressing push button 4p. 430
+The fault can also be acknowledge or reset by triggering an additional lubrication cycle by pressing push button 4p. 430
(Fig. 8)p. 430
Fig. 8 Control boardp. 430
+10.5 Progressive distributorp. 431
10.3 Controlp. 431
+Control boardp. 431
Control boardp. 431
The control board is integrated in the pump housing.p. 431
Fig. 9 Control board installed in the housingp. 431
Fig. 10 Control boardp. 431
+Voltage supplyp. 431
+Intermittent flashing signalp. 431
(Fig. 11)p. 431
Fig. 11 Jumper B/D plugged onp. 431
+Voltage supplyp. 431
+Voltage supplyp. 431
(Fig. 12)p. 431
Fig. 12 Jumper 15/30 plugged onp. 431
With jumper 39/15 plugged on the connections 15 and 30 are bridged within the control board.p. 431
Function displayp. 432
Fig. 13 Function display on circuit boardp. 432
+The function display indicates the same operating states as the control light in the LCD group display.p. 432
The function display indicates the same operating states as the control light in the LCD group display.p. 432
+l The control boardp. 432
+l The control boardp. 432
(Fig. 13)p. 432
Fig. 14 Time diagramp. 432
+tBp. 432
tBp. 432
+Operating hoursp. 432
Operating hoursp. 432
+tPp. 432
tPp. 432
+individual pause timesp. 432
individual pause timesp. 432
+Tp. 432
Tp. 432
+Lubrication cyclep. 432
Lubrication cyclep. 432
+T1p. 432
T1p. 432
+saved pause timesp. 432
saved pause timesp. 432
+T2p. 432
T2p. 432
+Duty timesp. 432
Duty timesp. 432
+l The lubrication cycle consists of a pause and a duty time. The duty time starts after the pause time has finished. After the machine has been started, the lubrication cycle will continue repeating itself.p. 432
l The lubrication cycle consists of a pause and a duty time. The duty time starts after the pause time has finished. After the machine has been started, the lubrication cycle will continue repeating itself.p. 432
l During the duty time the pump element delivers lubricant through the progressive distributors to the lubrication points.p. 432
+Pause time Pp. 432
(Fig. 15)p. 432
Fig. 15 Sequence of a lubrication cyclep. 432
+Ap. 432
Ap. 432
+Monitoring of motor and control lightp. 432
Monitoring of motor and control lightp. 432
+Bp. 432
Bp. 432
+Sequence of timep. 432
Sequence of timep. 432
+Cp. 432
Cp. 432
+Sequence of monitoring timep. 432
Sequence of monitoring timep. 432
+Ip. 432
Ip. 432
+Duty cyclep. 432
Duty cyclep. 432
+Pp. 432
Pp. 432
+Pausep. 432
Pausep. 432
+The pause time Pp. 432
(Fig. 15)p. 432
+l determines the frequency of lubrication cycles within the time of usep. 432
l determines the frequency of lubrication cycles within the time of usep. 432
l is started and stopped with the ignition switchp. 432
l can be changedp. 432
+When switching the ignition off, all pause times that have expired as well as the present operating states (faults) are saved and added up. This takes place, until the time set by the blue rotary switchp. 432
(Fig. 20)p. 432
When switching the ignition back on, the control will start exactly at the same point where it stopped before the ignition was switched off.p. 432
+Duty cycle Ip. 433
(Fig. 16)p. 433
Fig. 16 Sequence of a lubrication cyclep. 433
+Ap. 433
Ap. 433
+Monitoring of motor and control lightp. 433
Monitoring of motor and control lightp. 433
+Bp. 433
Bp. 433
+Sequence of timep. 433
Sequence of timep. 433
+Cp. 433
Cp. 433
+Sequence of monitoring timep. 433
Sequence of monitoring timep. 433
+Ip. 433
Ip. 433
+Duty cyclep. 433
Duty cyclep. 433
+Pp. 433
Pp. 433
+Pausep. 433
Pausep. 433
+The duty cycle Ap. 433
(Fig. 16)p. 433
(Fig. 17)p. 433
Fig. 17 Piston detector, B52p. 433
If the duty time is interrupted by switching of the ignition switch, it will be eresrated from the beginning when switched on again.p. 433
+Monitoring time Cp. 433
(Fig. 18)p. 433
Fig. 18 Sequence of a lubrication cyclep. 433
+Ap. 433
Ap. 433
+Monitoring of motor and control lightp. 433
Monitoring of motor and control lightp. 433
+Bp. 433
Bp. 433
+Sequence of timep. 433
Sequence of timep. 433
+Cp. 433
Cp. 433
+Sequence of monitoring timep. 433
Sequence of monitoring timep. 433
+Ip. 433
Ip. 433
+Duty cyclep. 433
Duty cyclep. 433
+Pp. 433
Pp. 433
+Pausep. 433
Pausep. 433
+A fixed monitoring time of max. 5 or 30 minutes (depending on jumper setting) runs parallel to the duty timep. 433
(Fig. 19)p. 433
Fig. 19 Jumper for monitoring rangesp. 433
1 – Jumper for monitoring time, 5 minutes (5min) or 30 minutes (30min).p. 433
2 – Jumper for 1st lubrication circuit (1 O) or for 2nd lubrication circuit (2 O).p. 433
+The monitoring time normally ends with the end of the duty time.p. 433
The monitoring time normally ends with the end of the duty time.p. 433
+l If no shut-down signal from the piston detector (initiator, B52) is received by the control board within 5 or 30 minutes, a fault message will be displayed.p. 433
l If no shut-down signal from the piston detector (initiator, B52) is received by the control board within 5 or 30 minutes, a fault message will be displayed.p. 433
+The indicator lamp will flash with the corresponding frequency and the pump will stop.p. 434
The indicator lamp will flash with the corresponding frequency and the pump will stop.p. 434
+l If the work cycle takes longer than 5 minutes, the monitoring time must be changed from 5 minutes (5 min) to 30 minutes (30 min) by simply replugging the jumper,p. 434
l If the work cycle takes longer than 5 minutes, the monitoring time must be changed from 5 minutes (5 min) to 30 minutes (30 min) by simply replugging the jumper,p. 434
l If two monitored lubrication circuits are available, the jumper must be replugged for two lubrication circuits (2 O).p. 434
Time settingp. 434
Fig. 20 Setting the pause timep. 434
+l Open the cover.p. 434
l Open the cover.p. 434
+The pause time can be set in 15 stages by the blue rotary switch.p. 434
The pause time can be set in 15 stages by the blue rotary switch.p. 434
+Set the pause time to position (1).p. 434
Set the pause time to position (1).p. 434
+The time ranges (hours or minutes) can be changed by replugging the jumper on the control board.p. 434
The time ranges (hours or minutes) can be changed by replugging the jumper on the control board.p. 434
Replugging the jumper requires removal of the circuit board.p. 434
+Plug the jumper for the time range hours (1 – 15h, right).p. 434
Plug the jumper for the time range hours (1 – 15h, right).p. 434
+After setting the pause time close the cover again.p. 434
After setting the pause time close the cover again.p. 434
+10.5 Progressive distributorp. 435
10.4 Lubrication processp. 435
+Main and sub-distributorp. 435
Main and sub-distributorp. 435
+Lubrication pointsp. 435
Lubrication pointsp. 435
The sub-distributor in the rear frame supplies the following points in the rear frame with grease:p. 435
+l the rocker bearings (4 pieces) on both steering cylindersp. 435
l the rocker bearings (4 pieces) on both steering cylindersp. 435
l top and bottom bearings on the articulated jointp. 435
The sub-distributor in the front frame supplies the following points in the rear frame with grease:p. 435
+l the live ring bearing in the oscillating jointp. 435
l the live ring bearing in the oscillating jointp. 435
l all bucket bearingsp. 435
l the upper rocker bearing on the bucket cylinderp. 435
+Main distributor and sub-distributors are connected by a main grease line. This results in a positive connection between the pump and the downstream progressive system.p. 435
Main distributor and sub-distributors are connected by a main grease line. This results in a positive connection between the pump and the downstream progressive system.p. 435
If a piston in a distributor does not move or is not able to displace any lubricant through its outlet ports, this distributor will block itself.p. 435
If one of the sub-distributors is blocked, the positive connection of the system will also block the main distributor. The complete progressive system will stop.p. 435
+The fundamental internal structure of the progressive distributor ensures self-monitoring of the working cycle in the distributor.p. 435
The fundamental internal structure of the progressive distributor ensures self-monitoring of the working cycle in the distributor.p. 435
The cross-linking of this system enables monitoring of the complete system.p. 435
Due to the use of the piston detector functional faults are immediately detected and indicated by a flashing sequence of the control light.p. 435
The complete system can be visually monitored by the pressure relief valve of the pump. If grease emerges from this pressure relief valve during the pumping process, there must be a blockage in the system.p. 435
+10.5 Progressive distributorp. 435
10.5 Progressive distributorp. 435
+Componentsp. 435
Componentsp. 435
Fig. 21p. 435
+1 Inlet fittingp. 435
1 Inlet fittingp. 435
2 Delivery bore from pistonp. 435
3 Fitting, assembledp. 435
4 Plug, pistonp. 435
5 Check valve, completep. 435
6 Clamping ring (brass)p. 435
7 Valve bodyp. 435
8 Cutting ringp. 435
9 Spigot nutp. 435
10 Connecting channelp. 435
11 Copper seal ringp. 435
12 Plugp. 435
+Features of a progressive distributorp. 435
Features of a progressive distributorp. 435
The expression “Progressive” hints to a speciality that occurs during the lubricant supply inside the distributor, such asp. 435
+l successive movement of the individual pistons in the distributor caused by the supplied pressurized lubricant.p. 435
l successive movement of the individual pistons in the distributor caused by the supplied pressurized lubricant.p. 435
l The pistons move in a preset sequence and in constantly repeated cycles.p. 435
l Each piston must have fully completed its movement before the movement of the next piston can take place, irrespective of whether the supply of lubricant is constant or intermittent.p. 435
l The pistons work in dependence on each other.p. 435
None of the connected lubrication points will be missed out.p. 435
Progressive distributors of type SSV are piston distributors.p. 435
+l They control the distribution of the lubricant (progressively) to the connected lubrication points.p. 435
l They control the distribution of the lubricant (progressively) to the connected lubrication points.p. 435
+l Per outlet and piston stroke a quantity of 0.2 cmp. 435
3p. 435
l By closing single outlets it is possible to deliver the double or multiple amounts of lubricant.p. 436
l This distributor provides the possibility to connect several lubrication points to one central lubrication point.p. 436
Description of functionp. 436
The following five illustrations show how the individual outlets are supplied with the proper amount of lubricant.p. 436
+For simplification we only show the delivery details for the outlets 2, 7, 5, 3 and 1. All other processes result from the logic pumping sequence.p. 436
For simplification we only show the delivery details for the outlets 2, 7, 5, 3 and 1. All other processes result from the logic pumping sequence.p. 436
Phase 1p. 436
Fig. 22 Phase 1p. 436
+The lubricant enters from above (vertical arrow) into the lubricant distributor and flows to the right end of piston Ap. 436
(Fig. 22)p. 436
The lubricant pressure moves piston A (horizontal arrow) to the left and presses the confined lubricant from the left hand end of piston A to outlet 2.p. 436
Phase 2p. 436
Fig. 23 Phase 2p. 436
+When piston Ap. 436
(Fig. 23)p. 436
The lubricant flowing in from above (vertical arrow) likewise moves piston B (horizontal arrow) to the left and presses the confined lubricant from the left hand end of piston B to outlet 7.p. 436
Phase 3p. 436
Fig. 24 Phase 3p. 436
+When piston Bp. 436
(Fig. 24)p. 436
The lubricant flowing in from above (vertical arrow) likewise moves piston C (horizontal arrow) to the left and presses the confined lubricant from the left hand end of piston C to outlet 5.p. 436
Phase 4p. 437
Fig. 25 Phase 4p. 437
+The connecting passage at the right hand end of piston Dp. 437
(Fig. 25)p. 437
Lubricant flowing in from above (vertical arrow) presses piston D to the left hand side, thus the confined lubricant from the left hand end of piston D leaves the distributor through outlet 3.p. 437
Phase 5p. 437
Fig. 26 Phase 5p. 437
+In phase 4 piston Dp. 437
(Fig. 26)p. 437
The flowing lubricant (vertical arrow) pushes piston A to the right (upper horizontal arrow) and conveys the confined lubricant to outlet 1.p. 437
During the continuing delivery sequence the pistons B – D move from left to right, one after the other.p. 437
Thus one complete revolution has come to an end and a new cycle can start.p. 437
If the flow of lubricant is interrupted the piston will stop. In this case no lubricant is conveyed to the lubrication points.p. 437
When lubricant flows through the distributor again, the cycle starts exactly at the point where it was interrupted.p. 437
+10.7 Check the central lubrication system, topping upp. 438
10.6 Lubrication oil pumpp. 438
+During the lubrication cycle the pump delivers lubricant to the connected lubrication points via several distributors.p. 438
During the lubrication cycle the pump delivers lubricant to the connected lubrication points via several distributors.p. 438
+Despite an existing fault monitoring feature the visual inspections and function checks of the lubrication system must be performed at regular intervals.p. 438
Despite an existing fault monitoring feature the visual inspections and function checks of the lubrication system must be performed at regular intervals.p. 438
+Componentsp. 438
Componentsp. 438
Fig. 27 Pump components:p. 438
+1 Tankp. 438
1 Tankp. 438
2 Pump elementp. 438
3 Pressure relief valvep. 438
4 Filling nipple, for emergency lubricationp. 438
5 Connection plug 2A1 (only for industrial applications), on BOMAG machines with fixed cablep. 438
6 Filling nipple, pumpp. 438
7 Control boardp. 438
8 Connection plug 1A1 (only for industrial applications)p. 438
9 Return flow connection, not usedp. 438
The pump is a compact multiple-line pump and consists of:p. 438
+l Container with agitator wingp. 438
l Container with agitator wingp. 438
l housing with built-in motorp. 438
l Control unitp. 438
l Pump element with pressure relief valvep. 438
l Filling facilityp. 438
+Hydraulic diagramp. 438
Hydraulic diagramp. 438
Fig. 28 Hydraulic diagram of pumpp. 438
+1 Container with agitator wingp. 438
1 Container with agitator wingp. 438
2 Pumpp. 438
3 Check valve, spring loadedp. 438
4 Pressure relief valvep. 438
+Rp. 438
Rp. 438
Return linep. 438
Pp. 438
Pressure linep. 438
+(3)p. 438
(Fig. 28)p. 438
The check valve serves the function of the pump element. It prevents the back flow of lubricant to the housing, i.e. to the container.p. 438
+(4)p. 438
(Fig. 28)p. 438
(Fig. 29)p. 438
The pressure relief valve limits the pressure in the system to the adjusted value.p. 438
+The valve opens at a pressure ofp. 438
305 barp. 438
Lubricant escaping from the pressure relief valve indicates a fault in the system.p. 438
Fig. 29 Pressure relief valvep. 439
Checking the pressure relief valvep. 439
Fig. 30 Checking the pressure relief valvep. 439
+3p. 439
3p. 439
+Pressure relief valvep. 439
Pressure relief valvep. 439
+Ap. 439
Ap. 439
+Hose, at least 1 m longp. 439
Hose, at least 1 m longp. 439
+Bp. 439
Bp. 439
+T-piecep. 439
T-piecep. 439
+Cp. 439
Cp. 439
+Pressure gauge (0-600 bar / 0-8708 psi)p. 439
Pressure gauge (0-600 bar / 0-8708 psi)p. 439
+Dp. 439
Dp. 439
+Relieve cockp. 439
Relieve cockp. 439
+l Connect the pressure gauge Cp. 439
+l Connect the pressure gauge Cp. 439
(Fig. 30)p. 439
+Do not connect the pressure gauge (C) directly to the pump element (3). Use a hose (A) with a length of at least 1 m. Very high pressure peaks, exceeding the above measuring range, will occur. In such cases the pump motor may stop. It can be blocked …p. 439
Do not connect the pressure gauge (C) directly to the pump element (3). Use a hose (A) with a length of at least 1 m. Very high pressure peaks, exceeding the above measuring range, will occur. In such cases the pump motor may stop. It can be blocked …p. 439
+l Start an additional lubrication cycle.p. 439
l Start an additional lubrication cycle.p. 439
Pump elementp. 439
Fig. 31 Pump elementp. 439
+1 Pistonp. 439
1 Pistonp. 439
2 Resetting springp. 439
3 Check valvep. 439
+The electric motor drives the eccentric 1p. 439
(Fig. 32)p. 439
+During operation the piston 2p. 439
(Fig. 31)p. 439
Fig. 32 Pump element drawing in greasep. 439
+1 Eccentricp. 439
1 Eccentricp. 439
2 Pistonp. 439
3 Springp. 439
4 Check valvep. 439
Fig. 33 Pump element pumpingp. 439
+1 Eccentricp. 439
1 Eccentricp. 439
2 Pistonp. 439
3 Springp. 439
4 Check valvep. 439
+10.7 Check the central lubrication system, topping upp. 440
10.7 Check the central lubrication system, topping upp. 440
+When using an external heavy duty lubrication device lubricate slowly and with interruptions.p. 440
+When using an external heavy duty lubrication device lubricate slowly and with interruptions.p. 440
When using an external heavy duty lubrication device lubricate slowly and with interruptions.p. 440
The following lubrication points are effectively and reliably supplied with lubricant by the central lubrication system.p. 440
+l 2 x on bearing block at bottom of dozer blade,p. 440
l 2 x on bearing block at bottom of dozer blade,p. 440
l 1 x eye for dozer blade cylinder,p. 440
l 4 x steering cylinder eyes,p. 440
l 2 x articulated joint,p. 440
l 4 x live ring of articulated jointp. 440
A differentiation is made between the time cycles for pause and duty.p. 440
Pause: No lubrication over a period of 60 minutes.p. 440
Duty cycle: Factory set.p. 440
+Checkp. 440
Checkp. 440
Fig. 34p. 440
+l Switch on the ignition.p. 440
l Switch on the ignition.p. 440
+l Actuate push buttonp. 440
(Fig. 34)p. 440
Fig. 35p. 440
+l The agitator in the transparent container 1p. 440
+l The agitator in the transparent container 1p. 440
(Fig. 35)p. 440
+Use the push button only to check the system.p. 440
Use the push button only to check the system.p. 440
+Failure of a lubrication pointp. 440
Failure of a lubrication pointp. 440
(e.g. a clogged lubrication point)p. 440
+l Grease emerging from opening 3p. 440
+l Grease emerging from opening 3p. 440
(Fig. 35)p. 440
l Identify and rectify the cause.p. 440
+Filling through the grease nipplep. 440
Filling through the grease nipplep. 440
+Ensure strict cleanliness, as otherwise the distributors may seize.p. 440
Ensure strict cleanliness, as otherwise the distributors may seize.p. 440
Do not fill the grease container by removing the cover.p. 440
Fill the grease container if it is only 1/4 filled.p. 440
+l Clean the grease nipple.p. 440
l Clean the grease nipple.p. 440
l Fill the grease container through the grease nipple (2) up to the "Max"-mark.p. 440
For quality and quantity of grease refer to the table of fuels, lubricants and filling capacities.p. 440
+l Switch on the ignition, actuate the push buttonp. 440
+l Switch on the ignition, actuate the push buttonp. 440
(Fig. 34)p. 440
+Filling with the hand pumpp. 440
Filling with the hand pumpp. 440
+Ensure strict cleanliness, as otherwise the distributors may seize.p. 440
Ensure strict cleanliness, as otherwise the distributors may seize.p. 440
For quality and quantity of grease refer to the table of fuels, lubricants and filling capacities.p. 440
Fig. 36p. 441
+l Remove both lids from the cartridge 1p. 441
+l Remove both lids from the cartridge 1p. 441
(Fig. 36)p. 441
l Unscrew the connecting fitting from the hand pump (2).p. 441
l Pull the actuator rod completely out.p. 441
l Slide the cartridge into the hand pump with the triangle mark to the front.p. 441
l Check whether the seal ring has been inserted into the connecting fitting.p. 441
l Screw the connecting fitting onto the hand pump.p. 441
Fig. 37p. 441
+l Clean the area around the locking cap on the central lubrication system.p. 441
l Clean the area around the locking cap on the central lubrication system.p. 441
+l Unscrew the locking cap from the central lubrication system and the locking plug from the hand pumpp. 441
(Fig. 37)p. 441
l Screw the hand pump onto the socket on the central lubrication system.p. 441
l Push the grease into the transparent container by operating the actuating rod.p. 441
l Unscrew the hand pump, insert a new cartridge and repeat the pumping procedure until the transparent container is filled up to the "Max"-mark.p. 441
+After filling screw locking cap and locking plug back on.p. 441
After filling screw locking cap and locking plug back on.p. 441
10.8 Faults and causesp. 441
+Indication of faultsp. 441
Indication of faultsp. 441
Fig. 38 Flashing frequencies in case of faultsp. 441
+Ap. 441
+Ap. 441
Ap. 441
+Motor defectivep. 441
Motor defectivep. 441
+Faultsp. 441
Faultsp. 441
If the motor does not start when operating the starter switch or the machine contact, or if the cable of the motor is defective, the control lamp will flash after 2 seconds as follows:p. 441
+l A= 1 second ”ON” – 1 second ”OFF”p. 441
l A= 1 second ”ON” – 1 second ”OFF”p. 441
+Bp. 441
+Bp. 441
Bp. 441
+Fault in lubrication circuit 1p. 441
Fault in lubrication circuit 1p. 441
e.g.:p. 441
+l blocked lubrication point(s)p. 441
l blocked lubrication point(s)p. 441
l blocked distributorp. 441
l main hose to distributor with piston detector interruptedp. 441
l air in system.p. 441
The above faults mean that the piston in the monitored distributor cannot move any more.p. 441
The control lamp shows the following flashing sequence:p. 441
+l 0.5 seconds ”ON” – 1 second ”OFF”p. 441
l 0.5 seconds ”ON” – 1 second ”OFF”p. 441
+Cp. 441
+Cp. 441
Cp. 441
+Fault in lubrication circuit 2 (not applicable)p. 441
Fault in lubrication circuit 2p. 441
+Dp. 441
+Dp. 441
Dp. 441
+Fault in lubrication circuits 1 and 2 (not applicable)p. 441
Fault in lubrication circuits 1 and 2p. 441
+Ep. 442
+Ep. 442
Ep. 442
+Empty signal: Container emptyp. 442
Empty signal:p. 442
The control lamp shows the following flashing sequence:p. 442
+l 0.5 seconds ”ON” – 0.5 seconds ”OFF”p. 442
l 0.5 seconds ”ON” – 0.5 seconds ”OFF”p. 442
+After 6 motor revolutions the empty signal will be converted to a flashing signal with the above mentioned frequency.p. 442
After 6 motor revolutions the empty signal will be converted to a flashing signal with the above mentioned frequency.p. 442
In case of a malfunction the piston detector (initiator) is not able to detect a piston movement and therefore cannot switch the pump off.p. 442
With the help of the parallel running monitoring time the controls switch the pump off at the end of the monitoring time (5 minutes).p. 442
+l This is followed by a fault signalp. 442
l This is followed by a fault signalp. 442
l The contact lamp flashesp. 442
l The pump does no longer start automatically.p. 442
+Fp. 442
+Fp. 442
Fp. 442
+Acknowledged fault (permanent light)p. 442
Acknowledged faultp. 442
Short pressing of button (< 1 second) acknowledges the fault signal, i.e the flashing of the control lamp changes to a permanent light.p. 442
+An acknowledged fault also remains stored after switching the drive switch or the machine contact off. When switching on again the control lamp flashes again, according to the respective fault.p. 442
An acknowledged fault also remains stored after switching the drive switch or the machine contact off. When switching on again the control lamp flashes again, according to the respective fault.p. 442
Rectify the fault and release additional lubricationp. 442
+l In the event of a fault check the central lubrication pump and the connected system for faults.p. 442
l In the event of a fault check the central lubrication pump and the connected system for faults.p. 442
Rectify the cause of the fault.p. 442
+l Switch the pump on again by triggering an additional lubrication cycle. Keep the button slightly longer depressed (> 2 seconds). If the fault is eliminated, the control lamp will go out at the end of the lubrication process.p. 442
l Switch the pump on again by triggering an additional lubrication cycle. Keep the button slightly longer depressed (> 2 seconds). If the fault is eliminated, the control lamp will go out at the end of the lubrication process.p. 442
+In case of a malfunction the pump will not automatically start to run again after rectification of the fault. The pump must be switched on.p. 442
In case of a malfunction the pump will not automatically start to run again after rectification of the fault. The pump must be switched on.p. 442
10.9 Fault – Cause – Remedyp. 443
+Faultp. 443
Faultp. 443
+Causep. 443
Causep. 443
+Remedyp. 443
Remedyp. 443
+Pump does not workp. 443
Pump does not workp. 443
+Electric line interruptedp. 443
Electric line interruptedp. 443
+Replace the electric linep. 443
Replace the electric linep. 443
+Pump defectivep. 443
Pump defectivep. 443
+Replace the pumpp. 443
Replace the pumpp. 443
+Pump works, but does not deliverp. 443
Pump works, but does not deliverp. 443
+Air cushion in pumping pistonp. 443
Air cushion in pumping pistonp. 443
+Vent the pumpp. 443
Vent the pumpp. 443
+Min. filling level fallen short ofp. 443
Min. filling level fallen short ofp. 443
+Fill up the provision containerp. 443
Fill up the provision containerp. 443
+Pump element defectivep. 443
Pump element defectivep. 443
+Replace the pump elementp. 443
Replace the pump elementp. 443
+No grease collar at the lubrication pointsp. 443
No grease collar at the lubrication pointsp. 443
+Pump does not workp. 443
Pump does not workp. 443
+See "Pump does not work"p. 443
See "Pump does not work"p. 443
+Pause time too long or lubrication period too shortp. 443
Pause time too long or lubrication period too shortp. 443
+Reduce pause time or extend lubrication timep. 443
Reduce pause time or extend lubrication timep. 443
+System blockedp. 443
System blockedp. 443
+See "Grease emerging from pressure relief valve"p. 443
See "Grease emerging from pressure relief valve"p. 443
+No grease collars at various lubrication pointsp. 443
No grease collars at various lubrication pointsp. 443
+Supply line to secondary distributor burst or leakingp. 443
Supply line to secondary distributor burst or leakingp. 443
+Replace the linep. 443
Replace the linep. 443
+Screw fittings leakingp. 443
Screw fittings leakingp. 443
+Retighten or replace screw fittingp. 443
Retighten or replace screw fittingp. 443
+No grease collar on one lubrication pointp. 443
No grease collar on one lubrication pointp. 443
+Corresponding grease line burst or leakingp. 443
Corresponding grease line burst or leakingp. 443
+Replace the linep. 443
Replace the linep. 443
+Screw fitting leakingp. 443
Screw fitting leakingp. 443
+Retighten or replace screw fittingp. 443
Retighten or replace screw fittingp. 443
+Pump speed too lowp. 443
Pump speed too lowp. 443
+High system pressure or low ambient temperaturep. 443
High system pressure or low ambient temperaturep. 443
+Check system / bearing pointp. 443
Check system / bearing pointp. 443
No damage (perform 1 or 2 intermediate lubrication cycles)p. 443
+Grease emerging from pressure relief valvep. 443
Grease emerging from pressure relief valvep. 443
+System pressure too highp. 443
System pressure too highp. 443
+Check systemp. 443
Check systemp. 443
+Progressive distributor blockedp. 443
Progressive distributor blockedp. 443
+Replace the distributorp. 443
Replace the distributorp. 443
+System blockedp. 443
System blockedp. 443
+Repair blocked / seized bearing pointsp. 443
Repair blocked / seized bearing pointsp. 443
+Cause for a blockage in the systemp. 443
Cause for a blockage in the systemp. 443
+l A crushed or blocked lubricant linep. 443
l A crushed or blocked lubricant linep. 443
l A bearing overfilled with lubricant or blockedp. 443
l An unsuitable lubricant for central lubrication systemsp. 443
l A blocked distributor outletp. 443
l A blocked distributorp. 443
Indication of a blockagep. 443
+l Grease emerging from pressure relief valvep. 443
l Grease emerging from pressure relief valvep. 443
Identify the location of the blockagep. 444
+All repair work must be carried out with utmost cleanliness.p. 444
All repair work must be carried out with utmost cleanliness.p. 444
Fig. 39p. 444
+l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 444
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 444
l 2.) Unscrew the cap screws on the distributor one after the other and operate the pump each time a cap screw is removed. The line (cap screw) at which the pressure drops, is the blocked line or lubrication point.p. 444
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication point.p. 444
Fig. 40 KIT to check central lubrication systemsp. 444
Failure of central lubrication system (grease emerges from relief valve)p. 445
+11 Enginep. 447
11 Enginep. 447
+11.9 Check, adjust the valve clearancep. 448
11.1 Diesel enginep. 448
+Refuse compactors of series BC 772 RB-2 are powered by 6-cylinder Deutz diesel engines type TCD 2015 and the BC 972/1172 RB-2 by an 8-cylinder engine type TCD 2015.p. 448
Refuse compactors of series BC 772 RB-2 are powered by 6-cylinder Deutz diesel engines type TCD 2015 and the BC 972/1172 RB-2 by an 8-cylinder engine type TCD 2015.p. 448
These engines are V-type engines with water cooling, whereby the cylinder banks are arranged to each other under a 90° angle.p. 448
The engines are designed in four-valve technology with turbo charging and intercooler. They are extremely compact and are fitted with a solenoid valve controlled electronic injection system (MVS).p. 448
23 Oil line to crankshaft and camshaft, compressor / hydraulic pumpp. 451
24 Compressor (optional)p. 451
25 Hydraulic pump (optional)p. 451
26 Pressure retaining valve (adjustable)p. 451
27 Return flow from compressor / hydraulic pump to crankcasep. 451
28 Return flow from exhaust turbo chargerp. 451
+11.9 Check, adjust the valve clearancep. 452
11.4 Coolant circuit TCD 2015p. 452
Fig. 1 Coolant diagramp. 452
+1 Coolant pumpp. 452
1 Coolant pumpp. 452
2 Lubrication oil coolerp. 452
3 Coolant channelp. 452
4 Cooling of cylinder liner/cylinder head (numbering/arrangement of cylinders depending on engine series)p. 452
5 Compressor (optional)p. 452
6 Transmission oil cooler (optional)p. 452
7 Additional cooler (optional)p. 452
8 Temperature sensorp. 452
9 Thermostatp. 452
10 Compensation tankp. 452
11 Filler socketp. 452
12 Heat exchangerp. 452
13 Cabin heater (optional)p. 452
+11.9 Check, adjust the valve clearancep. 453
11.5 Fuel circuit TCD 2015p. 453
Fig. 1 Fuel diagramp. 453
+1 Fuel tankp. 453
1 Fuel tankp. 453
2 min. distance 500 mmp. 453
3 Fuel supply line from tankp. 453
4 Manual priming pump for bleedingp. 453
5 Fuel pre-filter (example)p. 453
6 Fuel priming pumpp. 453
7 Fuel twin filterp. 453
8 Fuel supply line to injection pumpsp. 453
9 Injection pumpp. 453
10 Injection linep. 453
11 Injection valvesp. 453
12 Fuel supply line to injection pumpsp. 453
13 Fuel return line from injection pumpsp. 453
14 Pressure retaining valvep. 453
15 Fuel return line to fuel tankp. 453
+Fuel pre-filterp. 454
Fuel pre-filterp. 454
Fig. 2 Fuel pre-filterp. 454
+1 Filter bracketp. 454
1 Filter bracketp. 454
2 Filter cartridgep. 454
3 Water collecting bowlp. 454
4 Electric connectionp. 454
5 Drain plugp. 454
6 Manual fuel pumpp. 454
7 Bleeding screwp. 454
8 Sealing facep. 454
A Electric water level sensorp. 454
Fuel filter systemp. 455
Fig. 3 Fuel pre-filterp. 455
+1 Fuel pressure filter min. 3µmp. 455
1 Fuel pressure filter min. 3µmp. 455
2 Bleeding screwsp. 455
3 Fuel pre-filterp. 455
4 additional hand pumpp. 455
+11.9 Check, adjust the valve clearancep. 456
11.6 Injection system (MVS) TCD 2015p. 456
+The solenoid valve system (MVS) is a new fully electronically controlled diesel injection system without mechanical link to the operator (no governor rod). In contrast to conventional injection systems the MVS enables an absolutely unrestricted contr…p. 456
The solenoid valve system (MVS) is a new fully electronically controlled diesel injection system without mechanical link to the operator (no governor rod). In contrast to conventional injection systems the MVS enables an absolutely unrestricted contr…p. 456
The MVS consists of a pump with solenoid valve and injection nozzle for each individual cylinder.p. 456
The solenoid valve closes the fuel bypass in the plunger chamber, thus causing an increase in injection pressure and finally triggers the injection when the nozzle opening pressure is reached. If injection is to be ended, the valve will open the bypa…p. 456
The solenoid valves are triggered by the electronic control unit in dependence on the operatig parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a reliable and safe comple…p. 456
Fig. 1 MVS – Injection system TCD 2015p. 456
Fig. 2 Electrics of TCD 2015p. 457
+1 Oil pressure sensorp. 457
1 Oil pressure sensorp. 457
2 Fuel temperature sensorp. 457
3 Sensor for charge air temperature and charge air pressurep. 457
+In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 459
In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 459
On 6 and 8 cylinder engines TCD 2015 the exhaust gas recirculation has been realized internally through the exhaust valves. For this purpose the camshaft has been manufactured with an additional cam for short-term opening of the exhaust valvep. 459
Fig. 1 Exhaust valve control TCD 2015p. 459
+11.9 Check, adjust the valve clearancep. 460
11.8 Wastegate – charge pressure controller on TCD-enginesp. 460
+The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 460
The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 460
The Wastegate (exhaust gas bypass valve) is used to control the charge pressurep. 460
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust gas turbine into the exhaust withou…p. 460
The bypass valve is normally closedp. 460
Fig. 1 Exhaust gas turbocharger with Wastegatep. 460
Wastegate active, charge pressure control, i.e. bypass valve openp. 460
Fig. 1 Exhaust gas turbocharger with Wastegatep. 460
Wastegate on TCD 2013p. 461
Fig. 2 Exhaust gas turbocharger with Wastegatep. 461
+11.9 Check, adjust the valve clearancep. 462
11.9 Check, adjust the valve clearancep. 462
+We recommend to have this work carried out by trained personnel or our after sales service.p. 462
+We recommend to have this work carried out by trained personnel or our after sales service.p. 462
We recommend to have this work carried out by trained personnel or our after sales service.p. 462
Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 °C.p. 462
Fig. 3p. 462
+l Remove all valve coversp. 462
+l Remove all valve coversp. 462
(Fig. 3)p. 462
Fig. 4p. 462
+Adjustment diagramp. 462
+Adjustment diagramp. 462
(Fig. 4)p. 462
+Valvesp. 462
Valvesp. 462
+Cylinderp. 462
Cylinderp. 462
+overlappingp. 462
overlappingp. 462
+A1p. 462
A1p. 462
+B3p. 462
B3p. 462
+A3p. 462
A3p. 462
+B2p. 462
B2p. 462
+A2p. 462
A2p. 462
+B1p. 462
B1p. 462
+adjustmentp. 462
adjustmentp. 462
+B2p. 462
B2p. 462
+A2p. 462
A2p. 462
+B1p. 462
B1p. 462
+A1p. 462
A1p. 462
+B3p. 462
B3p. 462
+A3p. 462
A3p. 462
+l Turn the crankshaft until the valves are overlapping.p. 462
l Turn the crankshaft until the valves are overlapping.p. 462
+This engine is equipped with an internal exhaust recirculation system. During the intake cycle the exhaust valve opens for a short moment.p. 462
This engine is equipped with an internal exhaust recirculation system. During the intake cycle the exhaust valve opens for a short moment.p. 462
This must not be mistaken as overlapping of valves!p. 462
Fig. 5p. 462
+Check the valve clearancep. 462
Check the valve clearancep. 462
+l Intake valves 0,25 mmp. 462
l Intake valves 0,25 mmp. 462
l Exhaust valves 0,30 mmp. 462
+l A feeler gauge of appropriate thickness (1) must fit with little resistance between rocker arm (2)p. 462
(Fig. 5)p. 462
l If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.p. 462
+Adjusting the valve clearancep. 462
Adjusting the valve clearancep. 462
+l Loosen counter nut (4)p. 462
+l Loosen counter nut (4)p. 462
(Fig. 5)p. 462
l Adjust the setscrew (5) with a screwdriver, until the feeler gauge can be inserted and pulled out with little resistance after retightening the counter nut.p. 462
l Repeat the adjustment procedure on each cylinder.p. 462
Fig. 6p. 462
+l Assemble all cylinder nead covers with new gasketsp. 462
+l Assemble all cylinder nead covers with new gasketsp. 462
(Fig. 6)p. 462
+After a short test run check the engine for leaks.p. 462
After a short test run check the engine for leaks.p. 462
+11.10 Check the engine oil levelp. 463
11.10 Check the engine oil levelp. 463
+The machine must be in horizontal position. Just before testing run the engine approx. 2 minutes with idle speed. Shut the engine down.p. 463
+The machine must be in horizontal position. Just before testing run the engine approx. 2 minutes with idle speed. Shut the engine down.p. 463
The machine must be in horizontal position. Just before testing run the engine approx. 2 minutes with idle speed. Shut the engine down.p. 463
Fig. 7p. 463
+l Pull the dipstickp. 463
+l Pull the dipstickp. 463
(Fig. 7)p. 463
l Pull the dipstick back out again.p. 463
l The oil level must be near the ”Max”-mark.p. 463
l If the oil level is too low top up oil immediately.p. 463
For quality of oil refer to the table of fuels, lubricants and filling capacities.p. 463
+11.11 Change the engine oilp. 463
11.11 Change the engine oilp. 463
+Drain the engine oil only when the engine is warm. Preferably use oils of ACEA-classification E4-99/E6- 04. This allows the utilisation of the longest oil change intervals.p. 463
+Drain the engine oil only when the engine is warm. Preferably use oils of ACEA-classification E4-99/E6- 04. This allows the utilisation of the longest oil change intervals.p. 463
Drain the engine oil only when the engine is warm. Preferably use oils of ACEA-classification E4-99/E6- 04. This allows the utilisation of the longest oil change intervals.p. 463
Oil change intervals (operating hours) for ACEA quality:p. 463
+E4-99/E6-04p. 463
E4-99/E6-04p. 463
500 operating hoursp. 463
+With a fuel consumption of >50l/h the oil change must be performed every 250 operating hoursp. 463
With a fuel consumption of >50l/h the oil change must be performed every 250 operating hoursp. 463
+Danger of scalding!p. 463
Danger of scalding!p. 463
Danger of scalding when draining off hot oil!p. 463
+Environmental damage!p. 463
Environmental damage!p. 463
Do not let old oil seep into the ground, but dispose off environmentally.p. 463
Fig. 8p. 463
+l Remove the rear service door.p. 463
l Remove the rear service door.p. 463
+l Unscrew the safety cap 2p. 463
(Fig. 8)p. 463
l Take the oil drain hose (3) out of the right hand storage compartment and screw it on, drain the engine oil off and collect it.p. 463
l Once the old oil has run out remove the drain hose and screw the safety cap back on.p. 463
Fig. 9p. 464
+l Fill in new engine oilp. 464
+l Fill in new engine oilp. 464
(Fig. 9)p. 464
For quality and quantity of oil refer to the table of fuels, lubricants and filling capacities.p. 464
+l Screw the cap back on again.p. 464
l Screw the cap back on again.p. 464
Fig. 10p. 464
+l After a short test run check the oil level on the dipstickp. 464
+l After a short test run check the oil level on the dipstickp. 464
(Fig. 10)p. 464
+11.12 Changing the engine oil filterp. 464
11.12 Changing the engine oil filterp. 464
+Danger of scalding!p. 464
+Danger of scalding!p. 464
Danger of scalding!p. 464
There is a danger of scalding by hot oil when unscrewing the engine oil filter.p. 464
+Environmental hazard!p. 464
Environmental hazard!p. 464
Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.p. 464
Fig. 11p. 464
+l Loosen the engine oil filterp. 464
+l Loosen the engine oil filterp. 464
(Fig. 11)p. 464
l Wipe the sealing face clean.p. 464
l Apply a thin film of clean oil to the rubber seal of the new engine oil filter.p. 464
l Screw the new engine oil filter on hand-tight.p. 464
l Perform a short test run, inspect the engine for leaks and check the oil level, top up oil if necessary.p. 464
+11.13 Replacing the fuel pre-filter cartridge, bleeding the fuel systemp. 465
11.13 Replacing the fuel pre-filter cartridge, bleeding the fuel systemp. 465
+Fire hazard!p. 465
+Fire hazard!p. 465
Fire hazard!p. 465
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 465
+Health hazard!p. 465
Health hazard!p. 465
Do not inhale any fuel fumes.p. 465
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 465
Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 465
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 465
Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory.p. 465
+Catch running out fuel and dispose of environmentally.p. 465
Catch running out fuel and dispose of environmentally.p. 465
+Change the fuel pre-filter cartridgep. 465
Change the fuel pre-filter cartridgep. 465
Fig. 12p. 465
+l (1) Shut down the enginep. 465
+l (1) Shut down the enginep. 465
(Fig. 12)p. 465
l (2) Pull the cable off the water separator. Loosen the bleeding screw and drain off fuel from the bleeding screw.p. 465
l (3) Loosen and unscrew the fuel pre-filter cartridge using an appropriate filter wrench.p. 465
l (4) Unscrew the water separator from the filter cartridge.p. 465
l (5) Apply a thin coat of oil to the rubber seal of the water separator.p. 465
l (6) Turn the water separator on by hand, until the seal contacts, then tighten hand-tight.p. 465
l (7) Apply a thin coat of oil to the rubber seal of the filter element.p. 465
l (8) Turn the filter cartridge on by hand, until the seal contacts, then tighten hand-tight. Plug the cable of the water sensor back on.p. 465
+Bleed the fuel systemp. 465
Bleed the fuel systemp. 465
+Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 465
Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 465
Therefore bleed the fuel system after changing the fuel pre-filter or working on the fuel system.p. 465
Fig. 13p. 465
+l Slacken the bleeding screw (1)p. 465
+l Slacken the bleeding screw (1)p. 465
(Fig. 13)p. 465
l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles.p. 465
l Then tighten the bleeding screw while pumping.p. 465
l Slacken the bleeding screws on the fuel pre-filters for 2 to 3 turns.p. 465
l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screws without air bubbles.p. 465
l Then tighten the bleeding screws while pumping.p. 465
l Start the engine and run it 5 minutes with idle speed.p. 465
+11.14 Changing the fuel filter cartridgep. 466
11.14 Changing the fuel filter cartridgep. 466
+Fire hazard!p. 466
+Fire hazard!p. 466
Fire hazard!p. 466
No open fire, do not smoke, do not spill any fuel.p. 466
Do not inhale any fuel fumes.p. 466
+Catch running out fuel, do not let it seep into the ground.p. 466
Catch running out fuel, do not let it seep into the ground.p. 466
+l Open the left hand engine compartment doors.p. 466
l Open the left hand engine compartment doors.p. 466
Fig. 14p. 466
+l Loosen both fuel filtersp. 466
+l Loosen both fuel filtersp. 466
(Fig. 14)p. 466
+l Clean the sealing face on the filter carriers from any dirt.p. 466
l Clean the sealing face on the filter carriers from any dirt.p. 466
Fig. 15p. 466
+l Slightly oil the rubber seal on the new filter cartridgep. 466
+l Slightly oil the rubber seal on the new filter cartridgep. 466
(Fig. 15)p. 466
l Fill the filter cartridge with clean diesel fuel.p. 466
l Turn the new filter cartridge on by hand, until the seal contacts.p. 466
l Then tighten hand-tight.p. 466
l Check for leaks after a short test run.p. 466
+11.15 Checking condition of radiator, intercooler and hydraulic oil cooler, clean, cleaning the enginep. 466
11.15 Checking condition of radiator, intercooler and hydraulic oil cooler, clean, cleaning the enginep. 466
+Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins reduce the cooling effect. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or oil cooler and subsequently clean the …p. 466
+Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins reduce the cooling effect. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or oil cooler and subsequently clean the …p. 466
Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins reduce the cooling effect. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or oil cooler and subsequently clean the …p. 466
+Danger of injury!p. 466
Danger of injury!p. 466
Perform cleaning work only after the engine has cooled down and with the engine stopped!p. 466
Fig. 16p. 466
+l Remove the service covers on leftp. 466
+l Remove the service covers on leftp. 466
(Fig. 16)p. 466
Fig. 17p. 466
+l right hand sidep. 466
+l right hand sidep. 466
(Fig. 17)p. 466
+During cleaning take care not to damage the fins on hydraulic oil cooler, intercooler and radiator. Keep a safe distance with the spray nozzle.p. 466
During cleaning take care not to damage the fins on hydraulic oil cooler, intercooler and radiator. Keep a safe distance with the spray nozzle.p. 466
+Clean the coolers in the correct sequence.p. 467
Clean the coolers in the correct sequence.p. 467
+l Clean hydraulic oil cooler, intercooler and radiator from the air duct side first.p. 467
l Clean hydraulic oil cooler, intercooler and radiator from the air duct side first.p. 467
Fig. 18p. 467
+l Remove the service doorp. 467
+l Remove the service doorp. 467
(Fig. 18)p. 467
l Clean all coolers from the air intake side.p. 467
l Remove dried on dirt with a suitable brush.p. 467
l Blow the cooling air channels out with compressed air.p. 467
l In case of oily contamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time.p. 467
l If steam cleaning equipment is available, this should preferably be used.p. 467
+Cleaning the enginep. 467
Cleaning the enginep. 467
+After cleaning the coolers it is mandatory to clean the engine.p. 467
After cleaning the coolers it is mandatory to clean the engine.p. 467
Cover all parts of the electrical system, do not subject to the direct water jet.p. 467
Fig. 19p. 467
+l Blow the engine dry with compressed air. Flush lose dirt with a water jet out of the V-shaped space between the cylinders.p. 467
l Blow the engine dry with compressed air. Flush lose dirt with a water jet out of the V-shaped space between the cylinders.p. 467
+l The drain borep. 467
(Fig. 19)p. 467
Fig. 20p. 467
+l In case of oily contamination spray the engine with cold cleansing agent and spray it off with a water jet after s sufficient soaking time.p. 467
l In case of oily contamination spray the engine with cold cleansing agent and spray it off with a water jet after s sufficient soaking time.p. 467
+l Drain boresp. 467
(Fig. 20)p. 467
(Fig. 19)p. 467
l After wet cleaning run the engine warm to evaporate all water residues and to avoid corrosion.p. 467
l Reinstall the service covers.p. 467
+11.16 Changing the coolant, venting the cooling systemp. 468
11.16 Changing the coolant, venting the cooling systemp. 468
+Danger of scalding!p. 468
+Danger of scalding!p. 468
Danger of scalding!p. 468
Change the coolant only when the engine is cold.p. 468
+Do not start the engine after draining off the coolant.p. 468
Do not start the engine after draining off the coolant.p. 468
When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.p. 468
+Catch coolant and dispose of environmentally.p. 468
Catch coolant and dispose of environmentally.p. 468
Fig. 21p. 468
+l Open the safety flapp. 468
+l Open the safety flapp. 468
(Fig. 21)p. 468
Fig. 22p. 468
+l Unscrew the capp. 468
+l Unscrew the capp. 468
(Fig. 22)p. 468
Fig. 23p. 468
+l Connect the drain hose to the drain cockp. 468
+l Connect the drain hose to the drain cockp. 468
(Fig. 23)p. 468
l Guide the drain hose into a vessel of appropriate size.p. 468
l Open the drain cock and let the coolant run out.p. 468
l Once all coolant has run out close the drain cock, remove the drain hose and screw the plug back on.p. 468
Fig. 24p. 468
+l Fill coolant in through the opening in the compensation tankp. 468
+l Fill coolant in through the opening in the compensation tankp. 468
(Fig. 24)p. 468
For coolant quantity refer to the table of fuels, lubricants and filling capacities.p. 468
+l Close the compensation tank. For bleeding start the engine and run it warm.p. 468
l Close the compensation tank. For bleeding start the engine and run it warm.p. 468
l Check the coolant level, top up if necessary.p. 468
+11.17 Checking the anti-freeze concentrationp. 469
11.17 Checking the anti-freeze concentrationp. 469
+In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant.p. 469
+In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant.p. 469
In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant.p. 469
+Danger of scalding!p. 469
Danger of scalding!p. 469
Check the anti-freeze concentration only when the engine is cold.p. 469
+l Perform the inspection with conventional test equipment.p. 469
l Perform the inspection with conventional test equipment.p. 469
l The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.p. 469
+Health hazard!p. 469
Health hazard!p. 469
The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.p. 469
+Catch all anti-freeze agent and dispose of environmentally.p. 469
Catch all anti-freeze agent and dispose of environmentally.p. 469
+11.19 Servicing the fan V-beltp. 469
11.18 Checking the thermostat in disassembled statep. 469
+The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 83°C the thermostat is closed. Once…p. 469
The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 83°C the thermostat is closed. Once…p. 469
Fig. 1p. 469
+l Measure and write down the measurement "a" on the thermostatp. 469
+l Measure and write down the measurement "a" on the thermostatp. 469
(Fig. 1)p. 469
+Take note of different opening temperaturesp. 469
+Take note of different opening temperaturesp. 469
(Fig. 2)p. 469
Fig. 2p. 469
+"a" = Start of stroke (A-Bank, colour mark black ventilation groove at top) at approx. 79°Cp. 469
"a" = Start of stroke (A-Bank, colour mark black ventilation groove at top) at approx. 79°Cp. 469
"a" = Start of stroke (B-Bank, ventilation groove at top) at approx. 87°Cp. 469
Fig. 3p. 470
+l Warm up the thermostat in a water bathp. 470
+l Warm up the thermostat in a water bathp. 470
(Fig. 3)p. 470
+In order to determine the exact start of opening the temperature should be measured as close to the thermostat as possible, but without touching it.p. 470
In order to determine the exact start of opening the temperature should be measured as close to the thermostat as possible, but without touching it.p. 470
The water must thereby be stirred continuously, to ensure even temperature distribution.p. 470
The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.p. 470
Fig. 4p. 470
+l Measure and write down the measurement "b" on the thermostat .p. 470
+l Measure and write down the measurement "b" on the thermostat .p. 470
(Fig. 4)p. 470
l Calculate the stroke.p. 470
Stroke = b – ap. 470
+Stroke length min. 8 mm.p. 470
Stroke length min. 8 mm.p. 470
+11.19 Servicing the fan V-beltp. 470
11.19 Servicing the fan V-beltp. 470
+Danger of injury!p. 470
+Danger of injury!p. 470
Danger of injury!p. 470
Work on the fan V-belt must only be performed with the engine shut down.p. 470
+Checking the fan V-beltp. 470
Checking the fan V-beltp. 470
+A belt tension meter is required to check the V- belt tension.p. 470
A belt tension meter is required to check the V- belt tension.p. 470
Fig. 5p. 470
+l Inspect the entire circumference of the V-beltp. 470
+l Inspect the entire circumference of the V-beltp. 470
(Fig. 5)p. 470
l Replace damaged or cracked V-belts.p. 470
Fig. 6p. 470
+l Press the indicator arm (a) of the testerp. 470
+l Press the indicator arm (a) of the testerp. 470
(Fig. 6)p. 470
+l Place the meter in the middle between the V-belt pulleys on the back of the fan V-belt.p. 470
l Place the meter in the middle between the V-belt pulleys on the back of the fan V-belt.p. 470
Fig. 7p. 471
+l Actuate the push button (b)p. 471
+l Actuate the push button (b)p. 471
(Fig. 7)p. 471
+The indicator arm remains in the measured position.p. 471
The indicator arm remains in the measured position.p. 471
+l Take the measuring unit carefully off, without moving the indicating arm.p. 471
l Take the measuring unit carefully off, without moving the indicating arm.p. 471
Fig. 8p. 471
+l Read the V-belt tension where the upper edge of the indicating arm intersects with the measuring scalep. 471
+l Read the V-belt tension where the upper edge of the indicating arm intersects with the measuring scalep. 471
Air filter clogged / exhaust turbocharger defectivep. 476
+Check / replace if necessaryp. 476
Check / replace if necessaryp. 476
+Air filter service switch / indicator defectivep. 476
Air filter service switch / indicator defectivep. 476
+Check / replace if necessaryp. 476
Check / replace if necessaryp. 476
+Charge air pipe leakingp. 476
Charge air pipe leakingp. 476
+Check the charge air pipep. 476
Check the charge air pipep. 476
+Injection valve defectivep. 476
Injection valve defectivep. 476
+Check the injection valve / replace if necessaryp. 476
Check the injection valve / replace if necessaryp. 476
11.24 Special tools, Deutz engine (TCD 2015)p. 477
+12 Working hydraulicsp. 497
+12 Working hydraulicsp. 497
Hydraulic systemp. 498
+Hydraulic systemp. 498
Hydraulic systemp. 498
Travel system as well as steering and dozer blade on these machines are hydraulically operated.p. 498
This guarantees an almost loss-free transfer of engine output power to compactor wheels, steering cylinders and dozer blade/bucket control.p. 498
The pumps for the corresponding circuits are driven by the engine via a transfer box and convert the mechanical energy provided by the engine into hydraulic energy.p. 498
Inside the motors or the cylinders for steering or dozer blade actuation this hydraulic energy is then converted back to mechanical energy.p. 498
Since the medium oil is used for this transfer of power, any losses in power are only of minor significance.p. 498
All hydraulic circuits are protected against contamination by charge oil filters and a hydraulic oil return flow filter.p. 498
Safety elements in pumps and hydraulic control units protect the hydraulic system and the drive engine against overloads and damage resulting from such excessive loads.p. 498
To ensure quick heating of the hydraulic oil up to operating temperature the return flow from the hydraulic system flows directly back to the hydraulic oil tank, until the operating temperature is reached. When the oil temperature comes close to oper…p. 498
This ensures that the operating temperature is quickly reached, particularly during the cold season, and that the hydraulic system can be operated without any risks.p. 498
12.2 Working hydraulicsp. 498
+The working hydraulics on the sanitary landfill compactors BC 672-772 RB/RS (EPA II) cover the hydraulic systems for steering and dozer blade/bucket controls.p. 498
The working hydraulics on the sanitary landfill compactors BC 672-772 RB/RS (EPA II) cover the hydraulic systems for steering and dozer blade/bucket controls.p. 498
The working hydraulics mainly consist of the axial piston pump, the control valve block for the function dozer blade/bucket up / down, steering and on RS- machines also tipping of bucket, the 2 steering and the dozer blade cylinder (RS: additional ti…p. 498
A swash plate type axial piston pump supplies the system with pressure oil.p. 498
The movement of the dozer blade or bucket is controlled via a joystick next to the driver’s seat. The control is extremely light moving and sensitive.p. 498
When shifting the control lever forward and pressing the top push button at the same time the dozer blade/ bucket can be held in floating position (piston and piston rod sides of the lift cylinders are open to the tank). In this operating mode the do…p. 498
The electro-hydraulic operation of the working hydraulics is similar to the system used in machines of series BC 671/771-RS and identical with the machines of range BC 972. The joystick units are potentiometers, the signals of which are converted to …p. 498
Steering and working pumpp. 499
+Steering and working pumpp. 499
Steering and working pumpp. 499
The tandem pump for the working hydraulics consists of two identical swash-plate operated axial piston pumps with variable displacement. However, the pumps deliver oil only to one direction, i.e. the swash plate moves out of neutral position only to …p. 499
Fig. 18 Hydraulic pump for working hydraulicsp. 499
+1 Working pumpp. 499
1 Working pumpp. 499
2 Flow control valvep. 499
3 Pressure control valvep. 499
4 Resetting pistonp. 499
5 Control pistonp. 499
(B) to dozer blade control and steeringp. 499
(L) to hydraulic oil tankp. 499
(S) from hydraulic oil tankp. 499
(X) LS, load signal from steering and dozer bladep. 499
+When the engine is not running the swash plate is in max. displacement position, however, when starting the engine the swash plate will move immediately back towards zero, until the stand-by pressure adjusted on valve 2p. 499
(Fig. 18)p. 499
As long as the steering system or the bucket hydraulics do not require any oil, the pumps will maintain the so-called ”Stand-by pressure” (30 ±1 bar). Due to the flow control in the working hydraulics the engine has to supply power only when it …p. 499
+Working principlep. 499
Working principlep. 499
When looking at the working hydraulics, for better understanding one must always consider two different operating conditions:p. 499
+l Engine not runningp. 499
l Engine not runningp. 499
l Engine runningp. 499
When the engine is not running the swash plate in the steering and working pump is at maximum displacement position. The spring of the smaller control piston in the pump holds the swash plate in this position.p. 499
When starting the engine pressure builds up between the outlet on the steering and working pump and the inlet ”P” (front pump) and "P2" (rear pump) on the valve block. These two ports are connected inside the control block. This pressure increase…p. 500
The now increasing pressure moves the flow control valve spools on the pumps and opens a connection between the pump flow and the bigger control piston (reversing piston) for the pump swash plate.p. 500
Since the effective area of this piston is much bigger than the area of the counter piston, the increasing pressure moves the swash plates towards zero (despite the spring force supporting the counter piston).p. 500
The setting of the flow control valves ensures a so- called ”stand-by pressure” in the system.p. 500
The pressure control valve on the working pump limits the high pressure in the working hydraulics to 230 bar. If the system pressure increases up to the adjusted value because of steering or dozer blade operation, this pressure will move the spool in…p. 500
If the pressure drops below the adjusted value, the spring is able to close the pressure control valve and the pumps return to the previous displacement.p. 500
Control valve block, steering and dozer bladep. 501
+Control valve blockp. 501
Control valve blockp. 501
Fig. 19 Control valve blockp. 501
(A) LS signal to the working pumpsp. 501
(P) from rear working pumpp. 501
(P2) from front working pumpp. 501
Pst1, Pst2) from rear right hand charge pumpp. 501
The function of the control valve block is based on the principle of load pressure independent flow distribution. This concept enables quick and precise working with overlapping movements of several consumers under different load pressures.p. 501
The operator controls the speed for steering and dozer blade proportional to the deflection of the joystick or the dozer blade control lever, irrespective of the load pressure. The control valve spools in the individual sections of the control block …p. 501
The control valve block is located in the hydraulic connection from steering and working pump to the consumers (steering and dozer blade cylinders). Both work functions are integrated in the control block housing.p. 501
Pump, tank and LS-lines are internally linked and combined as central connections on the control block. In the control block all consumers are arranged in parallel mode.p. 501
The geometry of the fine control grooves in the control pistons is specially adapted to the characteristics of the corresponding consumer. The control pistons for the individual axes can thus be interchanged. The pistons must not be turned by 180°.p. 501
Besides the piston axes to control the consumer movements, the control block also contains components serving necessary system functions:p. 502
+l Stabilizing the systemp. 502
l Stabilizing the systemp. 502
l Securing the primary and secondary pressurep. 502
l Limiting the permissible LS-pressurep. 502
l Avoiding cavitation caused by external loads or decelerationp. 502
+The optimal adjustment of pump and control block ensures quick response with high stability.p. 502
Load-Sensingp. 502
If the working hydraulics (steering and dozer blade control) does not demand any power, the load signal (load sensing line ”LS”) for all consumers is dumped into the tank, in this case the load signal is 0 bar.p. 502
If one of the consumers requires hydraulic oil, the actuation of the steering or bucket hydraulics will generate a load signal.p. 502
Example steeringp. 502
In neutral position the steering valve is ”closed”, i.e. there is no connection between the valve inlet ”P” and one of the outlets ”A2” or ”B2” to the steering cylinders. The load signal line is directly connected with the tank return…p. 502
When operating the steering joystick the valve inlet port ”P” is connected with one of the outlets ”A2” or ”B2” and with the load sensing line ”LS”.p. 502
The pressure, which is now increasing because of the load resistance, is applied to the back of the flow control valve on the steering and working pump through the ”LS”-line. The spool in the flow control valve moves and interrupts the oil flow t…p. 502
The spring loaded counter piston actuates the swash plate and the pump delivers oil to the steering system.p. 502
When stopping the steering joystick movement after this steering operation, the 8/3-way valve in the steering valve block will automatically return to neutral position. The connection between valve inlet port ”P” and the valve outlets ”A2” or…p. 502
Steering controlp. 503
The steering movements are controlled by means of the "steering joystick" in the left hand arm rest of the operator's seat. The steering speed is proportional to the displacement of the joystick.p. 503
Due to the electronic control via the ESX-control the solenoid valves of the steering valve are triggered in pulses. With each pulse a minimum oil quantity is guided to the control piston of the steering spool (increase of steering angle) or relieved…p. 503
Dozer blade controlp. 503
The dozer blade movements (up, down and float position) are controlled by means of a ”joystick” on the right hand side of the driver’s seat.p. 503
With this joystick the ESX-control is electrically proportionally triggered via a potentiometer.p. 503
The lowering speed is proportional to the displacement of the joystick.p. 503
When operating the joystick forward and pressing the push button at the same time, the 2/2-way valve for float position will switch to ”float position”, i.e. both piston and piston rod sides of the lifting cylinders are connected with the tank. T…p. 503
When the joystick is pulled back, the valve is switched to position ”up”. Oil flows from the working pump through the valve block to the piston rod sides of the lifting cylinders and the dozer blade moves up.p. 503
The lifting speed is proportional to the displacement of the joystick.p. 503
Description of individual componentsp. 504
+LS drain valvep. 504
LS drain valvep. 504
The LS drain valve relieves the LS line to the tank, when all work functions are in neutral position (no function operated). When operating steering / dozer blade, the flow control valve will regulate the flow volume from the LS line to the tank, irr…p. 504
Fig. 20 LS drain valvep. 504
+1 Springp. 504
1 Springp. 504
2 Control pistonp. 504
3 Control orificep. 504
The 2-way flow limiting valve in cartridge design consists of housing, control piston with control orifice and spring. The control piston maintains the pressure drop across the orifice constant, irrespective of the LS pressure and the outflowing LS f…p. 504
LS shuttle valvep. 504
+The LS signal reported by the pressure balance with the highest pressure reaches the pump control through orifice 1p. 504
(Fig. 21)p. 504
Fig. 21 LS shuttle valvep. 504
+1 Orificep. 504
1 Orificep. 504
2 Orificep. 504
3 LS signal to pump controlp. 504
4 LS signal in control blockp. 504
5 effective to the valve blockp. 504
6 effective to the pumpp. 504
The cooperation of various orifices in the LS shuttle valve with the capacity of the LS hose between control block and pump (defined oil volume / line cross-section) leads to the damping of excessive pressure pulses in the system. Short and strong pr…p. 504
LS-pressure limitationp. 505
The LS pressure limitation limits the maximum LS pressure in the system. Once the LS pressure reaches the value set by the spring, the valve seat will open a connection to the tank and maintain the max. LS pressure at a constant level.p. 505
The cartridge type valve is screwed into the control block and factory set to a specific value.p. 505
Fig. 22 LS-pressure relief valvep. 505
+1 Counter nutp. 505
1 Counter nutp. 505
2 Basic housingp. 505
3 Valve seatp. 505
4 High pressure settingp. 505
5 Springp. 505
6 Tankp. 505
7 LS system pressurep. 505
Primary pressure relief valvep. 505
Fig. 23 Primary pressure relief valvep. 505
+1 Consumer portp. 505
1 Consumer portp. 505
2 Orifice D1p. 505
3 Spring 1p. 505
4 Main taperp. 505
5 Area A2p. 505
6 Orifice D2p. 505
7 Counter nutp. 505
8 Protective capp. 505
9 Adjustment spindlep. 505
10 Adjustment springp. 505
11 Pilot control taperp. 505
12 Spring 2p. 505
13 Tank portp. 505
14 Area A3p. 505
15 Volume Cp. 505
16 Area A1p. 505
The pilot controlled primary pressure relief valve is screwed into the side of the control block and, in its function of a safety valve, it limits the maximum pump pressure to the adjusted value (approx. 260 bar). Pressure peaks may be experienced in…p. 505
As long as the system pressure p is lower than the value adjusted with the adjustment spindle, the valve will remain closed. If pressure p exceeds the adjusted value, the pilot control taper will open and allow oil to flow from chamber C through orif…p. 505
Secondary / consumer valvesp. 506
+Shock valvep. 506
Shock valvep. 506
The cartridge type pilot controlled pressure/feed valves in the individual consumer ports A and B are screwed into the individual sections, above the control pistons. The valve protects the consumer circuit against overloads or damage caused e.g. by …p. 506
As a safety valve it limits the maximum pressure in the consumer and in the connecting line to the way valve to the adjusted value. The pressure has been adjusted and the blocked sealed by the manufacturer before delivery.p. 506
Fig. 24 Shock valvep. 506
+1 Consumer portp. 506
1 Consumer portp. 506
2 Orifice D1p. 506
3 Springp. 506
4 Main taperp. 506
5 Area A2p. 506
6 Orifice D2p. 506
7 Counter nutp. 506
8 Protective capp. 506
9 Adjustment spindlep. 506
10 Adjustment springp. 506
11 Pilot control taperp. 506
12 Spring 2p. 506
13 Tank portp. 506
14 Area A3p. 506
15 Volume Cp. 506
16 Area A1p. 506
Functionp. 506
The corresponding load pressure of the consumer port is applied to chamber C through orifice D1. Spring 1 in chamber C only ensures a stable installation position. As long as the consumer pressure p is lower than the value adjusted with the adjustmen…p. 506
Pre-tensioning valvep. 507
The valve block has two internal tank channels. The first one connects the shock valve for steering to the right and the outlet of a floating position valve directly with the tank. The second tank line is pre-tensioned by a 18 bar valve. Here all con…p. 507
Float position valvesp. 508
When switching the solenoids Y102, the float position valves connect both sides of the hydraulic cylinder with the tank return line.p. 508
Function of the control valve blockp. 508
(General description, the components may vary in detail from the BOMAG version. For better understanding the pressure balances, in particular, are shown as 3/3-way proportional valves, instead of 2 individual valves, as shown in the original hydrauli…p. 508
With the control piston in neutral position (no control current applied to the proportional solenoids connections a or b) the connection between pump and p’- channel (after measuring orifice) is blocked by the spool. Load retaining valves and press…p. 509
The pressure balances for the individual functions (steering / dozer blade) are arranged downstream of the control piston measuring orifice. They consists of a control piston (13) and a pressure spring (15), which ensures a stable initial position.p. 509
+Overlapping with a consumer with higher load pressurep. 510
Individual operation or consumer with highest loadp. 510
Fig. 26p. 510
The force of the pilot pressure, which is released by the control solenoids, shifts the control piston (6) proportionally against spring pressure. In this illustration the solenoid on connection "a" shifts the piston to the right against the spring i…p. 510
+The consumer pressure pp. 510
cp. 510
cp. 510
+In case of individual movements or if the load pressure of the consumer pp. 510
cp. 510
Feeding the LS-signal from the p’-channel, before the load retaining valves, ensures blocking of the consumer port, until the required working pressure is reached. This prevents short-term dropping of the consumer by removing oil volume from the co…p. 511
+The pressure balance is completely open and the p’- channel is connected with the consumer port pp. 511
cp. 511
+Overlapping with a consumer with higher load pressurep. 511
Overlapping of movementsp. 511
System saturatedp. 511
In saturated operation of the system the quantity requested through the measuring orifices is smaller than or identical with the pump flow.p. 511
+S Q consumerp. 511
Sp. 511
pumpp. 511
+Dpp. 511
Dp. 511
measuring orificep. 511
Dp. 511
LS controlp. 511
The difference between both values results from the losses in the supply line between pump and measuring orifices.p. 511
+Overlapping with a consumer with higher load pressurep. 512
Overlapping with a consumer with higher load pressurep. 512
Fig. 27p. 512
+A typical example for this is lifting the dozer blade while steering. The higher load pressure in the dozer blade circuit reduces the cross-section of the orifice in the pressure balance for the steering section. In this regulating position the contr…p. 512
cp. 512
Dp. 512
Subsaturation / priority functionp. 513
Fig. 28 Function of pressure balance under different load pressuresp. 513
(A) Load pressure lowp. 513
(B) Load pressure highp. 513
+1 Spring chamberp. 513
1 Spring chamberp. 513
2 Control orificep. 513
In case of subsaturation of the system the oil quantity demanded by the sum of the open measuring orifice cross-sections exceeds the maximum flow rate of the pump. The flow control valve no longer is able to generate the required system pressure by o…p. 513
In case of subsaturation the pump flow rate is solely determined by the power controller.p. 513
+S Qp. 513
Sp. 513
Consumerp. 513
Pumpp. 513
+In case of subsaturation of the system the pressure balances of both consumers are wide open and the LS pressure corresponds with the pressure p' behind the measuring orifice. However, the system/pump pressure drops with every degree of subsaturation…p. 513
Dp. 513
measuring orificep. 513
The pressure springs in the pressure balances for steering and dozer blade are of different designs (steering 1-2.5 bar, dozer blade 58 bar). This has the effect, that the steering pressure balance will stay open in case of subsaturation, whereas the…p. 513
+If the speed of one consumer is reduced during the overlapping of movements in subsaturation, i.e. the measuring orifice is closed, the degree of subsaturation will drop. Thep. 513
Dp. 513
measuring orificep. 513
+13 Tests and adjustments in working hydraulicsp. 515
+13 Tests and adjustments in working hydraulicsp. 515
Measuring and adjustment points on control valve blockp. 516
+Measuring and adjustment pointsp. 516
Measuring and adjustment pointsp. 516
Fig. 29 Control valve blockp. 516
+Pos.p. 517
Pos.p. 517
+Designationp. 517
Designationp. 517
+Pos. ii electric wiring diagramp. 517
Pos. ii electric wiring diagramp. 517
+Pos. in hydraulic diagramp. 517
Pos. in hydraulic diagramp. 517
+Measuring valuep. 517
Measuring valuep. 517
+1p. 517
1p. 517
+Proportional solenoid, steering rightp. 517
Proportional solenoid, steering rightp. 517
+Y92p. 517
Y92p. 517
+0 – 1000 mAp. 517
0 – 1000 mAp. 517
+1ap. 517
1ap. 517
+Proportional solenoid, steering leftp. 517
Proportional solenoid, steering leftp. 517
+Y93p. 517
Y93p. 517
+0 – 1000 mAp. 517
0 – 1000 mAp. 517
+2p. 517
2p. 517
+Switching solenoid, float positionp. 517
Switching solenoid, float positionp. 517
+Y102p. 517
Y102p. 517
+0 / 24Vp. 517
0 / 24Vp. 517
+2ap. 517
2ap. 517
+2. Switching solenoid, float positionp. 517
2. Switching solenoid, float positionp. 517
+Y102p. 517
Y102p. 517
+0 / 24Vp. 517
0 / 24Vp. 517
+3p. 517
3p. 517
+Proportional solenoid, blade downp. 517
Proportional solenoid, blade downp. 517
+Y109p. 517
Y109p. 517
+0 – 1000 mAp. 517
0 – 1000 mAp. 517
+3ap. 517
3ap. 517
+Proportional solenoid, blade up (on opposite side)p. 517
Proportional solenoid, blade up (on opposite side)p. 517
+Y108p. 517
Y108p. 517
+0 – 1000 mAp. 517
0 – 1000 mAp. 517
+4p. 517
4p. 517
+Pressure test port, pilot pressure steering leftp. 517
Pressure test port, pilot pressure steering leftp. 517
+Map. 517
Map. 517
+20 -30 barp. 517
20 -30 barp. 517
+4ap. 517
4ap. 517
+Proportional solenoid, pilot pressure steering right (on opposite side)p. 517
Proportional solenoid, pilot pressure steering right (on opposite side)p. 517
+Mbp. 517
Mbp. 517
+20 -30 barp. 517
20 -30 barp. 517
+5p. 517
5p. 517
+Pressure test port, pilot pressure blade upp. 517
Pressure test port, pilot pressure blade upp. 517
+Map. 517
Map. 517
+10 -30 barp. 517
10 -30 barp. 517
+5ap. 517
5ap. 517
+Proportional solenoid, pilot pressure blade down (on opposite side)p. 517
Proportional solenoid, pilot pressure blade down (on opposite side)p. 517
+Mbp. 517
Mbp. 517
+10 -30 barp. 517
10 -30 barp. 517
+6p. 517
6p. 517
+Pressure test port, tank pre-tensioning valvep. 517
Pressure test port, tank pre-tensioning valvep. 517
+Mtp. 517
Mtp. 517
+10 -15 barp. 517
10 -15 barp. 517
+7p. 517
7p. 517
+Pressure test port, working pressurep. 517
Pressure test port, working pressurep. 517
+Mpp. 517
Mpp. 517
+0 -230 +10 barp. 517
0 -230 +10 barp. 517
+8p. 517
8p. 517
+LS-pressure limitationp. 517
LS-pressure limitationp. 517
+0-210 + 10 barp. 517
0-210 + 10 barp. 517
+9p. 517
9p. 517
+Tank pre-loading valvep. 517
Tank pre-loading valvep. 517
+15 bar (dozer blade in top position, drop with floating position)p. 517
15 bar (dozer blade in top position, drop with floating position)p. 517
+10p. 517
10p. 517
+Pressure test port, steering leftp. 517
Pressure test port, steering leftp. 517
+M18p. 517
M18p. 517
+0 -230 +10 barp. 517
0 -230 +10 barp. 517
+11p. 517
11p. 517
+Pressure test port, steering rightp. 517
Pressure test port, steering rightp. 517
+M19p. 517
M19p. 517
+0 -230 +10 barp. 517
0 -230 +10 barp. 517
+12p. 517
12p. 517
+Pressure test port, blade downp. 517
Pressure test port, blade downp. 517
+M31p. 517
M31p. 517
+0 -230 +10 barp. 517
0 -230 +10 barp. 517
+13p. 517
13p. 517
+Pressure test port, blade upp. 517
Pressure test port, blade upp. 517
+M32p. 517
M32p. 517
+0 -230 +10 barp. 517
0 -230 +10 barp. 517
+14p. 517
14p. 517
+mechanical endstopp. 517
mechanical endstopp. 517
+15p. 517
15p. 517
+Shock valvep. 517
Shock valvep. 517
+260 barp. 517
260 barp. 517
Tests and adjustments on the steering/working pumpp. 518
+Measuring and adjustment pointsp. 518
Measuring and adjustment pointsp. 518
Fig. 30 Tandem working pump with pressure/flow control valvep. 518
+Pos.p. 518
Pos.p. 518
+Designationp. 518
Designationp. 518
+Pos. in hydraulic diagramp. 518
Pos. in hydraulic diagramp. 518
+Measuring valuep. 518
Measuring valuep. 518
+1p. 518
1p. 518
+Stand-by pressure adjustment screwp. 518
Stand-by pressure adjustment screwp. 518
+30 ± 1 bar at Pos. 3p. 518
30 ± 1 bar at Pos. 3p. 518
+2p. 518
2p. 518
+High pressure adjustment screwp. 518
High pressure adjustment screwp. 518
+230 +10 bar at Pos. 3p. 518
230 +10 bar at Pos. 3p. 518
+3p. 518
3p. 518
+High pressure test portp. 518
High pressure test portp. 518
+0 – 230 +10 barp. 518
0 – 230 +10 barp. 518
+4p. 518
4p. 518
+LS-pressure test portp. 518
LS-pressure test portp. 518
+Xp. 518
Xp. 518
+0 – 210 +10 barp. 518
0 – 210 +10 barp. 518
Tests and adjustmentsp. 519
+Checking/adjusting stand-by pressurep. 519
Checking/adjusting stand-by pressurep. 519
Fig. 31p. 519
+l Connect a 60-bar pressure gauge to high pressure test portp. 519
+l Connect a 60-bar pressure gauge to high pressure test portp. 519
(Fig. 31)p. 519
+l Connect a 60-bar pressure gauge to LS pressure test port 4p. 519
(Fig. 29)p. 519
+Do not operate the steering and the dozer blade, since this would destroy the pressure gauge.p. 519
Do not operate the steering and the dozer blade, since this would destroy the pressure gauge.p. 519
+l Start the engine and run it at low idle speed.p. 519
l Start the engine and run it at low idle speed.p. 519
l Read high and LS pressure values in non-operated state.p. 519
Nominal value:p. 519
30 ± 2 bar high pressure (stand-by pressure)p. 519
approx. 0 bar LS-pressurep. 519
+Adjustment procedurep. 519
Adjustment procedurep. 519
+l If necessary correct the standby pressure on the flow control valve (upper setscrew 1p. 519
+l If necessary correct the standby pressure on the flow control valve (upper setscrew 1p. 519
(Fig. 29)p. 519
+Adjustment procedurep. 519
Checking/adjusting high pressurep. 519
Fig. 32p. 519
+l Connect a 600-bar pressure gauge to high pressure test portp. 519
+l Connect a 600-bar pressure gauge to high pressure test portp. 519
(Fig. 32)p. 519
+l Connect a 600-bar pressure gauge to LS pressure test port 4p. 519
(Fig. 29)p. 519
+Danger of squashing!p. 519
Danger of squashing!p. 519
Make sure nobody is near the dozer blade.p. 519
+l Start the engine and run it with high idle speed.p. 519
l Start the engine and run it with high idle speed.p. 519
l Raise the dozer blade and hold the control lever against the end stop.p. 519
Nominal value:p. 519
230 +10 bar on the high pressure test portp. 519
LS-pressure 210 + 10 bar.p. 519
+Adjustment procedurep. 519
Adjustment procedurep. 519
+l If necessary correct high pressure on the lower setscrew 2p. 519
+l If necessary correct high pressure on the lower setscrew 2p. 519
(Fig. 29)p. 519
Checking/adjusting the LS-pressure for the working pumpsp. 520
Fig. 33p. 520
+l Connect a 600-bar pressure gauge to high pressure test portp. 520
+l Connect a 600-bar pressure gauge to high pressure test portp. 520
(Fig. 33)p. 520
+l Connect a 600-bar pressure gauge to LS pressure test port (4)p. 520
(Fig. 29)p. 520
l Operate the steering/dozer blade slowly from neutral to end stop, read both pressure gauges.p. 520
Nominal value:p. 520
As long as the working cylinders are moving the LS- value should always be approx. 30 bar lower than the actual high pressure. When holding the control levers against the end stop the LS-pressure should increase to 210 + 10 bar.p. 520
+l If there is no or a too low LS-signal, you should first check the electric triggering of the control valves. If the electrical system is Ok, you should check the LS-system (valve block, hoses).p. 520
l If there is no or a too low LS-signal, you should first check the electric triggering of the control valves. If the electrical system is Ok, you should check the LS-system (valve block, hoses).p. 520
l If both pressures are too low at the same level, the fault is caused by the pump. The pump high pressure can be corrected on the lower adjustment screw. Should this not be possible, either the pressure/flow control valve or the pump itself is defec…p. 520
+14 Travel hydraulicsp. 521
+14 Travel hydraulicsp. 521
Hydraulic systemp. 522
+Hydraulic systemp. 522
Hydraulic systemp. 522
Travel system as well as steering and dozer blade on these machines are hydraulically operated.p. 522
This guarantees an almost loss-free transfer of engine output power to compactor wheels, steering cylinders and dozer blade/bucket control.p. 522
The pumps for the corresponding circuits are driven by the engine via a transfer box and convert the mechanical energy provided by the engine into hydraulic energy.p. 522
Inside the motors or the cylinders for steering or dozer blade actuation this hydraulic energy is then converted back to mechanical energy.p. 522
Since the medium oil is used for this transfer of power, any losses in power are only of minor significance.p. 522
All hydraulic circuits are protected against contamination by charge oil filters and a hydraulic oil return flow filter.p. 522
Safety elements in pumps and hydraulic control units protect the hydraulic system and the drive engine against overloads and damage resulting from such excessive loads.p. 522
To ensure quick heating of the hydraulic oil up to operating temperature the return flow from the hydraulic system flows directly back to the hydraulic oil tank, until the operating temperature is reached. When the oil temperature comes close to oper…p. 522
This ensures that the operating temperature is quickly reached, particularly during the cold season, and that the hydraulic system can be operated without any risks.p. 522
Travel system (general description)p. 523
+Travel drivep. 523
Travel drivep. 523
Fig. 34 Schematic, front right hand travel circuitp. 523
The travel system of the sanitary landfill compactor works with four closed hydraulic circuits. Each of these circuits consists of a travel pump (variable displacement pump) and a travel motor (variable displacement motor). Always two travel pumps ar…p. 523
Both tandem units are driven by the diesel engine via a transfer box. This transfer box is flanged to the flywheel side of the engine.p. 523
All four pumps are simultaneously controlled by pilot pressure. The pilot oil needed to control the travel pumps is supplied by four charge pumps. The pump flow from the charge pumps is also used to feed the closed travel circuits and to compensate l…p. 523
The end of each tandem pump unit carries a charge pump. The charge pumps are gear pumps which are driven by through-shafts with the output speed of the transfer box.p. 523
The charge pumps draw the hydraulic oil out of the hydraulic oil tank and deliver it through a 12 µ fine filters to serve the individual functions (control of travel pumps, boost check valves). The charge oil flow from the rear right charge pump (wh…p. 523
The travel pumps are equipped with all control and safety elements needed for operation in a closed hydraulic circuit, such as servo control unit, combined high pressure relief and boost check valves, charge pressure relief valve and pressure overrid…p. 523
All travel motors can be operated with two different displacements and therefore with two different travel speed ranges. The highest speed range is used as transport speed, whereas the slow speed range is used as working speed. Since the travel motor…p. 523
All planetary gears are equipped with integrated multi- disc brakes.p. 524
These multi-disc brakes are opened by charge pressure and will close automatically when the charge pressure supply is interrupted. This can be accomplished by shutting the engine down, by a fault in the hydraulic system (travel system), by the brake …p. 524
Travel pumpp. 525
+Travel pumpp. 525
Travel pumpp. 525
+The travel pumps are swash plate controlled HYDROMATIK axial piston pumps with variable displacement. Always one pump of series A4VG 71 DA (driven pump) and one pump of series A4VG 71 DG (dragged pump) are connected. The end of each tandem pump unit …p. 525
The travel pumps are swash plate controlled HYDROMATIK axial piston pumps with variable displacement. Always one pump of series A4VG 71 DA (driven pump) and one pump of series A4VG 71 DG (dragged pump) are connected. The end of each tandem pump unit …p. 525
Fig. 1 Hydraulic diagram of travel pumpp. 525
+1 Travel pumpp. 525
1 Travel pumpp. 525
2 4/3-way valve (travel direction)p. 525
3 Control pistonp. 525
4 High pressure relief valves with boost check valvesp. 525
5 Charge pressure relief valvep. 525
6 DA-control valvep. 525
7 Pressure override valvep. 525
8 Shuttle valvep. 525
(A) to / from travel motorp. 525
(B) to / from travel motorp. 525
(PS) to PS pump 2p. 525
(X1) to X1 on pump 2p. 525
(X2) to X2 on pump 2p. 525
The flow rate of the travel pump is determined by the displacement and the actual drive speed of the pump. It is proportional to drive speed and displacement. The possibility of the infinite swash plate adjustment enables an infinite alteration of th…p. 525
The pump is equipped with all control and safety elements needed for operation in a closed hydraulic circuit, such asp. 525
+l High pressure relief valvesp. 525
l High pressure relief valvesp. 525
l Boost check valvesp. 525
l Charge pressure relief valvep. 525
l Pressure override valve andp. 525
l Servo controlp. 525
.p. 525
Fig. 2 Cross-section of travel pumpp. 526
The spherical valve plate centres the cylinder block, which is tightly connected with the drive shaft, and avoids the appearance of unwanted transverse forces.p. 526
Belleville springs hold the complete drive section (valve plate, cylinder block, swash plate) together and eliminate appearing wear in axial direction immediately. Due to this design principle the pump has a very high rate of efficiency over the enti…p. 526
+Charge pressure relief valvep. 527
Pump controlp. 527
Fig. 3 Travel pump controlp. 527
+1 Control valve cartridgep. 527
1 Control valve cartridgep. 527
2 Charge pressure relief valvep. 527
3 Pressure override valvep. 527
4 Controlp. 527
5 4/3-way valve (travel direction)p. 527
6 Outlet orificep. 527
7 Inlet orificep. 527
8 Charge pumpp. 527
(A) High pressure portp. 527
(B) High pressure portp. 527
Fig. 4 DA-control valvep. 528
+1 Charge pumpp. 528
1 Charge pumpp. 528
2 Circlipp. 528
3 Controller tubep. 528
4 Stepped pistonp. 528
5 Ringp. 528
6 Circlipp. 528
7 Nutp. 528
8 Washerp. 528
9 Pressure springp. 528
10 O-ringp. 528
11 Spring cupp. 528
12 Circlipp. 528
13 Threaded pinp. 528
14 Controller screwp. 528
15 Locking nutp. 528
16 Charge pressure valvep. 528
17 Housing channelp. 528
18 Pilot pressure channelp. 528
19 Control edgep. 528
20 Control edgep. 528
21 Measuring orificep. 528
22 Borep. 528
The pump is infinitely controlled with pilot pressure from neutral position to the desired flow direction and to the desired displacement.p. 529
The necessary hydraulic oil for the pump control is provided by the charge circuit of the respective tandem pump. The oil supplied by the charge pump flows to the DA-control valve.p. 529
At an engine speed between low idle speed and control start (for values refer to the technical data) the pump flow rate is so low, that almost all oil can flow through the inside of the control valve cartridge to the charge system for the travel pump…p. 529
When raising the engine speed beyond the control start, the flow rate from the charge pump will also increase. This higher oil flow rate causes a far higher pressure drop at the orifice and pushes the inner spool against the spring. The movement of t…p. 529
At control end (for values refer to the technical data) the bores are fully open.p. 529
Since the bores have a considerable throttle effect even when they are fully open, the pilot pressure will never be higher than max. 14 bar.p. 529
At control start (bores are beginning to open) the static pressure is approx. 6 bar.p. 529
If the solenoid valve is now actuated to one of the two possible directions, the pilot pressure is high enough to actuate the pump slowly out of neutral position. The pump starts to deliver oil to the respective travel motor.p. 529
Raising the engine speed will also increase the oil flow from the charge pump, the bores around the control valve spool (orifice) will open further and the pilot pressure will gradually increase. The displacement increases and the pump delivers a lar…p. 529
The rest of the oil flows through the DA-control valve to the charge pressure relief valves in the travel pumps. The setting of these valves (see technical data) determines the charge pressure.p. 529
Fig. 5 Arrangement of valvesp. 530
+1 DA-control valvep. 530
1 DA-control valvep. 530
2 Charge pressure valvep. 530
3 High pressure relief valvep. 530
4 Pressure override valvep. 530
5 Travel direction valvep. 530
6 High pressure relief valvep. 530
7 Inlet orificep. 530
8 Charge pumpp. 530
9 Travel pumpp. 530
(A) High pressure portp. 530
(B) High pressure portp. 530
+The charge circuit is necessary for the compensation of leaks and flushing quantities in a closed hydraulic circuit and for controlling the pump.p. 530
Pilot controlled high pressure relief valvep. 531
Fig. 6 Pilot controlled high pressure relief valvep. 531
+1 Valve sleevep. 531
1 Valve sleevep. 531
2 Pressure springp. 531
3 Pistonp. 531
4 O-ringp. 531
5 Pilot valvep. 531
6 Valve bodyp. 531
7 Valve bodyp. 531
8 O-ringp. 531
9 Pressure spring (high pressure)p. 531
10 Locking nutp. 531
11 Setscrewp. 531
12 High pressure circuitp. 531
13 Charge circuitp. 531
The charge oil flow is now available at the boost check valves for the closed hydraulic circuit. The boost check valves are non-return valves, which are integrated in the high pressure relief valves. Their back is always loaded with the actual pressu…p. 531
The charge oil (charge oil circuit) from the charge pressure relief valve acts on the ring area A1 of piston (3).p. 531
The piston is lifted off because the force (P x A1) is higher than the sum of spring force (2) and counteracting force (P x A2).p. 531
Charge oil can now flow into the low pressure side of the closed hydraulic circuit.p. 531
This ensures permanent filling of the closed circuit.p. 531
+Charge pressure relief valvep. 532
High pressure relief valvep. 532
Fig. 8 Valve settingsp. 532
(A) HPRV closedp. 532
(B) HPRV openp. 532
(C) Charge circuitp. 532
(D) Pressure reliefp. 532
(E) High pressure sidep. 532
+High pressure relief valve closed (A)p. 532
High pressure relief valve closed (A)p. 532
High pressure acts on area A3 and tries to lift the piston (3) of its seat. High pressure is guided through valve sleeve (1) to the back of piston (3). The effective area A2 is bigger than A3, the piston is therefore pressed down in its seat and seal…p. 532
+High pressure relief valve open (B)p. 532
High pressure relief valve open (B)p. 532
If the high pressure exceeds the value adjusted on pilot (5) with the high pressure spring (9), the pilot will open against the high pressure spring (9). Oil will now flow through valve sleeve (1) and pilot (5) to the charge pressure side.p. 532
This causes a pressure drop at piston (3) and the piston is lifted off its seat.p. 532
The connection between high pressure side and charge pressure side opens, whereby the high pressure value set by the high pressure spring (9) is maintained.p. 532
+Charge pressure relief valvep. 533
Charge pressure relief valvep. 533
Fig. 9 Charge pressure relief valvep. 533
+1 Plugp. 533
1 Plugp. 533
2 Setscrewp. 533
3 Valve pistonp. 533
4 Spring cupp. 533
5 Pressure springp. 533
6p. 533
7p. 533
8 O-ringp. 533
9 Collar nutp. 533
The charge oil coming from the DA-control valve enters the charge pressure relief valve through the charge oil channel and acts against area A1 on the valve cone.p. 533
If the force acting against the valve cone exceeds the force of the pressure spring, the valve cone will be lifted off its seat in the valve body and charge oil can flow into the housing channel.p. 533
The closed circuitp. 534
As soon as the swash plate inside the travel pump is displaced out of neutral position, the pump will start to deliver oil to the respective travel motor.p. 534
In dependence on the speed of the diesel engine the swash plate can be infinitely displaced out of neutral position up to maximum displacement position.p. 534
Immediately after the swash plate has been moved out of neutral the pressure in the hoses from pump to motor will increase. This pressure is higher than the pressure in the hose from the motor to the pump. The pressure in the hose from pump to motor …p. 534
The high pressure relief valves protect the closed hydraulic circuit and the combustion engine against overloads (e.g. short pressure peaks). In such a case the valve on the high pressure side will open and relieve oil through the boost check valve i…p. 534
Since permanent responding of the high pressure relieve valves would cause extreme overheating of the hydraulic oil and quickly lead to serious damage, this system is protected by another kind of primary pressure limitation, the pressure override. Ea…p. 534
The high pressure in the system is permanently reported to the pressure override valve via a shuttle valve between both sides of the closed hydraulic travel circuit. The pressure override valve itself is connected with the pilot oil flow from the DA-…p. 534
If the high pressure in the travel system increases up to the setting of the pressure override, this high pressure will push the valve spool in the pressure override against the pressure spring. This guides part of the pilot oil flow between DA-contr…p. 534
The pressure drop in the pilot oil supply reduces the force acting on the control piston and the pump swashes back towards neutral. This reduces the pump displacement, until the pump pressure is in accordance with the value adjusted with the pressure…p. 534
If the pressure drops below the setting of the pressure override, the pilot oil flow is opened again and the pump will return to the previously chosen displacement.p. 534
As a measure to avoid any reaction of the high pressure relief valves, the pressure override is adjusted to a lower value than the high pressure relief valves.p. 534
Pressure override valvep. 535
Fig. 10 Pressure override valvep. 535
+1 Valve pistonp. 535
1 Valve pistonp. 535
2 Borep. 535
3 Valve seatp. 535
4 Pistonp. 535
5 Valve bushingp. 535
6 Control pistonp. 535
7 Spring cupp. 535
8 Pressure springp. 535
9 Setscrewp. 535
10 Pilot pressure channelp. 535
11 Housing channelp. 535
12 High pressure circuitp. 535
13 High pressure circuitp. 535
14 Valve seatp. 535
Adjustment values see next page.p. 535
The minimum difference between high pressure relief valve and pressure override is 30 bar.p. 535
Travel motorsp. 536
+Travel motorsp. 536
Travel motorsp. 536
+Each wheel of the sanitary landfill compactor is driven by a HYDROMATIK bent axle motor A6VM 160 HA 2T. These motors are designed with two different displacements an can therefore be operated in two different travel speed ranges, as desired.p. 536
Each wheel of the sanitary landfill compactor is driven by a HYDROMATIK bent axle motor A6VM 160 HA 2T. These motors are designed with two different displacements an can therefore be operated in two different travel speed ranges, as desired.p. 536
Fig. 1 Travel motor A6VM 160 HA 2Tp. 536
+1 Control start setscrewp. 536
1 Control start setscrewp. 536
The motors are connected to the associated travel pumps via the high pressure ports A and B. The high pressure hydraulic oil flows through the respective high pressure port to the back of the working pistons. Since these pistons are arranged under an…p. 536
Once a piston has passed through its dead centre (max. extension), the piston will change to the low pressure side. The continuing rotation presses the piston back into the cylinder. This forces the hydraulic oil from the cylinder chamber through the…p. 536
Charge pressure can be applied to the control unit on the travel motor via a solenoid valve. This changes the angle between piston drum and output shaft.p. 536
In this context a large angle means high displacement. In low speed range the motor works with a high torque. With a small angle these conditions are exactly opposite.p. 536
When driving the refuse compactor in high speed range, he travel motors will automatically start to adjust towards high displacement once a certain pressure level is reached. At the same time the torque increases accordingly.p. 536
Fig. 2 Hydraulic diagram travel motorp. 537
(A) Stage 1p. 537
(B) Stage 2p. 537
(C) Control rangep. 537
+1 Enginep. 537
1 Enginep. 537
2 Check valvep. 537
3 Check valvep. 537
4 Pre-control pistonp. 537
5 Pressure relief valvep. 537
6 Flushing valvep. 537
7 Planetary drivep. 537
8 Control pistonp. 537
+The brake is designed and intended as a parking and emergency brake. Unnecessary use of the emergency stop during travel operation reduces the lifetime of the brake discs and should therefore be avoided!p. 537
Motor works in speed range 1p. 537
If speed range 1 (slow) is selected, charge pressure is applied to port X. This pressure causes reversing of the pilot control piston (4) against the spring forces F2 and F3. The high pressure in A or B is guided through the corresponding non-return …p. 537
+The brake is designed and intended as a parking and emergency brake. Unnecessary use of the emergency stop during travel operation reduces the lifetime of the brake discs and should therefore be avoided!p. 538
Motor works in speed range 2 or 3p. 538
Pilot pressure below control startp. 538
The high pressure in A or B is guided through the corresponding non-return valves to the pilot control piston. With pressures up to control start of the travel motors (pressure values see technical data) the adjustable spring force F3 of the control …p. 538
Operating pressure within the control rangep. 538
With the automatic displacement control (high pressure dependent), the adjustment of the displacement (proportional swashing angle) is accomplished automatically in dependence on the operating pressure. The control start is pre-set by the adjustment …p. 538
The pressure increase spring F2 prevents the pilot control piston from opening completely. Due to the ”restrictor effect” of the slightly opened control piston, the pressure applied to A2 is lower than the operating pressure. Only when the operat…p. 538
The two motors on one side of the machine are linked via the ports ”G”. Through these ports the pressure in the travel circuit with the highest pressure is reported to the other motor. The motor with the lower pressure thereby responds exactly in…p. 538
This type of control ensures that both motors on one machine side work with almost the same displacement / speed. This prevents the unloaded motor from changing to max. speed, if one of the wheels is unloaded (e.g. when raising the wheels with the do…p. 538
Since the output speed of the motors is too high for direct driving of the wheels, the motor output speed is reduced to final working speed by planetary gears.p. 538
Each wheel unit therefore consists of a hydraulic motor with a planetary gear.p. 538
The motors are directly connected to the planetary gears via splined shafts.p. 538
The housings of the planetary gears also contain the multi-disc brakes. The brakes run in an oil bath and are therefore almost wear-free. The brakes are released by charge pressure and close automatically when the charge pressure drops below the brak…p. 538
+The brake is designed and intended as a parking and emergency brake. Unnecessary use of the emergency stop during travel operation reduces the lifetime of the brake discs and should therefore be avoided!p. 538
The brake is designed and intended as a parking and emergency brake. Unnecessary use of the emergency stop during travel operation reduces the lifetime of the brake discs and should therefore be avoided!p. 538
Filtrationp. 539
+Filtrationp. 539
Filtrationp. 539
+Function and lifetime of a hydraulic system depend decisively on the cleanliness of the power transmission medium (hydraulic oil).p. 539
Function and lifetime of a hydraulic system depend decisively on the cleanliness of the power transmission medium (hydraulic oil).p. 539
For this reason it is mandatory to filter the hydraulic oil permanently while the machine is working. In closed hydraulic circuits the full flow filtration of the charge circuit and the return flow from the individual components has been found very b…p. 539
+Charge circuit filtrationp. 539
Charge circuit filtrationp. 539
Both charge circuits are fitted with one 12 µm fine filter each. The oil flows through these filters to the individual consumers and functions.p. 539
The filters are fitted with by-pass valves. These open at a pressure differential (pressure difference between filter inlet and filter outlet) of 3.5 bar. This pressure differential depends on the filter contamination and the viscosity of the hydraul…p. 539
Pressure differential switches on the filters report any increase of the pressure differential into the cabin. These switches are designed for a pressure differential of 2.5 bar. The respective information will therefore already be available before t…p. 539
+Return flow filter blockp. 539
Return flow filter blockp. 539
As a second measure to keep the oil free of any impurities, all leaks, flushing quantities and return flows are guided back to the tank through a central return flow filter block.p. 539
The return flow filter block contains two 80 µ filters, two dirt sensors, one pressure switch and a temperature controlled 3/2-way valve.p. 539
All return flows pass through the primary filter, followed by a temperature controlled valve (thermostat). This valve guides the oil flow directly back to the tank, until the operating temperature is reached. At an oil temperature of 55 °C the valve…p. 539
If the primary filter is dirty, the oil flow is guided through the secondary filter. The oil can only pass through this filter when the static pressure in front of the primary filter is higher than 2 bar. In this case the oil is no longer cooled. The…p. 539
In addition to this the dirt sensor (permanent magnet) reports any metallic contamination in the oil via a visual indicator in the cabin.p. 539
Transfer box filter unitp. 540
+Oil circuitp. 540
Oil circuitp. 540
+A pump inside the transfer box pumps the oil in the transfer box through a cooling circuit and finally through a filter.p. 540
A pump inside the transfer box pumps the oil in the transfer box through a cooling circuit and finally through a filter.p. 540
A pressure relief valve is installed in front of the filter inlet. It limits the pressure to 12 bar in low and 25 bar in high idle speed of the engine, at a gear oil temperature of min. 40°C.p. 540
Fig. 1p. 540
+1 Filter unitp. 540
1 Filter unitp. 540
2 Pressure relief valvep. 540
3 Differential pressure switchp. 540
4 Pressure relief to gearboxp. 540
5 filtered oil to transfer boxp. 540
6 from cooling circuitp. 540
7 Separation PRV-settingp. 540
+Pos.p. 540
Pos.p. 540
+Designationp. 540
Designationp. 540
+Measuring valuep. 540
Measuring valuep. 540
+1p. 540
1p. 540
+Filter unitp. 540
Filter unitp. 540
+2p. 540
2p. 540
+Pressure relief valvep. 540
Pressure relief valvep. 540
+25 bar in high idle and min. 40°C oil temperaturep. 540
25 bar in high idle and min. 40°C oil temperaturep. 540
+3p. 540
3p. 540
+Differential pressure switchp. 540
Differential pressure switchp. 540
+2.4 barp. 540
2.4 barp. 540
+15 Tests and adjustments in travel hydraulicsp. 541
15 Tests and adjustments in travel hydraulicsp. 541
+15.3 Checking high pressure relief valves and pressure override
Measuring and adjustment points on tandem travel pump unit
+Measuring and adjustment points
Measuring and adjustment points
Fig. 2
+Pos.
Pos.
+Designation
Designation
+Pos. in electric wiring diagram
Pos. in electric wiring diagram
+Pos. in hydraulic diagram
Pos. in hydraulic diagram
+Measuring value
Measuring value
+1
1
+Port A, high pressure reverse, driven pump
Port A, high pressure reverse, driven pump
+08A, 11A
08A, 11A
+2
2
+High pressure relief valves, driven pump
High pressure relief valves, driven pump
+480 -20 bar
480 -20 bar
+3
3
+PS-line, pilot pressure supply to pressure override
PS-line, pilot pressure supply to pressure override
+4
4
+Port A, high pressure reverse, dragged pump
Port A, high pressure reverse, dragged pump
+09A, 12A
09A, 12A
+5
5
+High pressure relief valves, dragged pump
High pressure relief valves, dragged pump
+480 -20 bar
480 -20 bar
+6
6
+Port B, high pressure forward, dragged pump
Port B, high pressure forward, dragged pump
+7
7
+Plug T2, dragged pump
Plug T2, dragged pump
+T2
T2
+8
8
+Port B, high pressure forward, driven pump
Port B, high pressure forward, driven pump
+B
B
+9
9
+Plug T2, driven pump
Plug T2, driven pump
+T2
T2
+10
10
+Plug a, solenoid valve forward
Plug a, solenoid valve forward
+Y 16
Y 16
+a
a
+0 / 24V
0 / 24V
+11
11
+Port T1, leak oil to return flow filter, driven pump, with magnetic plug
Port T1, leak oil to return flow filter, driven pump, with magnetic plug
+T1
T1
+12
12
+Test port X1, control chamber pressure reverse
Test port X1, control chamber pressure reverse
+M6, M16, X1
M6, M16, X1
+0 – 14 bar, **)
0 – 14 bar, **)
+13
13
+Port T1, leak oil to return flow filter, dragged pump, with magnetic plug
Port T1, leak oil to return flow filter, dragged pump, with magnetic plug
+T1
T1
+14
14
+Test port G, charge pressure
Test port G, charge pressure
+M7, M17, G3
M7, M17, G3
+0 ± 2 bar in high idle speed***)
0 ± 2 bar in high idle speed***)
+15
15
+Test port X2, control chamber pressure forward
Test port X2, control chamber pressure forward
+M5, M15, X2
M5, M15, X2
+0 – 14 bar **)
0 – 14 bar **)
+16
16
+Port S, charge pressure from hydraulic oil filter
Port S, charge pressure from hydraulic oil filter
+17
17
+Plug b, solenoid valve reverse
Plug b, solenoid valve reverse
+Y 17
Y 17
+b
b
+0 / 24V
0 / 24V
+18
18
+Charge pressure relief valve, driven pump
Charge pressure relief valve, driven pump
+30 ± 2 bar in high idle speed***)
30 ± 2 bar in high idle speed***)
+19
19
+DA-control valve
DA-control valve
+*)
*)
+20
20
+Pressure override, driven pump
Pressure override, driven pump
+430 +10/-20 bar
430 +10/-20 bar
+21
21
+Test port MB, high pressure forward, driven pump
Test port MB, high pressure forward, driven pump
+M2, M12, MB
M2, M12, MB
+430 +10/-20 bar
430 +10/-20 bar
+22
22
+Charge pressure relief valve, dragged pump
Charge pressure relief valve, dragged pump
+30 ± 2 bar in high idle speed***)
30 ± 2 bar in high idle speed***)
+23
23
+Pressure override, dragged pump
Pressure override, dragged pump
+430 +10/-20 bar
430 +10/-20 bar
+24
24
+Test port MB, high pressure forward, dragged pump
Test port MB, high pressure forward, dragged pump
+M4, M14, MB
M4, M14, MB
+430 +10/-20 bar
430 +10/-20 bar
+25
25
+Port S1, suction connection charge pump from tank
Port S1, suction connection charge pump from tank
+26
26
+Port P, charge pump pressure port to filter
Port P, charge pump pressure port to filter
+27
27
+Test port MA, high pressure reverse, dragged pump
Test port MA, high pressure reverse, dragged pump
+M3, M13, MA
M3, M13, MA
+430 +10/-20 bar
430 +10/-20 bar
+28
28
+Test port MA, high pressure reverse, driven pump
Test port MA, high pressure reverse, driven pump
+M1, M11, MA
M1, M11, MA
+430 +10/-20 bar
430 +10/-20 bar
*), **), ***); see adjustment instructions
+15.3 Checking high pressure relief valves and pressure override
15.2 Pressure tests in the travel circuit
+Whenever performing tests make sure you direct visual contact with the driver.
Whenever performing tests make sure you direct visual contact with the driver.
+1. Run the machine warm to operating temperature (approx. 40°C hydraulic oil temperature).
1. Run the machine warm to operating temperature (approx. 40°C hydraulic oil temperature).
+Fig. 1
Fig. 1
+2. Connect the following pressure gauges
+2. Connect the following pressure gauges
(Fig. 1)
+1 High pressure, travel pump rear left, 600 bar.
1 High pressure, travel pump rear left, 600 bar.
2 High pressure, travel pump front left, 600 bar.
3 High pressure, travel pump front right, 600 bar.
4 High pressure, travel pump rear right, 600 bar.
5 Charge pressure, left hand tandem pump 60 bar.
6 Charge pressure, right hand tandem pump 60 bar.
7 Control chamber pressure, left hand tandem pump 60 bar.
8 Control chamber pressure, right hand tandem pump 60 bar.
+Make sure there are no persons in front of or behind the machine.
Make sure there are no persons in front of or behind the machine.
+Fig. 2
Fig. 2
+3. Input module
+3. Input module
(Fig. 2)
+4. Start the engine, select 2nd speed range and switch to travel direction reverse.
4. Start the engine, select 2nd speed range and switch to travel direction reverse.
+Do not actuate the emergency stop.
Do not actuate the emergency stop.
+5. Accelerate the engine slowly up to full speed and watch the pressure gauges.
5. Accelerate the engine slowly up to full speed and watch the pressure gauges.
+Nominal values:
Nominal values:
High pressures must increase evenly to 430 +10/ -20 bar. The charge pressures must not drop considerably (
Control chamber pressures must increase evenly to approx. 14 bar.
+15.3 Checking high pressure relief valves and pressure override
15.3 Checking high pressure relief valves and pressure override
+1. Run the machine up to operating temperature (40°C hydraulic oil temperature).
1. Run the machine up to operating temperature (40°C hydraulic oil temperature).
+Fig. 1
Fig. 1
+2. Input module
+2. Input module
(Fig. 1)
+Fig. 2
Fig. 2
+3. Connect a 600 bar pressure gauge to both high pressure ports
+3. Connect a 600 bar pressure gauge to both high pressure ports
(Fig. 2)
+Fig. 3
Fig. 3
+4. Pull the electric plugs A and B
+4. Pull the electric plugs A and B
(Fig. 3)
+Fig. 4
Fig. 4
+5. Turn the adjustment screw of the pressure override
+5. Turn the adjustment screw of the pressure override
(Fig. 4)
+Make sure there are no persons in front of or behind the machine.
Make sure there are no persons in front of or behind the machine.
+6. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction
6. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction
+Do not actuate the emergency stop.
Do not actuate the emergency stop.
+Perform the following test for max. 3 seconds, as otherwise the pump may be destroyed by overheating!
Perform the following test for max. 3 seconds, as otherwise the pump may be destroyed by overheating!
+7. Accelerate for a moment (max. 3 seconds) to full speed and read the pressure gauges.
7. Accelerate for a moment (max. 3 seconds) to full speed and read the pressure gauges.
+Nominal value:
Nominal value:
480 -20 bar
+Fig. 5
Fig. 5
+8. If necessary adjust the high pressure relief valves
+8. If necessary adjust the high pressure relief valves
(Fig. 5)
+9. Repeat this test to the opposite travel direction.
9. Repeat this test to the opposite travel direction.
+10. Repeat these tests for the rear pump.
10. Repeat these tests for the rear pump.
+Fig. 6
Fig. 6
+11. Adjust the pressure override
+11. Adjust the pressure override
(Fig. 6)
+12. Adjust the pressure override on the rear pump to 430 bar (high pressure measurement on rear pump).
12. Adjust the pressure override on the rear pump to 430 bar (high pressure measurement on rear pump).
+If the pressure override is not correctly adjusted on one of the pumps (remains blocked) the high pressure in the respective circuit may increase up to the setting of the high pressure relief valves.
If the pressure override is not correctly adjusted on one of the pumps (remains blocked) the high pressure in the respective circuit may increase up to the setting of the high pressure relief valves.
+13. Perform the same tests for the second tandem pump.
13. Perform the same tests for the second tandem pump.
+15.4 Charge pump high pressure test
15.4 Charge pump high pressure test
+Special tools:
Special tools:
Gear pump testing device, 600 bar pressure gauge.
+Fig. 1
Fig. 1
+1. Close the pump outlet port with a 200 bar pressure gauge
+1. Close the pump outlet port with a 200 bar pressure gauge
(Fig. 1)
+2. Crank the engine with the starter (pull the plug off the solenoid valve or keep the engine shut-down depressed).
2. Crank the engine with the starter (pull the plug off the solenoid valve or keep the engine shut-down depressed).
+3. Read the pressure gauge.
3. Read the pressure gauge.
+Nominal value:
Nominal value:
200 bar
+4. If the nominal value is not reached, replace the charge pump.
4. If the nominal value is not reached, replace the charge pump.
+15.5 Travel pump high pressure test (individual test)
15.5 Travel pump high pressure test (individual test)
+Fig. 1
Fig. 1
+1. Close the high pressure ports
+1. Close the high pressure ports
(Fig. 1)
+Fig. 2
Fig. 2
+2. Input module
+2. Input module
(Fig. 2)
+Fig. 3
Fig. 3
+Pull the electric plugs A and B
+Pull the electric plugs A and B
(Fig. 3)
+Fig. 4
Fig. 4
+3. Connect a 600 bar pressure gauge to the high pressure test port of the pump
+3. Connect a 600 bar pressure gauge to the high pressure test port of the pump
(Fig. 4)
+Do not actuate the emergency stop.
Do not actuate the emergency stop.
+4. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction
4. Start the engine, select 2nd speed range and shift the travel lever to the desired travel direction
+5. Raise the engine speed for a moment and read the pressure gauge.
5. Raise the engine speed for a moment and read the pressure gauge.
+Nominal value:
Nominal value:
410 to 440 bar
+6. If the nominal value is not reached, check pressure override and high pressure relief valves. If the valves are o.k., replace or repair the travel pump.
6. If the nominal value is not reached, check pressure override and high pressure relief valves. If the valves are o.k., replace or repair the travel pump.
+15.6 Checking charge pressure
15.6 Checking charge pressure
+1. Run the machine until operating temperature is achieved, then shut down the engine.
1. Run the machine until operating temperature is achieved, then shut down the engine.
+Fig. 5
Fig. 5
+2. Block the front charge pressure relief valve 1
+2. Block the front charge pressure relief valve 1
(Fig. 5)
+3. Connect a 60 bar pressure gauge to the charge pressure test port (3).
3. Connect a 60 bar pressure gauge to the charge pressure test port (3).
+4. Start the engine and run it with half speed.
4. Start the engine and run it with half speed.
+5. Set the rear charge pressure relief valve (2) to 30 bar.
5. Set the rear charge pressure relief valve (2) to 30 bar.
+6. Run the engine with maximum speed (the charge pressure increases).
6. Run the engine with maximum speed (the charge pressure increases).
+7. Loosen the blocked valve until the charge pressure of 30 bar is reached again.
7. Loosen the blocked valve until the charge pressure of 30 bar is reached again.
+8. Check the charge pressure again at idle speed.
8. Check the charge pressure again at idle speed.
+Nominal value:
Nominal value:
min. 28 +/- 2 bar
+9. Should the pressure of 28 bar not be reached, repeat the basic adjustment with a pressure higher than 30 bar, but on both valves identical.
9. Should the pressure of 28 bar not be reached, repeat the basic adjustment with a pressure higher than 30 bar, but on both valves identical.
+10. Check and adjust the other tandem pump accordingly.
10. Check and adjust the other tandem pump accordingly.
+15.7 Adjusting the DA-control valve
15.7 Adjusting the DA-control valve
+1. Warm the machine up to operating temperature.
1. Warm the machine up to operating temperature.
+Fig. 1
Fig. 1
+2. Input module
+2. Input module
(Fig. 1)
+3. Select 2nd speed range.
3. Select 2nd speed range.
+Fig. 2
Fig. 2
+4. Connect 600 bar pressure gauges to the high pressure test ports (MA or MB) of both tandem pumps (1) / (2) and (3) / (4)
+4. Connect 600 bar pressure gauges to the high pressure test ports (MA or MB) of both tandem pumps (1) / (2) and (3) / (4)
(Fig. 2)
+5. Start the engine and raise the engine speed to 950 +/- 50 rpm.
5. Start the engine and raise the engine speed to 950 +/- 50 rpm.
+6. Select the travel direction in accordance with the chosen high pressure test port (in this illustration reverse) and read the pressure gauge.
6. Select the travel direction in accordance with the chosen high pressure test port (in this illustration reverse) and read the pressure gauge.
+Do not operate foot brake and emergency stop.
Do not operate foot brake and emergency stop.
+Nominal value:
Nominal value:
High pressure 50 bar as mean value
+7. Raise the engine speed to 1700 rpm.
7. Raise the engine speed to 1700 rpm.
+Nominal value:
Nominal value:
High pressure 400 bar
+Fig. 3
Fig. 3
+8. If deviations from the nominal value for control start are found the pressure must be adjusted on the corresponding DA-control valve
+8. If deviations from the nominal value for control start are found the pressure must be adjusted on the corresponding DA-control valve
(Fig. 3)
+Turn clockwise = control start at higher engine speed.
Turn clockwise = control start at higher engine speed.
Turn anti-clockwise = control start at lower engine speed.
Both tandem pumps must be equalized, i.e. for a synchronous operation the adjustment values of right and left hand pumps should be almost identical.
+15.8 Checking the control chamber pressure
15.8 Checking the control chamber pressure
+1. Warm the machine up to operating temperature.
1. Warm the machine up to operating temperature.
+Fig. 1
Fig. 1
+2. Input module
+2. Input module
(Fig. 1)
+3. Select 2nd speed range.
3. Select 2nd speed range.
+Fig. 2
Fig. 2
+4. Connect one 60 bar pressure gauge each to the test ports (X1 and X2)
+4. Connect one 60 bar pressure gauge each to the test ports (X1 and X2)
(Fig. 2)
+5. Start the engine.
5. Start the engine.
+Do not operate foot brake and emergency stop.
Do not operate foot brake and emergency stop.
+Nominal value:
Nominal value:
Engine speed 950 ± 50 rpm: approx. 6 bar
Engine speed 1700 ± 50 rpm: approx. 12…14 bar
+The measurement of control start and control end under high pressure are much more meaningful than the control chamber pressure, because these measurements actually measure the effective pressure to the wheels.
The measurement of control start and control end under high pressure are much more meaningful than the control chamber pressure, because these measurements actually measure the effective pressure to the wheels.
15.9 Measuring and adjustment points on travel motors
Fig. 1 Travel motor front right
+Pos.
Pos.
+Designation
Designation
+Pos. in electric wiring diagram
Pos. in electric wiring diagram
+Pos. in hydraulic diagram
Pos. in hydraulic diagram
+Measuring value
Measuring value
+1
1
+Control pressure test port
Control pressure test port
+M23, M24, M25, M26
M23, M24, M25, M26
+0 – 430 bar
0 – 430 bar
+2
2
+High pressure test port
High pressure test port
+M27, M28; M29, M30, G
M27, M28; M29, M30, G
+0-430 bar (actual high pressure)
0-430 bar (actual high pressure)
+3
3
+Setscrew for control start
Setscrew for control start
+4
4
+Setscrew for Qmax
Setscrew for Qmax
+G
G
+do not turn!
do not turn!
+5
5
+Flushing valve
Flushing valve
Adjusting the control start of the travel motors
+l Run the machine up to operating temperature (min. 40°C hydraulic oil temperature).
l Run the machine up to operating temperature (min. 40°C hydraulic oil temperature).
l Install 600 bar pressure gauges to both test ports on the corresponding travel motor.
l Use input code 500 on the CAN-Bus input module to block the brake.
l Choose 2nd speed range and any travel direction and slowly increase the engine speed while keeping an eye on the pressure gauges.
+Nominal value:
Nominal value:
up to 280 bar high pressure can be read on the lower test port (G) actual high pressure, the upper test port (M1) approx. 0 bar.
from a high pressure of approx. 280 bar the pressure at M1 must increase together with the high pressure, so that full high pressure is also indicated here when approx. 380 bar is reached.
+l If necessary correct the adjustment on the setscrew. Turning in reduces and turning out increases the control start.
l If necessary correct the adjustment on the setscrew. Turning in reduces and turning out increases the control start.
+1 revolution of the control start adjustment screw results in a 100 bar change!
1 revolution of the control start adjustment screw results in a 100 bar change!
Checking the displacement setting of the travel motors
Fig. 1
+1 Pilot pressure port (pressure in swashing cylinder)
+1 Pilot pressure port (pressure in swashing cylinder)
1 Pilot pressure port (pressure in swashing cylinder)
2 High pressure port „G“
+3 Electric plug, brake solenoid valve
+3 Electric plug, brake solenoid valve
3 Electric plug, brake solenoid valve
4 Setscrew, displacement adjustment
Special tools:
+2 x 600 bar pressure gauges
2 x 600 bar pressure gauges
2 pressure test hoses
+Always perform this test after replacing one or several motors.
Always perform this test after replacing one or several motors.
If a new motor was installed, fill, bleed and, if necessary, flush the hydraulic system as described.
+1. Run the machine warm in the first speed range, until the hydraulic oil has a reached a temperature of approx. 50 °C.
1. Run the machine warm in the first speed range, until the hydraulic oil has a reached a temperature of approx. 50 °C.
+2. Connect a high pressure gauge 2
+2. Connect a high pressure gauge 2
(Fig. 1)
+This pressure gauge shows the load dependent high pressure in travel operation.
This pressure gauge shows the load dependent high pressure in travel operation.
+3. Connect a high pressure gauge (1) to the corresponding pilot pressure test port on the motor to be tested.
3. Connect a high pressure gauge (1) to the corresponding pilot pressure test port on the motor to be tested.
+This pressure gauge shows the pressure in the swashing cylinder.
This pressure gauge shows the pressure in the swashing cylinder.
+Input module, enter PIN-CODE.
Input module, enter PIN-CODE.
Secure all wheels with wedges.
+The adjustments can be made in any travel direction.
The adjustments can be made in any travel direction.
+4. Start the engine and let it run in idle speed, select second speed range and the respective travel direction.
4. Start the engine and let it run in idle speed, select second speed range and the respective travel direction.
+Do not actuate the emergency stop switch.
Do not actuate the emergency stop switch.
+5. Slowly raise the engine speed, read both pressure gauges.
5. Slowly raise the engine speed, read both pressure gauges.
+Nominal value:
Nominal value:
As the engine speed increases, the pressure on pressure gauge (2) port “G“ will increase.
The pressure on pressure gauge (2) increases from approx. 29 bar to 280 bar, while pressure gauge (1) does not indicate any pressure.
Once the pressure on pressure gauge (2) exceeds 280 bar, the pressure on pressure gauge (1) also starts to increase.
When pressure gauge (2) reaches 380 bar, pressure gauge (1) must also reach 380 bar.
At pressure above 380 bar both pressure gauges (2 and 1) must have identical readings.
+Evaluation of test:
Evaluation of test:
If the specified values are not reached adjust the pilot pressure on screw (4).
+If pressure gauge (2) shows 380 bar, while pressure gauge (1) shows less than 380 bar, turn the adjustment screw in anti-clockwise direction.
If pressure gauge (2) shows 380 bar, while pressure gauge (1) shows less than 380 bar, turn the adjustment screw in anti-clockwise direction.
If pressure gauges (2) and (1) show identical pressure values before reaching 380 bar, turn the adjustment screw in clockwise direction.
+6. Repeat this test on all other travel motors.
6. Repeat this test on all other travel motors.
15.11 Filter unit for transfer box / pressure relief valve
+Filter unit
Filter unit
Fig. 1
+1 Filter unit
1 Filter unit
2 Pressure relief valve
3 Pressure differential switch
4 Pressure relief to gearbox
5 filtered oil to transfer box
6 from cooling circuit
7 Separation PRV-setting
+Pos.
Pos.
+Designation
Designation
+Measuring value
Measuring value
+1
1
+Filter unit
Filter unit
+2
2
+Pressure relief valve
Pressure relief valve
+25 bar in high idle and min. 40°C oil temperature
25 bar in high idle and min. 40°C oil temperature
+3
3
+Pressure differential switch
Pressure differential switch
+2.4 bar
2.4 bar
Adjusting the pressure relief valve
+l Run the machine warm (min. 40°C gear oil temperature) and shut the engine down.
l Run the machine warm (min. 40°C gear oil temperature) and shut the engine down.
+l Unscrew the pressure relief valve from the filter inlet port
(Fig. 1)
l Close the outlet towards the filter on the disconnected T-fitting with a plug (P/N 055 427 05).
l Close the filter inlet port with plug (P/N 055 427 05) and nut (P/N 055 450 25).
l Start the engine and adjust the pressure relief valve to 25 bar in high idle speed / 12 bar in low idle speed; then shut the engine down again.
l Reconnect the pressure relief valve to the filter.
+16 Special tools, tests and adjustmentsp. 559
+16 Special tools, tests and adjustmentsp. 559
16.1 Special tools, tests and adjustmentsp. 560
+Fig. 1p. 560
Fig. 1p. 560
+1. Vibration reed frequency meterp. 560
1. Vibration reed frequency meterp. 560
+1000 – 4000 rpmp. 560
1000 – 4000 rpmp. 560
+17 – 67 Hzp. 560
17 – 67 Hzp. 560
+BOMAG part-no.: 300 120 80p. 560
BOMAG part-no.: 300 120 80p. 560
+Fig. 2p. 560
Fig. 2p. 560
+2. Sirometer (frequency meter)p. 560
2. Sirometer (frequency meter)p. 560
+800 – 50.000 rpmp. 560
800 – 50.000 rpmp. 560
+14 – 750 Hzp. 560
14 – 750 Hzp. 560
+BOMAG part-no.: 059 710 02p. 560
BOMAG part-no.: 059 710 02p. 560
+Fig. 3p. 560
Fig. 3p. 560
+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 °Cp. 560
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 °Cp. 560
BOMAG part-no.: 050 100 75p. 560
+Fig. 4p. 560
Fig. 4p. 560
+4. Digital rpm-meter for petrol enginesp. 560
4. Digital rpm-meter for petrol enginesp. 560
BOMAG part-no.: 079 948 99p. 560
+Fig. 5p. 561
Fig. 5p. 561
+5. Digital rpm-meter for petrol enginesp. 561
5. Digital rpm-meter for petrol enginesp. 561
BOMAG part-no.: 059 711 12p. 561
+Fig. 6p. 561
Fig. 6p. 561
+6. Digital rpm-meter, optical/mechanical, universal usep. 561
6. Digital rpm-meter, optical/mechanical, universal usep. 561
BOMAG part-no.: 079 948 98p. 561
+Fig. 7p. 561
Fig. 7p. 561
+7. Infrared manual thermometer, -18 to 275°Cp. 561
7. Infrared manual thermometer, -18 to 275°Cp. 561
BOMAG part-no.: 057 668 06p. 561
+Fig. 8p. 561
Fig. 8p. 561
+8. Hydraulic test case, largep. 561
8. Hydraulic test case, largep. 561
BOMAG part-no.: 007 610 03p. 561
+4 X 600 bar pressure gaugesp. 561
4 X 600 bar pressure gaugesp. 561
4 X 60 bar pressure gaugesp. 561
8 pressure test hosesp. 561
+Fig. 9p. 562
Fig. 9p. 562
+9. Hydraulic test case, smallp. 562
9. Hydraulic test case, smallp. 562
BOMAG part-no.: 079 930 01p. 562
+2X 60 bar pressure gaugep. 562
2X 60 bar pressure gaugep. 562
2X 600 bar pressure gaugesp. 562
4 pressure test hosesp. 562
+Fig. 10p. 562
Fig. 10p. 562
+10. Pressure test hosesp. 562
10. Pressure test hosesp. 562
+1000 mm BOMAG part-no.: 079 930 02p. 562
1000 mm BOMAG part-no.: 079 930 02p. 562
+2500 mm BOMAG part-no.: 079 930 03p. 562
2500 mm BOMAG part-no.: 079 930 03p. 562
+Fig. 11p. 562
Fig. 11p. 562
+11. Pressure gaugep. 562
11. Pressure gaugep. 562
+60 bar BOMAG part-no.: 059 721 07p. 562
60 bar BOMAG part-no.: 059 721 07p. 562
+600 bar BOMAG part-no.: 059 721 04p. 562
600 bar BOMAG part-no.: 059 721 04p. 562
+Fig. 12p. 562
Fig. 12p. 562
+12. Adapter for pressure test hosep. 562
12. Adapter for pressure test hosep. 562
BOMAG part-no.: 055 439 02p. 562
+Fig. 13p. 563
Fig. 13p. 563
+13. Gear pump testing devicep. 563
13. Gear pump testing devicep. 563
BOMAG part-no.: 007 610 05p. 563
+Fig. 14p. 563
Fig. 14p. 563
+14. Vacuum pump for hydraulic oil tankp. 563
14. Vacuum pump for hydraulic oil tankp. 563
+BOMAG part-no.: 007 610 04 (12 Volt)p. 563
BOMAG part-no.: 007 610 04 (12 Volt)p. 563
+BOMAG part-no.: 007 610 24 (24 Volt)p. 563
BOMAG part-no.: 007 610 24 (24 Volt)p. 563
+17 Oscillating articulated jointp. 565
+17 Oscillating articulated jointp. 565
17.1 Removing and installing live ring, oscillating articulated jointp. 566
+Disassembling the live ringp. 566
Disassembling the live ringp. 566
+Safely support front and rear frames as well as oscillating articulated joint. Danger of squashing!p. 566
Safely support front and rear frames as well as oscillating articulated joint. Danger of squashing!p. 566
+Fig. 1p. 566
Fig. 1p. 566
+1. Remove the front cover 1p. 566
+1. Remove the front cover 1p. 566
(Fig. 1)p. 566
+Fig. 2p. 566
Fig. 2p. 566
+2. Disassemble the cover 1p. 566
+2. Disassemble the cover 1p. 566
(Fig. 2)p. 566
+Fig. 3p. 566
Fig. 3p. 566
+3. Remove cover 1p. 566
+3. Remove cover 1p. 566
(Fig. 3)p. 566
+Fig. 4p. 567
Fig. 4p. 567
+4. Raise the dozer blade to end position and tie it to the front frame in this positionp. 567
+4. Raise the dozer blade to end position and tie it to the front frame in this positionp. 567
(Fig. 4)p. 567
+5. Release the brakes on both front final drives.p. 567
5. Release the brakes on both front final drives.p. 567
+Before releasing the multi-disc brake secure the machine against unintended rolling.p. 567
Before releasing the multi-disc brake secure the machine against unintended rolling.p. 567
+6. Remove the brake lines.p. 567
6. Remove the brake lines.p. 567
+Fig. 5p. 567
Fig. 5p. 567
+7. Install measuring adapters 1 and 2p. 567
+7. Install measuring adapters 1 and 2p. 567
(Fig. 5)p. 567
+8. Start the engine, the multi-disc brake will open automatically.p. 567
8. Start the engine, the multi-disc brake will open automatically.p. 567
+9. After releasing the brake shut down the engine. Disconnect the pressure test hose from the measuring adapter fitted to the port on the final drive.p. 567
9. After releasing the brake shut down the engine. Disconnect the pressure test hose from the measuring adapter fitted to the port on the final drive.p. 567
+Front drive without brake, secure the front frame against rolling.p. 567
Front drive without brake, secure the front frame against rolling.p. 567
+10. Connect the vacuum pump and generate vacuum in the hydraulic oil tank.p. 567
10. Connect the vacuum pump and generate vacuum in the hydraulic oil tank.p. 567
+11. Mark all hydraulic lines, hoses and electrical lines from the front to the rear frame, disconnect them from the connection points in the front frame, remove the hose clamps and lay the hoses down. Close all connections immediately with plugs.p. 567
11. Mark all hydraulic lines, hoses and electrical lines from the front to the rear frame, disconnect them from the connection points in the front frame, remove the hose clamps and lay the hoses down. Close all connections immediately with plugs.p. 567
+Fig. 6p. 567
Fig. 6p. 567
+Ensure correct routing of hoses and lines in the roller guide 1p. 567
+Ensure correct routing of hoses and lines in the roller guide 1p. 567
(Fig. 6)p. 567
+12. Drain or pump the fuel from the fuel tank.p. 567
12. Drain or pump the fuel from the fuel tank.p. 567
+Fire hazard! Do not smoke, do not use open fire!p. 567
Fire hazard! Do not smoke, do not use open fire!p. 567
+Fig. 7p. 568
Fig. 7p. 568
+13. Safely support the rear end of the rear frame on both sides 1p. 568
+13. Safely support the rear end of the rear frame on both sides 1p. 568
(Fig. 7)p. 568
+Danger of squashing!p. 568
Danger of squashing!p. 568
+Fig. 8p. 568
Fig. 8p. 568
+14. Fasten the lifting tackle to the front frame.p. 568
14. Fasten the lifting tackle to the front frame.p. 568
+15. Front lifting points 1p. 568
+15. Front lifting points 1p. 568
(Fig. 8)p. 568
+Fig. 9p. 568
Fig. 9p. 568
+16. Rear lifting points 1p. 568
+16. Rear lifting points 1p. 568
(Fig. 9)p. 568
+Fig. 10p. 568
Fig. 10p. 568
+17. Front frame safely suspended by lifting gearp. 568
+17. Front frame safely suspended by lifting gearp. 568
(Fig. 10)p. 568
+Do not stand or step under loads being loaded. Danger of squashing!p. 568
Do not stand or step under loads being loaded. Danger of squashing!p. 568
+Fig. 11p. 569
Fig. 11p. 569
+18. Place a plastic pad 1p. 569
+18. Place a plastic pad 1p. 569
(Fig. 11)p. 569
+19. Disconnect the lubrication hoses from connections (2).p. 569
19. Disconnect the lubrication hoses from connections (2).p. 569
+20. Remove the bars and knock out the bolts (3).p. 569
20. Remove the bars and knock out the bolts (3).p. 569
+Grease the parts.p. 569
Grease the parts.p. 569
+Fig. 12p. 569
Fig. 12p. 569
+21. Unscrew all hexagon screws 1p. 569
+21. Unscrew all hexagon screws 1p. 569
(Fig. 12)p. 569
+Cover the threads with copper paste OKS 240.p. 569
Cover the threads with copper paste OKS 240.p. 569
Tightening torque: 463 Nm.p. 569
+22. Move the front frame carefully forward for approx. 2 m, until the oscillating articulated joint is free.p. 569
22. Move the front frame carefully forward for approx. 2 m, until the oscillating articulated joint is free.p. 569
+Secure dozer blade or front frame against turning over. Danger of squashing! Do not step or work under suspended loads. Danger of squashing!p. 569
Secure dozer blade or front frame against turning over. Danger of squashing! Do not step or work under suspended loads. Danger of squashing!p. 569
+23. Support front frame and dozer blade in a safe manner.p. 569
23. Support front frame and dozer blade in a safe manner.p. 569
+Fig. 13p. 569
Fig. 13p. 569
+24. Disassemble roller guide 1p. 569
+24. Disassemble roller guide 1p. 569
(Fig. 13)p. 569
+25. Attach the lifting tackle to the fuel tank.p. 569
25. Attach the lifting tackle to the fuel tank.p. 569
+Fig. 14p. 570
Fig. 14p. 570
+26. Unscrew the rear hexagon screws from fuel tank 1p. 570
+26. Unscrew the rear hexagon screws from fuel tank 1p. 570
(Fig. 14)p. 570
+Fig. 15p. 570
Fig. 15p. 570
+27. Remove the front bracketp. 570
+27. Remove the front bracketp. 570
(Fig. 15)p. 570
+28. Lift the fuel tank out of the front frame.p. 570
28. Lift the fuel tank out of the front frame.p. 570
+Fig. 16p. 570
Fig. 16p. 570
+29. Disconnect lubrication hoses 1p. 570
+29. Disconnect lubrication hoses 1p. 570
(Fig. 16)p. 570
+30. Attach the lifting tackle to the oscillating articulated joint.p. 570
30. Attach the lifting tackle to the oscillating articulated joint.p. 570
+Danger of squashing!p. 570
Danger of squashing!p. 570
+Fig. 17p. 570
Fig. 17p. 570
+31. Disconnect the top and bottom grease hoses 1p. 570
+31. Disconnect the top and bottom grease hoses 1p. 570
(Fig. 17)p. 570
+Fig. 18p. 571
Fig. 18p. 571
+32. Unscrew the socket head cap screws 1 and 2p. 571
+32. Unscrew the socket head cap screws 1 and 2p. 571
(Fig. 18)p. 571
+33. Take the live ring off completely.p. 571
33. Take the live ring off completely.p. 571
+Fig. 19p. 571
Fig. 19p. 571
+Tighten the outer socket head cap screws first, then lubricate the live ring. During the lubrication process keep turning the live ring and lubricate until the grease emerges from the sealing lip.p. 571
Tighten the outer socket head cap screws first, then lubricate the live ring. During the lubrication process keep turning the live ring and lubricate until the grease emerges from the sealing lip.p. 571
+34. Align and fasten the live ring accordinglyp. 571
+34. Align and fasten the live ring accordinglyp. 571
(Fig. 19)p. 571
+Cover the threads with copper paste OKS 240.p. 571
Cover the threads with copper paste OKS 240.p. 571
Tightening torque: 463 Nm.p. 571
+35. Extract the oscillating articulated joint completely.p. 571
35. Extract the oscillating articulated joint completely.p. 571
+36. Replace screws and sleeves.p. 571
36. Replace screws and sleeves.p. 571
+37. Use a sleeve for each screw.p. 571
37. Use a sleeve for each screw.p. 571
Repairing the oscillating articulated joint
Fig. 1p. 572
+1 Self-aligning bearingp. 573
+1 Self-aligning bearingp. 573
1 Self-aligning bearingp. 573
2 Central blockp. 573
3 Consolep. 573
4 Taper roller bearingp. 573
5 Dirt scraperp. 573
6 Hexagon screwp. 573
7 Hexagon screwp. 573
8 Roll pinp. 573
+9 Snap ringp. 573
+9 Snap ringp. 573
9 Snap ringp. 573
10 Seal ringp. 573
11 Boltp. 573
12 Sleevep. 573
13 Coverp. 573
14 Flanged coverp. 573
15 Washerp. 573
+1. Store the disassembled oscillating articulated joint safely.p. 573
1. Store the disassembled oscillating articulated joint safely.p. 573
+Danger of squashing!p. 573
Danger of squashing!p. 573
+2. Unscrew the hexagon screw 6p. 573
+2. Unscrew the hexagon screw 6p. 573
(Fig. 1)p. 573
+3. Take off cover (13) and disc (15).p. 573
3. Take off cover (13) and disc (15).p. 573
+Insert roll pin (8) into the bore of the disc.p. 573
Insert roll pin (8) into the bore of the disc.p. 573
+4. Attach the lifting tackle to the console (3).p. 573
4. Attach the lifting tackle to the console (3).p. 573
+Danger of squashing!p. 573
Danger of squashing!p. 573
+5. Drive bolt (11) with a mandrel.p. 573
5. Drive bolt (11) with a mandrel.p. 573
+Grease the bolt.p. 573
Grease the bolt.p. 573
+6. Knock sleeves (12) out of the console.p. 573
6. Knock sleeves (12) out of the console.p. 573
+7. Unscrew hexagon screws (6) from the flanged cover (14).p. 573
7. Unscrew hexagon screws (6) from the flanged cover (14).p. 573
+8. Take off the flanged cover (14).p. 573
8. Take off the flanged cover (14).p. 573
+9. Remove the dirt scraper (5).p. 573
9. Remove the dirt scraper (5).p. 573
+Assemble the new dirt scraper with grease.p. 573
Assemble the new dirt scraper with grease.p. 573
+10. Take out the snap ring (9)..p. 573
10. Take out the snap ring (9)..p. 573
+11. Knock out taper roller bearing (4), take out inner dirt scrapers (5).p. 573
11. Knock out taper roller bearing (4), take out inner dirt scrapers (5).p. 573
+Assemble the new dirt scraper with grease. Use new taper roller bearings.p. 573
Assemble the new dirt scraper with grease. Use new taper roller bearings.p. 573
+12. Check the pivot bearings (1) for the steering cylinders, if necessary assemble new ones.p. 573
12. Check the pivot bearings (1) for the steering cylinders, if necessary assemble new ones.p. 573
17.3 Removing and installing the steering cylindersp. 574
+Securing the machinep. 574
Securing the machinep. 574
+Fig. 1p. 574
Fig. 1p. 574
+1. Drive the machine on a level base of sufficient load bearing capacity.p. 574
1. Drive the machine on a level base of sufficient load bearing capacity.p. 574
+2. Swing the articulation lock 1p. 574
+2. Swing the articulation lock 1p. 574
(Fig. 1)p. 574
+Fig. 2p. 574
Fig. 2p. 574
+3. Push the lever for dozer blade controlp. 574
+3. Push the lever for dozer blade controlp. 574
(Fig. 2)p. 574
+Fig. 3p. 574
Fig. 3p. 574
+4. …. and rest it on the groundp. 574
+4. …. and rest it on the groundp. 574
(Fig. 3)p. 574
+Fig. 4p. 575
Fig. 4p. 575
+5. Press button "a"p. 575
+5. Press button "a"p. 575
(Fig. 4)p. 575
+6. Shift the dozer blade control lever to float position "I".p. 575
6. Shift the dozer blade control lever to float position "I".p. 575
+7. Shut down the engine.p. 575
7. Shut down the engine.p. 575
+Adjust the electric end position dampingp. 575
Removing the steering cylindersp. 575
+Fig. 1p. 575
Fig. 1p. 575
+1. Open the rear access doorp. 575
+1. Open the rear access doorp. 575
(Fig. 1)p. 575
+Fig. 2p. 575
Fig. 2p. 575
+2. Remove the plates for the electric end position dampingp. 575
+2. Remove the plates for the electric end position dampingp. 575
(Fig. 2)p. 575
+Fig. 3p. 575
Fig. 3p. 575
+Catch running out hydraulic oil and dispose of environmentally.p. 575
Catch running out hydraulic oil and dispose of environmentally.p. 575
+Before disconnecting any hydraulic connections you must make sure that the engine has been shut down and the system pressure has been relieved.p. 575
Before disconnecting any hydraulic connections you must make sure that the engine has been shut down and the system pressure has been relieved.p. 575
+3. Disconnect the hydraulic hosesp. 575
+3. Disconnect the hydraulic hosesp. 575
(Fig. 3)p. 575
+4. Close connections and hoses with plugs.p. 575
4. Close connections and hoses with plugs.p. 575
+Fig. 4p. 576
Fig. 4p. 576
+5. Disassemble lubrication grease hose 1p. 576
+5. Disassemble lubrication grease hose 1p. 576
(Fig. 4)p. 576
+6. Unscrew the screws (3) and remove the flat steel bar (4).p. 576
6. Unscrew the screws (3) and remove the flat steel bar (4).p. 576
+Danger of squashing!p. 576
Danger of squashing!p. 576
The steering cylinder has a weight of approx. 45 kg.p. 576
+7. Knock out steering bolts (5).p. 576
7. Knock out steering bolts (5).p. 576
+Fig. 5p. 576
Fig. 5p. 576
+Old design lubrication grease hosep. 576
+Old design lubrication grease hosep. 576
(Fig. 5)p. 576
+8. Disassemble lubrication grease hose 1p. 576
+8. Disassemble lubrication grease hose 1p. 576
(Fig. 5)p. 576
+9. Unscrew the screws (3) and remove the flat steel bar (4).p. 576
9. Unscrew the screws (3) and remove the flat steel bar (4).p. 576
+10. Knock out steering bolts (5).p. 576
10. Knock out steering bolts (5).p. 576
+11. Lift the steering cylinders out of the machine and lay them down safely.p. 576
11. Lift the steering cylinders out of the machine and lay them down safely.p. 576
+Fig. 6p. 576
Fig. 6p. 576
+New design lubrication grease hosep. 576
+New design lubrication grease hosep. 576
(Fig. 6)p. 576
+12. Remove the lubrication grease hose 1p. 576
+12. Remove the lubrication grease hose 1p. 576
(Fig. 6)p. 576
+13. Unscrew the screws (3) and remove the flat steel bar (3).p. 576
13. Unscrew the screws (3) and remove the flat steel bar (3).p. 576
+14. Knock out steering bolts (5).p. 576
14. Knock out steering bolts (5).p. 576
+15. Lift the steering cylinders out of the machine and lay them down safely.p. 576
15. Lift the steering cylinders out of the machine and lay them down safely.p. 576
+Adjust the electric end position dampingp. 576
Assembling the steering cylindersp. 576
+Fig. 1p. 576
Fig. 1p. 576
+1. Reassemble in reverse order.p. 576
1. Reassemble in reverse order.p. 576
+2. Check the rocker bearing, replace if necessaryp. 576
+2. Check the rocker bearing, replace if necessaryp. 576
(Fig. 1)p. 576
+The cylinders may be carefully retracted and extended with compressed air or by pressing manually.p. 576
The cylinders may be carefully retracted and extended with compressed air or by pressing manually.p. 576
Assemble the bearing bolt with some greasep. 576
+Adjust the electric end position dampingp. 577
Bleedingp. 577
+Fig. 1p. 577
Fig. 1p. 577
+1. Check the hydraulic oil levelp. 577
+1. Check the hydraulic oil levelp. 577
(Fig. 1)p. 577
+Do not step or stand in the articulation area of the machine when the engine is running.p. 577
Do not step or stand in the articulation area of the machine when the engine is running.p. 577
+Steer the machine several times to right and left with the engine running at idle speed.p. 577
Steer the machine several times to right and left with the engine running at idle speed.p. 577
Due to trapped air hydraulic cylinders may initially perform erratically, but normally vent themselves after a few strokedp. 577
+2. Check hydraulic connections for leaks.p. 577
2. Check hydraulic connections for leaks.p. 577
+3. Check the hydraulic oil level once again.p. 577
3. Check the hydraulic oil level once again.p. 577
+Adjust the electric end position dampingp. 577
Adjust the electric end position dampingp. 577
+Fig. 1p. 577
Fig. 1p. 577
+Steer the machine fully to the left to adjust the right hand initiator.p. 577
Steer the machine fully to the left to adjust the right hand initiator.p. 577
Steer the machine fully to the right to adjust the left hand initiator.p. 577
+1. Turn the initiatorsp. 577
+1. Turn the initiatorsp. 577
(Fig. 1)p. 577
+2. Steer the machine against the end stop.p. 577
2. Steer the machine against the end stop.p. 577
+3. Adjust the space between initiator and contact face to 5mm.p. 577
3. Adjust the space between initiator and contact face to 5mm.p. 577
+4. Tighten the counter nut.p. 577
4. Tighten the counter nut.p. 577
+18 Suppliers documentationp. 579
+18 Suppliers documentationp. 579
18.1 Travel pumpp. 581
18.2 Steering/working pumpp. 683
18.3 Travel motorp. 709
This repair manual describes the fixed displacement motor A6VM, which is identical with the travel motor A6VE, which differs only by a different housing design.p. 710
18.4 Wheel drivep. 763
18.5 Control valve blockp. 823
+19 Circuit diagramsp. 867
19 Circuit diagramsp. 867
S/N Wiring diagram 570 700 35p. 868
+S/N Wiring diagram 570 700 35p. 869
19.1 Hydraulic diagram 571 908 15p. 869
S/N Wiring diagram 570 700 35p. 870
S/N Wiring diagram 570 700 35p. 872
+S/N Wiring diagram 570 700 35p. 873
19.2 Wiring diagram 570 700 35p. 873
S/N Wiring diagram 570 700 35p. 874
+S/N Wiring diagram 570 700 35p. 874
S/N Wiring diagram 570 700 35p. 874
+S/N 101 570 571 001p. 874
Ûp. 874
+S/N 101 570 581 001p. 874
Ûp. 874
+S/N 101 570 591 001p. 874
Ûp. 874
+S/N 101 570 821 001p. 874
Ûp. 874
+S/N 101 570 831 001p. 874
Ûp. 874
+S/N 101 570 921 001p. 874
Ûp. 874
+S/N 101 570 931 001p. 874
Ûp. 874
S/N Wiring diagram 570 700 37p. 875
+S/N Wiring diagram 570 700 37p. 903
19.3 Wiring diagram 570 700 37p. 903
S/N Wiring diagram 570 700 37p. 904
+S/N Wiring diagram 570 700 37p. 904
S/N Wiring diagram 570 700 37p. 904
+S/N 101 570 571 007p. 904
Ûp. 904
+S/N 101 570 581 021p. 904
Ûp. 904
+S/N 101 570 591 007p. 904
Ûp. 904
+S/N 101 570 821 005p. 904
Ûp. 904
+S/N 101 570 831 015p. 904
Ûp. 904
+S/N 101 570 921 002p. 904
Ûp. 904
S/N Wiring diagram 570 700 39p. 905
+S/N Wiring diagram 570 700 39p. 933
19.4 Wiring diagram 570 700 39p. 933
S/N Wiring diagram 570 700 39p. 934
+S/N Wiring diagram 570 700 39p. 934
S/N Wiring diagram 570 700 39p. 934
+S/N 101 570 571 012p. 934
Ûp. 934
+S/N 101 570 581 035p. 934
Ûp. 934
+S/N 101 570 591 009p. 934
Ûp. 934
+S/N 101 570 821 008p. 934
Ûp. 934
+S/N 101 570 831 022p. 934
Ûp. 934
S/N Wiring diagram 570 700 42p. 935
+S/N Wiring diagram 570 700 42p. 963
19.5 Wiring diagram 570 700 42p. 963
S/N Wiring diagram 570 700 42p. 964
+S/N Wiring diagram 570 700 42p. 964
S/N Wiring diagram 570 700 42p. 964
+S/N 101 570 571 026p. 964
Ûp. 964
+S/N 101 570 581 075p. 964
Ûp. 964
+S/N 101 570 591 019p. 964
Ûp. 964
+S/N 101 570 821 026p. 964
Ûp. 964
+S/N 101 570 831 041p. 964
Ûp. 964
S/N Wiring diagram 570 700 44p. 965
+S/N Wiring diagram 570 700 44p. 993
19.6 Wiring diagram 570 700 44p. 993
S/N Wiring diagram 570 700 44p. 994
+S/N Wiring diagram 570 700 44p. 994
S/N Wiring diagram 570 700 44p. 994
+S/N 101 570 571 029p. 994
Ûp. 994
+S/N 101 570 581 130p. 994
Ûp. 994
+S/N 101 570 591 036p. 994
Ûp. 994
+S/N 101 570 821 047p. 994
Ûp. 994
+S/N 101 570 831 060p. 994
Ûp. 994
Why Correct Procedures and Specs Matter on These Machines
Sanitary landfill compactors work in some of the harshest conditions in heavy equipment – abrasive refuse, steep grades and constant impact loading. The BOMAG BC 672 and BC 772 series rely on a hydrostatic travel system with four closed circuits, a load-sensing working hydraulic system and electronic control units that manage engine and machine functions together. Getting a pressure setting wrong on the travel pump, misadjusting the DA-control valve or ignoring a fault code from the EMR3 can quickly lead to overheating, loss of travel power or damage to the travel motors and planetary drives. This manual provides the actual adjustment values, tightening torques, pressure settings and diagnostic sequences that BOMAG specifies – not generic guesses. It also includes the safety regulations and environmental notes that apply when working on fuel, hydraulic and air conditioning systems. For a machine of this size and complexity, having the correct service documentation is the difference between a repair that lasts and a repeat failure.
Instant PDF Delivery
This BOMAG BC 672 RB-2 / BC 772 RB-2 / BC 772 RS-2 / BC 672 EB-2 / BC 772 EB-2 service manual is delivered as a PDF download immediately after purchase. No shipping, no waiting for a physical book. The file opens on any device – laptop, tablet or smartphone – and all pages are printable, so you can take the relevant sections straight to the machine. Whether you are servicing the Deutz engine, tracing a wiring fault with the circuit diagrams, adjusting the travel pump or rebuilding the oscillating articulated joint, the information is in your hands the moment you need it.
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