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Complete BOMAG service manual for BC 462 RB, BC 472 RB, BC 472 RS and BC 462 EB refuse and earth compactors. Covers engine, electrics, hydraulics, air conditioning, central lubrication, articulated joint, compactor wheels and full wiring diagrams. 774 pages, PDF.
This BOMAG BC462 RB BC472 RB RS BC462 EB Compactor Service Manual is the comprehensive workshop reference for the 21 to 25 tonne class refuse and earth compactors. It covers the BC 462 RB refuse compactor with dozer blade, BC 472 RB refuse compactor with dozer blade, BC 472 RS refuse compactor with bucket and BC 462 EB fast running earth compactor. Whether you are servicing a single machine or maintaining a fleet across landfill and earthworks sites, this manual gives you the procedures, specifications and diagnostic information needed to carry out repairs correctly.
File Details
Manual Type: Service Manual
Brand: BOMAG
Models Covered: BC 462 RB, BC 472 RB, BC 472 RS, BC 462 EB
Language: English
Page Count: 774
File Format: PDF
Document Number: 008 917 13
Serial Numbers: S/N 101 930 00 …> through S/N 101 930 07 …> (covering BC 472 RB, BC 472 RS, BC 462 EB and BC 462 RB variants)
Chapters Covered
The BOMAG BC462 RB BC472 RB RS BC462 EB Compactor Service Manual is organised into the following major sections:
IMAGES PREVIEW
General — Introduction, safety regulations, general repair instructions, tightening torques
Earth compactor – refuse compactor — Machine overview and design features
Technical data — Full machine, engine, hydraulic and electrical specifications
Maintenance — General notes, fuels and lubricants, running-in instructions, maintenance table
Electrics — Components, terminal designations, current and voltage, resistance, series/parallel connection, Ohm’s law, metrology, diodes, relays, fuses, Telemeanique switch, plug connectors, Deutsch DT and DTM plugs, inductive proximity switches, batteries, main battery switch, cab electrics, fuses, machine electrics
Engine electrics — EMR3 system components, pin assignment EDC16/EMR3, camshaft and crankshaft speed sensors, rail pressure sensor, fuel pressure sensor, fuel control unit, injector, oil pressure sensor, charge air temperature and pressure sensor, coolant temperature sensor, glow plugs, water in fuel sensor, fuel pre-heating, air filter vacuum switch, coolant level float switch, charge control and rpm meter, flashing code diagnostics, SERDIA and CAN-bus diagnostics, EMR3 fault code list, generator, electric starter
Engine — Diesel engine description TCD 2013 4 and 6 cylinder 2 valves, lubrication oil circuit, coolant circuit, fuel system, Deutz Common Rail (DCR) injection system, exhaust gas recirculation, engine problems, Wastegate charge pressure controller, valve clearance adjustment, engine oil and filter change, water separator service, fuel pre-filter and fuel filter cartridge replacement, coolant level and change, anti-freeze concentration, thermostat, ribbed V-belts, combustion air filter, crankcase ventilation valve, engine mounts, special tools
Air conditioning system — Physical basics, refrigerant R134a, compressor oil, working principle, monitoring devices, component descriptions, compressor oil level, magnetic clutch, inspection and maintenance, service procedures, V-belts, drying and evacuation, emptying, leak test, filling instructions, troubleshooting, steam table for R134a
Central lubrication system — System layout, technical description, control, lubrication process, progressive distributor, lubrication oil pump, checking and filling, faults and causes, fault-cause-remedy, failure of central lubrication system
Hydraulics — Hydraulic circuit, travel pump A4VG110 DA, travel pump A4VG110 HT, axial piston swash plate principle, troubleshooting axial piston pumps, travel circuit, troubleshooting variable displacement axial piston motor, steering and working hydraulics, hydraulic oil level, hydraulic oil fine filter change, hydraulic oil and breather filter change
Oscillating articulated joint — Repair overview, repairing the articulated joint
Compactor wheels and dozer blade — Replacing wheel caps, adjusting scrapers and edge cutter, checking and replacing cutting plates
Suppliers documentation — Steering and working pump, wheel drive, travel motor
As a whole, this BOMAG compactor service manual gives the technician a complete framework for maintaining and repairing the BC 462 RB, BC 472 RB, BC 472 RS and BC 462 EB machines. The engine chapter alone covers the Deutz TCD 2013 L06 2V in enough depth for major overhaul work, including the Common Rail injection system and exhaust gas recirculation. The electrical section provides the EMR3 fault code list and flashing code diagnostics, which is essential for troubleshooting the electronic engine control. The hydraulics chapter covers the A4VG110 travel pumps in both DA and HT configurations, the travel motors, steering and working hydraulics, and the flushing and charge circuits. The air conditioning and central lubrication chapters give full service procedures for these systems. The circuit diagram section includes the hydraulic diagram and five wiring diagram variants, making this manual directly usable for tracing faults in the machine’s electrical and hydraulic systems.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BC462 RB BC472 RB RS BC462 EB Compactor Service Manual” 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. 8
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. 8
+Documentationp. 8
Documentationp. 8
For the BOMAG machines described in this manual the following documentation is additionally available:p. 8
+1 Operating and maintenance instructionsp. 8
1 Operating and maintenance instructionsp. 8
2 Spare parts cataloguep. 8
3 Wiring diagram*p. 8
4 Hydraulic diagram*p. 8
5 Service Informationp. 8
Use only genuine BOMAG spare parts.p. 8
Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.p. 8
This manual is not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins".p. 8
In case of a new release all necessary changes will be included.p. 8
In the course of technical development we reserve the right for technical modifications without prior notification.p. 8
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. 8
+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. 8
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. 8
BOMAG GmbHp. 8
Printed in Germanyp. 8
Copyright by BOMAGp. 8
* The applicable documents valid at the date of printing are part of this manual.p. 8
+Generalp. 9
Safety regulationsp. 9
+Important notesp. 9
Important notesp. 9
+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. 9
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. 9
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 9
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. 9
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. 9
+Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for persons.p. 9
Paragraphs marked like this highlight possible dangers for persons.p. 9
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Observe the regulations for the protection of the environment.p. 9
+Generalp. 9
Generalp. 9
+l For repair and maintenance work move the machine on a firm base and shut it down.p. 9
l For repair and maintenance work move the machine on a firm base and shut it down.p. 9
l Always secure the machine against unintended rolling.p. 9
l Secure the engine reliably against unintentional starting.p. 9
l Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard.p. 9
l Block the articulated joint with the articulation lock.p. 9
l Use protective clothes like hard hat, safety boots and gloves.p. 9
l Keep unauthorized persons away from the machine during repair work.p. 9
l Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.p. 9
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. 9
l Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.p. 9
l Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank.p. 9
l When performing welding work strictly comply with the respective welding instructions.p. 9
+Transport work with cranes and lifting tacklep. 9
Transport work with cranes and lifting tacklep. 9
+Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 9
Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 9
+l Follow the operating instructions of the manufacturer when working with cranes.p. 9
l Follow the operating instructions of the manufacturer when working with cranes.p. 9
l Follow the operating instructions of the operator when working with cranes.p. 9
l Always comply with the applicable accident prevention instructions when working with cranes and lifting tackle.p. 9
+Precautions and codes of conduct for welding workp. 9
Precautions and codes of conduct for welding workp. 9
Welding work must only be carried out by properly trained personnel.p. 9
+Electric shock!p. 9
Electric shock!p. 9
Sparks, fire hazard, burning of skin!p. 9
Infrared or ultraviolet radiation (arc), flashing of eyes!p. 9
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. 9
+l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 9
l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 9
l Ensure good conductivity between ground cable and workpiece, avoid joints and bearings.p. 9
l Start the extraction fan before starting work and guide with the progressing work as required.p. 10
l Always isolate the burner when laying it down (remove possible electrode residues).p. 10
l Protect cables from being damaged, use cables with insulated couplings.p. 10
l Ensure sufficient fire protection, keep a fire extinguisher at hand.p. 10
l Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission.p. 10
l Remove any combustible materials from the welding area or cover such items appropriately.p. 10
l Name a fire watch during and after welding work.p. 10
l Place welding rod holders and inert gas welding guns only on properly insulated bases.p. 10
l Place the inert gas bottles in a safe place and secure them against falling over.p. 10
l Use a protective screen or hand shield with welding filter, wear welding gloves and clothes.p. 10
l Switch the welding unit off before connecting welding cables.p. 10
l Check electrode holders and electric cables at regular intervals.p. 10
Behaviour in case of faultsp. 10
+l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 10
l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 10
l In case of failure of the extraction system switch the system off and have it repaired by expert personnel.p. 10
Maintenance; waste disposalp. 10
+l Replace damaged insulating jaws and welding rod holders immediately.p. 10
l Replace damaged insulating jaws and welding rod holders immediately.p. 10
l Replace the welding wire reels only in de-energized state.p. 10
What to do in case of accidents; First Aidp. 10
+l Keep calm.p. 10
l Keep calm.p. 10
l Call first air helpers.p. 10
l Report the accident.p. 10
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. 10
+Operation of high-voltage systemsp. 10
Operation of high-voltage systemsp. 10
+The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here.p. 10
The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here.p. 10
+The high-voltage system must only be operated and serviced by qualified and authorized personnel.p. 10
The high-voltage system must only be operated and serviced by qualified and authorized personnel.p. 10
Before starting operation the operator must check the proper condition of the system.p. 10
+Possibility of injury or even death caused by electric shock:p. 10
Possibility of injury or even death caused by electric shock:p. 10
+l if persons come into contact with live parts,p. 10
+l if persons come into contact with live parts,p. 10
l if persons come into contact with live parts,p. 10
+l in case of faulty insulation of live parts,p. 10
l in case of faulty insulation of live parts,p. 10
+l inadequate, unsuitable insulation,p. 10
l inadequate, unsuitable insulation,p. 10
+l if melted parts flake off in case of short circuits.p. 10
l if melted parts flake off in case of short circuits.p. 10
+Old oilsp. 10
Old oilsp. 10
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. 10
+l Wear protective clothes and safety gloves, if possible.p. 10
l Wear protective clothes and safety gloves, if possible.p. 10
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. 10
l Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately.p. 10
l Apply protective cream before starting work, so that oil can be easier removed from the skin.p. 10
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. 10
l Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin.p. 10
l Do not put oil soaked cloths into your pockets.p. 10
l Avoid clothes getting soiled by oil.p. 10
l Overalls must be washed at regular intervals. Dispose of non-washable clothes environmentally.p. 10
l If possible degrease components before handling.p. 10
+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. 11
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. 11
+Hydraulicsp. 11
Hydraulicsp. 11
+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. 11
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. 11
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. 11
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. 11
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. 11
Reattach all guards and safety installations after all work has been completed.p. 11
+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. 11
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. 11
+Fuelsp. 11
Fuelsp. 11
+Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Follow the valid accident prevention instructions when handling fuels.p. 11
The following notes refer to general safety precautions for danger free handling of fuel.p. 11
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. 11
+l Fire extinguishers charged with FOAM, COp. 11
+l Fire extinguishers charged with FOAM, COp. 11
2p. 11
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. 11
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. 11
+Hot fuelsp. 11
Hot fuelsp. 11
Please apply the following measures before draining of fuel to prepare for repair work:p. 11
+l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 11
l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 11
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. 11
+Synthetic rubberp. 11
Synthetic rubberp. 11
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. 11
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. 11
+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. 11
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. 11
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. 11
+Poisonous substancesp. 11
Poisonous substancesp. 11
Some of the fluids and substances used are toxic and must under no circumstances be consumed.p. 11
Skin contact, especially with open wounds, must be avoided.p. 11
These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, fuels, washing additives, refrigerants, lubricants and various bonding agents.p. 11
+Enginep. 12
Enginep. 12
+Do not work on the fuel system while the engine is running. (Danger to life!)p. 12
Do not work on the fuel system while the engine is running. (Danger to life!)p. 12
Once the engine has stopped wait approx. 5 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!)p. 12
Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!)p. 12
When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!)p. 12
+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. 12
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. 12
l Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/- 0105 Electric precautions against dangerous contact voltages).p. 12
l Cover all electric components properly before wet cleaning.p. 12
+Air conditioning systemp. 12
Air conditioning systemp. 12
+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. 12
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. 12
+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. 12
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. 12
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. 12
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. 12
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. 12
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. 12
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. 12
+Handling pressure vesselsp. 12
Handling pressure vesselsp. 12
+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. 12
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. 12
l Secure pressure vessels against tipping over or rolling away.p. 12
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. 12
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. 12
l Do not heat up refrigerant bottles with an open flame. Excessive temperatures can damage the material and cause the decomposition of refrigerant.p. 12
l Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures.p. 12
+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. 12
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. 12
+Batteryp. 13
Batteryp. 13
+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. 13
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. 13
l Work only well ventilated rooms (formation of oxyhydrogen gas).p. 13
l Do not lean over the battery while it is under load, being charged or tested (danger of explosion).p. 13
l Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the batteryp. 13
l Use battery chargers etc. only in strict compliance with the operating instructions.p. 13
l After an accident with acid flush the skin with a sufficient amount of water and seek medical advice.p. 13
l Do not allow children access to batteries.p. 13
l When mixing battery fluid always pour acid into water, never vice-versa.p. 13
+Special safety regulationsp. 13
Special safety regulationsp. 13
+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. 13
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. 13
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. 13
l Unauthorized changes to the machine are prohibited for safety reasons.p. 13
l Do not perform any cleaning work while the engine is running.p. 13
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. 13
l If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!).p. 13
l Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous!p. 13
l Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.p. 13
l Always ensure an adequate supply of fresh air when refuelling in closed rooms.p. 13
l Dispose of used filters in accordance with applicable environmental regulations.p. 13
l When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations.p. 13
l Do not heat up oils higher than 160 °C because they may ignite.p. 13
l Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations.p. 13
l Dispose of old batteries according to applicable environmental regulations.p. 13
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. 13
l Do not exceed the max. permissible tire pressure.p. 13
+The values specified in the table apply for screws:p. 14
General repair instructionsp. 14
+Generalp. 14
Generalp. 14
+l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 14
l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 14
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. 14
+The values specified in the table apply for screws:p. 14
Electricsp. 14
+Generalp. 14
Generalp. 14
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. 14
Diagnostics according to planp. 14
Well structured trouble shooting procedures can save time and money.p. 14
Random tests have revealed that purely electronic components or control units only very rarely are the actual cause of failures:p. 14
+l In approx. 10 % of the examined cases the problems were caused by control units.p. 14
l In approx. 10 % of the examined cases the problems were caused by control units.p. 14
l In approx. 15 % sensors and actuators were the cause of the problems.p. 14
By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.).p. 14
General:p. 14
+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. 14
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. 14
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. 14
l Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately.p. 14
l Do not disconnect or connect battery or generator while the engine is running.p. 14
l Do not operate the main battery switch under load.p. 14
l Do not use jump leads after the battery has been removed.p. 14
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. 14
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. 14
l Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!p. 14
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. 15
l Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions.p. 15
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. 15
+Electrics and weldingp. 15
Electrics and weldingp. 15
+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. 15
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. 15
+l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 15
l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 15
l Isolate the generator and all control units from the electric circuit.p. 15
l Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.p. 15
l When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings.p. 15
+The values specified in the table apply for screws:p. 15
Batteryp. 15
Rules for the handling of batteriesp. 15
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. 15
Fasten the terminal clamps with a little force as possible.p. 15
Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related development of heat.p. 15
Make sure the battery is properly fastened in the vehicle.p. 15
+The values specified in the table apply for screws:p. 16
Generatorp. 16
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. 16
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. 16
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. 16
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. 16
Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle.p. 16
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. 16
+The values specified in the table apply for screws:p. 16
Starter motorp. 16
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. 16
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. 16
Starter motors must not be cleaned with high pressure steam cleaning equipment.p. 16
The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection).p. 16
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. 16
Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.p. 16
+The values specified in the table apply for screws:p. 17
Hydraulic systemp. 17
+Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 17
Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 17
+Please notep. 17
Please notep. 17
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 17
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 17
+l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 17
l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 17
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 17
l During repair work keep all openings closed with clean plastic plugs and caps.p. 17
l Never run pumps, motors and engines without oil or hydraulic oil.p. 17
l When cleaning hydraulic components take care not to damage any fine machine surfaces.p. 17
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. 17
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. 17
l Avoid the formation of rust on fine machined caused by hand sweat.p. 17
l Use new O-rings or seal rings for reassembly.p. 17
l Use only hydraulic oil as sliding agent when reassembling. Do not use any grease!p. 17
l Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.p. 17
l Check the hydraulic oil level before and after the work.p. 17
l Fill in only clean oil as specified in the maintenance instructions.p. 17
l Check the hydraulic system for leaks, if necessary find and rectify the cause.p. 17
l Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions.p. 17
l After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system.p. 17
l Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).p. 17
l After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.p. 17
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. 17
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. 17
+Before commissioningp. 17
Before commissioningp. 17
+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. 17
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. 17
l After changing a component flush the hydraulic system as described in the flushing instructions.p. 17
+Taking into operationp. 17
Taking into operationp. 17
+l Bleed the hydraulic circuits.p. 17
l Bleed the hydraulic circuits.p. 17
l Start up the hydraulic system without load.p. 17
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. 17
+After taking into operationp. 17
After taking into operationp. 17
+l Check fittings and flanges for leaks.p. 17
l Check fittings and flanges for leaks.p. 17
l After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary.p. 17
l Do not adjust pressure relief valves and control valves to values above their specified values.p. 17
+The values specified in the table apply for screws:p. 18
Air conditioning systemp. 18
+Chemicals/ozone layer regulationp. 18
Chemicals/ozone layer regulationp. 18
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. 18
Work on air conditioning systems must only be carried out by persons who:p. 18
+l have proven to have sufficient expert knowledge,p. 18
l have proven to have sufficient expert knowledge,p. 18
l have the necessary equipment to undertake such tasks,p. 18
l are reliable andp. 18
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. 18
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. 18
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 18
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 18
+l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 18
l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 18
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. 18
l Connections, screw fittings and their immediate surrounding areas must be cleaned before removal.p. 18
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 18
l During repair work keep all openings closed with clean plastic plugs and caps.p. 18
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. 18
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. 18
l Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but must generally be replaced.p. 18
l Do not fill up refrigerant, but extract existing refrigerant and refill the system.p. 18
l Different types of refrigerant must not be mixed. Only the refrigerant specified for the corresponding air conditioning system must be used.p. 18
l Refrigerant circuits with refrigerant type R134a must only be operated with the compressor oil / refrigeration oil approved for the compressor.p. 18
l Used compressor oil/refrigeration oil must be disposed of in strict compliance with applicable environmental regulations.p. 18
l Due to its chemical properties compressor oil / refrigeration oil must never be disposed of together with engine or transmission oil.p. 18
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. 18
l All O-rings/seal rings as well as pipe/ hose fittings must be oiled with compressor/refrigeration oil bfore assembly.p. 18
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. 18
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. 18
l Use new O-rings or seal rings for reassembly.p. 18
l Always used 2 spanners to work on pipes/hoses to avoid damages .p. 18
l Tighten screw fittings with the specified torque.p. 18
l Check all pipes/hoses, screw fittings or components for damage, replace if necessary.p. 18
l Do not leave the refrigerant circuit unnecessarily open to the atmosphere.p. 18
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. 18
l Compressor valves must only be opened after the system has been properly sealed.p. 18
l The use of leak detection spray is not permitted. If such substances are used the WARRANTY will become null and void.p. 18
l If the air conditioning system had been opened for repair work, a new drier should be installed in the refrigerant circuit.p. 19
l After completion of repair work screw locking caps (with seals) on all valve connections service connections.p. 19
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. 19
l Never run the compressor with an insufficient amount of refrigerant.p. 19
+The values specified in the table apply for screws:p. 19
Notes on cleanliness for Common Rail enginesp. 19
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. 19
Fig. 1p. 19
+l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 19
l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 19
+l When parts are unpacked any connections must be closed with suitable plugs or caps, in order to preventp. 19
(Fig. 1)p. 19
+Notes and measures to be applied before starting work in the fuel systemp. 19
Notes and measures to be applied before starting work in the fuel systemp. 19
+l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 19
l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 19
l Before starting work in the fuel system clean the complete engine and the engine compartment with the system still closed.p. 19
l The engine should be dry before work is started in the fuel system.p. 19
l Blow drying with compressed air is only permitted while the fuel system is still closed.p. 20
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. 20
l Electrical plug connections must be plugged in during jet cleaning.p. 20
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. 20
l Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 20
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. 20
l Air movements, which could swirl up dust, such as brake repairs or starting of engines, must be strictly avoided.p. 20
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. 20
l No general machine tools should be operated in this room.p. 20
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 20
l Engine compartment area where dirt particles could come loose, should be covered with new, clean foil.p. 20
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. 20
+Notes and measures to be applied during work in the fuel systemp. 20
Notes and measures to be applied during work in the fuel systemp. 20
+l Wear clean working clothes.p. 20
l Wear clean working clothes.p. 20
l Use only lint-free cleaning cloths for work in the fuel system.p. 20
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. 20
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. 20
l Do not use any previously used cleaning or testing fluids for cleaning.p. 20
l Compressed air should never be used for cleaning when the fuel system is open.p. 20
l Work on disassembled components must only be carried out at a specially furnished work place.p. 20
l When disassembling or assembling components you should not use any materials from which particles or fibres could flake off (cardboard, wood, towels).p. 20
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. 20
l Close openings on components and engine immediately with suitable plugs/caps.p. 20
l Plugs/caps must only be removed just before the installation.p. 20
l Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use.p. 20
l Take new parts out of their original packaging just before installation.p. 20
l Disassembled components must be stored in new, sealable bags or – if available – in the packaging material of the new components.p. 20
l Always use the original packaging material of the new part to return the disassembled old component.p. 20
+Notes and measures concerning the workshop areap. 20
Notes and measures concerning the workshop areap. 20
+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. 20
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. 20
l The workshop floor must be sealed or tiled.p. 20
l No welding equipment, grinding machines, general machine tools, brake or power test benches must be operated in this room.p. 20
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 20
+Notes and measures for work place and tools in the workshopp. 20
Notes and measures for work place and tools in the workshopp. 20
+l A special work place must be set up for work on disassembled components.p. 20
l A special work place must be set up for work on disassembled components.p. 20
l Clean disassembly and assembly tools at regular intervals and keep these in a closed tool cabinet.p. 20
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. 21
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. 21
+The values specified in the table apply for screws:p. 21
Fuel hosesp. 21
Fig. 2p. 21
+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. 21
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. 21
+The values specified in the table apply for screws:p. 22
Gaskets and mating surfacesp. 22
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 22
+l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 22
l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 22
l Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 22
l Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 22
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. 22
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. 22
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. 22
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. 22
Assembly of radial sealsp. 22
Fig. 3p. 22
+l Lubricate the sealing lips (2)p. 22
+l Lubricate the sealing lips (2)p. 22
(Fig. 3)p. 22
l Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 22
+If possible, use an assembly sleeve (1p. 22
+If possible, use an assembly sleeve (1p. 22
(Fig. 3)p. 22
to protect the lip from being damaged by sharp edges, threads or splines.p. 22
+l Lubricate the outer rim (arrow 3p. 22
+l Lubricate the outer rim (arrow 3p. 22
(Fig. 3)p. 22
Fig. 4p. 22
+l Press or knock the seal into the housing, until it is flush with the housing surface.p. 22
l Press or knock the seal into the housing, until it is flush with the housing surface.p. 22
+If possible, use a "bell" (1p. 22
+If possible, use a "bell" (1p. 22
(Fig. 4)p. 22
that the seal will not skew.p. 22
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. 22
+The values specified in the table apply for screws:p. 23
Feather keys and keywaysp. 23
+Feather keys may only be reused if they are free of damage.p. 23
Feather keys may only be reused if they are free of damage.p. 23
Fig. 5p. 23
+l Clean and thoroughly examine the feather key.p. 23
l Clean and thoroughly examine the feather key.p. 23
l Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 23
+The values specified in the table apply for screws:p. 23
Ball and roller bearingsp. 23
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 23
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 23
Fig. 6p. 23
+l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 23
l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 23
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. 23
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. 23
l Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 23
l Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 23
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. 23
l Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 24
l Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 24
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. 24
Fig. 7p. 24
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 24
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 24
(Fig. 7)p. 24
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 24
+The values specified in the table apply for screws:p. 24
Screws and nutsp. 24
Tightening torquep. 24
+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. 24
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. 24
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. 24
Self-locking nuts must generally be replaced after disassembly.p. 24
The use of screws with too high strength can cause damage!p. 24
+l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 24
l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 24
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. 24
+l Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 24
The same applies for self-locking nuts.p. 24
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. 24
Strength classes, metric screwsp. 25
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. 25
Fig. 8 Identification of screwsp. 25
Example: A screw is identified with 12.9.p. 25
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 25
2p. 25
+l The nominal tensile strength is 12 X 100 N/mmp. 25
+l The nominal tensile strength is 12 X 100 N/mmp. 25
2p. 25
2p. 25
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 25
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 25
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 25
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 25
+l The lower tensile strength is 9/10 X 1200 N/mmp. 25
+l The lower tensile strength is 9/10 X 1200 N/mmp. 25
2p. 25
2p. 25
+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. 25
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. 25
Strength classes of metric nutsp. 25
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. 25
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 25
Fig. 9 Identification of nutsp. 25
+In a connection with a screw, these nuts 1p. 25
(Fig. 9)p. 25
Nut height above 0.8 d (d = nominal dimension).p. 25
+Strength class of nutp. 25
Strength class of nutp. 25
+Strength class of associated screwp. 25
Strength class of associated screwp. 25
+4p. 25
4p. 25
+3.6, 4.6, 4.8p. 25
3.6, 4.6, 4.8p. 25
+5p. 25
5p. 25
+3.6, 4.6, 4.8p. 25
3.6, 4.6, 4.8p. 25
5.6, 5.8p. 25
+6p. 25
6p. 25
+6.8p. 25
6.8p. 25
+8p. 25
8p. 25
+8.8p. 25
8.8p. 25
+9p. 25
9p. 25
+9.8p. 25
9.8p. 25
+10p. 25
10p. 25
+10.8p. 25
10.8p. 25
+12p. 25
12p. 25
+12.8p. 25
12.8p. 25
Nuts for screw joints with limited load factor (04, 05)p. 25
+The preceding "0" indicates that, due to their low height, nuts 2p. 25
(Fig. 9)p. 25
Nut height below 0,8 d (d = nominal dimension).p. 25
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 25
+This standard contains strength classes (hardness classes) for nuts 3p. 25
(Fig. 9)p. 25
Nut height below 0,5 d (d = nominal dimension).p. 25
Identification in clock systemp. 26
Fig. 10 Identification of nuts in clock systemp. 26
+For small nutsp. 26
(Fig. 10)p. 26
+l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 26
l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 26
l The strength class is identified by a dash (b).p. 26
Identification of UNF-threadsp. 26
Fig. 11p. 26
Screwsp. 26
+The screw head is marked with a stamped in, round cavity 3p. 26
(Fig. 11)p. 26
Nutsp. 26
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 26
Studs and brake rodsp. 26
At the outmost end a short end of the component is reduced to its core diameter (1).p. 26
Cotter pinsp. 27
Fig. 12p. 27
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 27
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 27
+The values specified in the table apply for screws:p. 28
Tightening torquesp. 28
+The values specified in the table apply for screws:p. 28
The values specified in the table apply for screws:p. 28
+l black oiledp. 28
l black oiledp. 28
l with surface protection A4Cp. 28
l with surface protection DACROMETp. 28
+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. 28
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. 28
+Tightening torques for screws with metric unified threadp. 28
+Tightening torques for screws with metric unified threadp. 28
+Tightening torques for screws with metric unified threadp. 28
+Coefficient of friction m tot. = 0,14p. 28
mp. 28
+Screw dimensionp. 28
Screw dimensionp. 28
+Tightening torques Nmp. 28
Tightening torques Nmp. 28
+8.8p. 28
8.8p. 28
+10.9p. 28
10.9p. 28
+12.9p. 28
12.9p. 28
+M4p. 28
M4p. 28
+3p. 28
3p. 28
+5p. 28
5p. 28
+5p. 28
5p. 28
+M5p. 28
M5p. 28
+6p. 28
6p. 28
+9p. 28
9p. 28
+10p. 28
10p. 28
+M6p. 28
M6p. 28
+10p. 28
10p. 28
+15p. 28
15p. 28
+18p. 28
18p. 28
+M8p. 28
M8p. 28
+25p. 28
25p. 28
+35p. 28
35p. 28
+45p. 28
45p. 28
+M10p. 28
M10p. 28
+50p. 28
50p. 28
+75p. 28
75p. 28
+83p. 28
83p. 28
+M12p. 28
M12p. 28
+88p. 28
88p. 28
+123p. 28
123p. 28
+147p. 28
147p. 28
+M14p. 28
M14p. 28
+137p. 28
137p. 28
+196p. 28
196p. 28
+235p. 28
235p. 28
+M16p. 28
M16p. 28
+211p. 28
211p. 28
+300p. 28
300p. 28
+358p. 28
358p. 28
+M18p. 28
M18p. 28
+290p. 28
290p. 28
+412p. 28
412p. 28
+490p. 28
490p. 28
+M20p. 28
M20p. 28
+412p. 28
412p. 28
+578p. 28
578p. 28
+696p. 28
696p. 28
+M22p. 28
M22p. 28
+560p. 28
560p. 28
+785p. 28
785p. 28
+942p. 28
942p. 28
+M24p. 28
M24p. 28
+711p. 28
711p. 28
+1000p. 28
1000p. 28
+1200p. 28
1200p. 28
+M27p. 28
M27p. 28
+1050p. 28
1050p. 28
+1480p. 28
1480p. 28
+1774p. 28
1774p. 28
+M30p. 28
M30p. 28
+1420p. 28
1420p. 28
+2010p. 28
2010p. 28
+2400p. 28
2400p. 28
+Tightening torques for screws with metric unified fine threadp. 28
+Tightening torques for screws with metric unified fine threadp. 28
+Tightening torques for screws with metric unified fine threadp. 28
+Coefficient of friction m tot. = 0,14p. 28
mp. 28
+Screw dimensionp. 28
Screw dimensionp. 28
+Tightening torques Nmp. 28
Tightening torques Nmp. 28
+8.8p. 28
8.8p. 28
+10.9p. 28
10.9p. 28
+12.9p. 28
12.9p. 28
+M8 x 1p. 28
M8 x 1p. 28
+26p. 28
26p. 28
+37p. 28
37p. 28
+48p. 28
48p. 28
+M10 x 1.25p. 28
M10 x 1.25p. 28
+52p. 28
52p. 28
+76p. 28
76p. 28
+88p. 28
88p. 28
+M12 x 1,25p. 28
M12 x 1,25p. 28
+98p. 28
98p. 28
+137p. 28
137p. 28
+126p. 28
126p. 28
+M12 x 1.5p. 28
M12 x 1.5p. 28
+93p. 28
93p. 28
+127p. 28
127p. 28
+152p. 28
152p. 28
+M14 x 1.5p. 28
M14 x 1.5p. 28
+152p. 28
152p. 28
+216p. 28
216p. 28
+255p. 28
255p. 28
+M16 x 1.5p. 28
M16 x 1.5p. 28
+225p. 28
225p. 28
+318p. 28
318p. 28
+383p. 28
383p. 28
+M18 x 1.5p. 28
M18 x 1.5p. 28
+324p. 28
324p. 28
+466p. 28
466p. 28
+554p. 28
554p. 28
+M20 x 1.5p. 28
M20 x 1.5p. 28
+461p. 28
461p. 28
+628p. 28
628p. 28
+775p. 28
775p. 28
+M22 x 1.5p. 28
M22 x 1.5p. 28
+618p. 28
618p. 28
+863p. 28
863p. 28
+1058p. 28
1058p. 28
+M24 x 2p. 28
M24 x 2p. 28
+780p. 28
780p. 28
+1098p. 28
1098p. 28
+1294p. 28
1294p. 28
+M27 x2p. 28
M27 x2p. 28
+1147p. 28
1147p. 28
+1578p. 28
1578p. 28
+1920p. 28
1920p. 28
+M30 x 2p. 28
M30 x 2p. 28
+1568p. 28
1568p. 28
+2254p. 28
2254p. 28
+2695p. 28
2695p. 28
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 29
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 29
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 29
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. 29
+Screw dimensionp. 29
Screw dimensionp. 29
+Tightening torques Nmp. 29
Tightening torques Nmp. 29
+8.8p. 29
8.8p. 29
+10.9p. 29
10.9p. 29
+12.9p. 29
12.9p. 29
+M16p. 29
M16p. 29
+169p. 29
169p. 29
+240p. 29
240p. 29
+287p. 29
287p. 29
+M16 x 1.5p. 29
M16 x 1.5p. 29
+180p. 29
180p. 29
+255p. 29
255p. 29
+307p. 29
307p. 29
+M18p. 29
M18p. 29
+232p. 29
232p. 29
+330p. 29
330p. 29
+392p. 29
392p. 29
+M18 x 1.5p. 29
M18 x 1.5p. 29
+260p. 29
260p. 29
+373p. 29
373p. 29
+444p. 29
444p. 29
+M20p. 29
M20p. 29
+330p. 29
330p. 29
+463p. 29
463p. 29
+557p. 29
557p. 29
+M20 x 1.5p. 29
M20 x 1.5p. 29
+369p. 29
369p. 29
+502p. 29
502p. 29
+620p. 29
620p. 29
+M22p. 29
M22p. 29
+448p. 29
448p. 29
+628p. 29
628p. 29
+754p. 29
754p. 29
+M22 x 1.5p. 29
M22 x 1.5p. 29
+495p. 29
495p. 29
+691p. 29
691p. 29
+847p. 29
847p. 29
+M24p. 29
M24p. 29
+569p. 29
569p. 29
+800p. 29
800p. 29
+960p. 29
960p. 29
+M24 x 2p. 29
M24 x 2p. 29
+624p. 29
624p. 29
+879p. 29
879p. 29
+1036p. 29
1036p. 29
+M27p. 29
M27p. 29
+840p. 29
840p. 29
+1184p. 29
1184p. 29
+1520p. 29
1520p. 29
+M27 X 2p. 29
M27 X 2p. 29
+918p. 29
918p. 29
+1263p. 29
1263p. 29
+1536p. 29
1536p. 29
+M30p. 29
M30p. 29
+1136p. 29
1136p. 29
+1608p. 29
1608p. 29
+1920p. 29
1920p. 29
+M30 x 2p. 29
M30 x 2p. 29
+1255p. 29
1255p. 29
+1804p. 29
1804p. 29
+2156p. 29
2156p. 29
+3/4“ – 10 UNCp. 29
3/4“ – 10 UNCp. 29
+276p. 29
276p. 29
+388p. 29
388p. 29
+464p. 29
464p. 29
+3/4“ – 16 UNCp. 29
3/4“ – 16 UNCp. 29
+308p. 29
308p. 29
+432p. 29
432p. 29
+520p. 29
520p. 29
+Tightening torques for wheel nuts (fine thread)p. 29
+Tightening torques for wheel nuts (fine thread)p. 29
+Tightening torques for wheel nuts (fine thread)p. 29
+Coefficient of friction m tot. = 0,14p. 29
mp. 29
These values result in a 90% utilization of the yield pointp. 29
+Thread diameterp. 29
Thread diameterp. 29
+Tightening torques Nmp. 29
Tightening torques Nmp. 29
+10.9p. 29
10.9p. 29
+M12x1.5p. 29
M12x1.5p. 29
+100p. 29
100p. 29
+M14x1.5p. 29
M14x1.5p. 29
+150p. 29
150p. 29
+M18x1.5p. 29
M18x1.5p. 29
+300 – 350p. 29
300 – 350p. 29
+M20x1.5p. 29
M20x1.5p. 29
+400 – 500p. 29
400 – 500p. 29
+M22x1.5p. 29
M22x1.5p. 29
+500 – 600p. 29
500 – 600p. 29
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
+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. 30
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. 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 UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 30
+Tightening torques for screws with UNC thread,p. 30
+Tightening torques for screws with UNC thread,p. 30
+Coefficient of friction m tot. = 0,14p. 30
mp. 30
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 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
+1/4“ – 20p. 30
1/4“ – 20p. 30
+11p. 30
11p. 30
+15p. 30
15p. 30
+19p. 30
19p. 30
+5/16“ – 18p. 30
5/16“ – 18p. 30
+23p. 30
23p. 30
+32p. 30
32p. 30
+39p. 30
39p. 30
+3/8“ – 16p. 30
3/8“ – 16p. 30
+39p. 30
39p. 30
+55p. 30
55p. 30
+66p. 30
66p. 30
+7/16“ – 14p. 30
7/16“ – 14p. 30
+62p. 30
62p. 30
+87p. 30
87p. 30
+105p. 30
105p. 30
+1/2“ – 13p. 30
1/2“ – 13p. 30
+96p. 30
96p. 30
+135p. 30
135p. 30
+160p. 30
160p. 30
+9/16“ – 12p. 30
9/16“ – 12p. 30
+140p. 30
140p. 30
+200p. 30
200p. 30
+235p. 30
235p. 30
+5/8“ – 11p. 30
5/8“ – 11p. 30
+195p. 30
195p. 30
+275p. 30
275p. 30
+330p. 30
330p. 30
+3/4“ – 10p. 30
3/4“ – 10p. 30
+345p. 30
345p. 30
+485p. 30
485p. 30
+580p. 30
580p. 30
+7/8“ – 9p. 30
7/8“ – 9p. 30
+560p. 30
560p. 30
+770p. 30
770p. 30
+940p. 30
940p. 30
+1“ – 8p. 30
1“ – 8p. 30
+850p. 30
850p. 30
+1200p. 30
1200p. 30
+1450p. 30
1450p. 30
+1 1/8“ – 7p. 30
1 1/8“ – 7p. 30
+1200p. 30
1200p. 30
+1700p. 30
1700p. 30
+2000p. 30
2000p. 30
+1 1/4“ – 7p. 30
1 1/4“ – 7p. 30
+1700p. 30
1700p. 30
+2400p. 30
2400p. 30
+2900p. 30
2900p. 30
+1 3/8“ – 6p. 30
1 3/8“ – 6p. 30
+2200p. 30
2200p. 30
+3100p. 30
3100p. 30
+3700p. 30
3700p. 30
+1 1/2“ – 6p. 30
1 1/2“ – 6p. 30
+3000p. 30
3000p. 30
+4200p. 30
4200p. 30
+5100p. 30
5100p. 30
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 30
+Tightening torques for screws with UNF thread,p. 30
+Tightening torques for screws with UNF thread,p. 30
+Coefficient of friction m tot. = 0,14p. 31
mp. 31
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 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
+1/4“ – 28p. 30
1/4“ – 28p. 30
+13p. 30
13p. 30
+18p. 30
18p. 30
+22p. 30
22p. 30
+5/16“ – 24p. 30
5/16“ – 24p. 30
+25p. 30
25p. 30
+35p. 30
35p. 30
+42p. 30
42p. 30
+3/8“ – 24p. 30
3/8“ – 24p. 30
+45p. 30
45p. 30
+63p. 30
63p. 30
+76p. 30
76p. 30
+7/16“ – 20p. 30
7/16“ – 20p. 30
+70p. 30
70p. 30
+100p. 30
100p. 30
+120p. 30
120p. 30
+1/2“ – 20p. 30
1/2“ – 20p. 30
+110p. 30
110p. 30
+155p. 30
155p. 30
+185p. 30
185p. 30
+9/16“ – 18p. 30
9/16“ – 18p. 30
+155p. 30
155p. 30
+220p. 30
220p. 30
+260p. 30
260p. 30
+5/8“ – 18p. 30
5/8“ – 18p. 30
+220p. 30
220p. 30
+310p. 30
310p. 30
+370p. 30
370p. 30
+3/4“ – 16p. 30
3/4“ – 16p. 30
+385p. 30
385p. 30
+540p. 30
540p. 30
+650p. 30
650p. 30
+7/8“ -14p. 30
7/8“ -14p. 30
+620p. 30
620p. 30
+870p. 30
870p. 30
+1050p. 30
1050p. 30
+1“ – 12p. 31
1“ – 12p. 31
+930p. 31
930p. 31
+1300p. 31
1300p. 31
+1600p. 31
1600p. 31
+1 1/8“ – 12p. 31
1 1/8“ – 12p. 31
+1350p. 31
1350p. 31
+1900p. 31
1900p. 31
+2300p. 31
2300p. 31
+1 1/4“ – 12p. 31
1 1/4“ – 12p. 31
+1900p. 31
1900p. 31
+2700p. 31
2700p. 31
+3200p. 31
3200p. 31
+1 3/8“ – 12p. 31
1 3/8“ – 12p. 31
+2600p. 31
2600p. 31
+3700p. 31
3700p. 31
+4400p. 31
4400p. 31
+1 1/2“ – 12p. 31
1 1/2“ – 12p. 31
+3300p. 31
3300p. 31
+4600p. 31
4600p. 31
+5600p. 31
5600p. 31
+2 Earth compactor – refuse compactorp. 33
+2 Earth compactor – refuse compactorp. 33
Refuse compactor – earth compactorp. 34
+21 to 25 tp. 34
21 to 25 tp. 34
+Customized for small landfill sitesp. 34
Customized for small landfill sitesp. 34
All over the world BOMAG refuse compactors of the medium and high weight range as well as the fast running BOMAG earth compactors convince with efficiency abd reliability on large landfill sites and in earth construction. The consequent technical imp…p. 34
The technology that ensures effectiveness and reliability on very large sanitary landfill and construction sites is also of great use on smaller landfill sites and medium size constructions. This is why BOMAG has designed a new, lighter family of mac…p. 34
Four machines – common benefits.No matter whether you choose the fast running earth compactor or one of the three refuse compactor versions, each of these machines incorporates decades of experience of BOMAG and is perfectly adapted to your needs a…p. 34
+l No entry of refuse into frame or engine compartment due to the fully closed belly pan.p. 34
l No entry of refuse into frame or engine compartment due to the fully closed belly pan.p. 34
l Optimal compaction effect and traction due to constant ground contact of the compactor wheels and tension free frame due to the robust oscillating articulated joint designed for highest loads in landfill operation.p. 34
l Various designs of compactor wheels for perfect adaptation to your application.p. 34
l Highest compaction due to the special BOMAG wheel concept with teeth and compacting elements.p. 34
+The perfect combination of application optimized technologyp. 36
The perfect combination of application optimized technologyp. 36
+l Highest possible compaction of soil and refuse as well as traction for all wheel versions, because the wheels are kept clean by the adjustable scraper system.p. 36
l Highest possible compaction of soil and refuse as well as traction for all wheel versions, because the wheels are kept clean by the adjustable scraper system.p. 36
l Modern, powerful turbo diesel engine with 195 kW.p. 36
l Low wear travel system with hydraulic overload protection and 4 hydrostatic wheel motors: no powershift transmission, no axles, no drive shafts.p. 36
l Trouble free operation and long maintenance intervals due to highly effective fine filtration in the hydraulic system.p. 36
l Modern, powerful turbo diesel engine with 195 kW.p. 36
l Comfortable driver's work place with vibration insulated cabin and joystick control for steering and dozer blade or bucket.p. 36
l Excellent access to the daily maintenance points due to the wide opening engine hood.p. 36
l Easy transportation between points of use: The fast running earth compactor and some of the refuse compactors are only 3 m in width – and can therefore be simply transported without special permission.p. 36
+3 Technical datap. 39
3 Technical datap. 39
Technical datap. 40
Fig. 13p. 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
+H4p. 40
+Hp. 40
4p. 40
+Kp. 40
Kp. 40
+Lp. 40
Lp. 40
+BC 462 RBp. 40
BC 462 RBp. 40
+3500p. 40
3500p. 40
+2998p. 40
2998p. 40
+2660p. 40
2660p. 40
+2885p. 40
2885p. 40
+1660p. 40
1660p. 40
+3390p. 40
3390p. 40
+1990p. 40
1990p. 40
+600p. 40
600p. 40
+8290p. 40
8290p. 40
+BC 472 RBp. 40
BC 472 RBp. 40
+3500p. 40
3500p. 40
+3600p. 40
3600p. 40
+2660p. 40
2660p. 40
+3335p. 40
3335p. 40
+1660p. 40
1660p. 40
+3390p. 40
3390p. 40
+1990p. 40
1990p. 40
+600p. 40
600p. 40
+8290p. 40
8290p. 40
+Subject to technical alterations.p. 40
Subject to technical alterations.p. 41
+BC 462 RBp. 40
BC 462 RBp. 40
+BC 472 RBp. 40
BC 472 RBp. 40
+Weightsp. 40
Weightsp. 40
+Operating weight (CECE)p. 40
Operating weight (CECE)p. 40
+kgp. 40
kgp. 40
+21300p. 40
21300p. 40
+24000p. 40
24000p. 40
+Front axle load (CECE)p. 40
Front axle load (CECE)p. 40
+kgp. 40
kgp. 40
+10600p. 40
10600p. 40
+12000p. 40
12000p. 40
+Rear axle load (CECE)p. 40
Rear axle load (CECE)p. 40
+kgp. 40
kgp. 40
+10700p. 40
10700p. 40
+12000p. 40
12000p. 40
+Max. operating weightp. 40
Max. operating weightp. 40
+kgp. 40
kgp. 40
+22500p. 40
22500p. 40
+26000p. 40
26000p. 40
+Dimensionsp. 40
Dimensionsp. 40
+Rear overhangp. 40
Rear overhangp. 40
+mmp. 40
mmp. 40
+1460p. 40
1460p. 40
+1460p. 40
1460p. 40
+Travel characteristicsp. 40
Travel characteristicsp. 40
+Travel speed range I (forward, reverse)p. 40
Travel speed range I (forward, reverse)p. 40
+km/hp. 40
km/hp. 40
+0 – 4.5p. 40
0 – 4.5p. 40
+0 – 4.5p. 40
0 – 4.5p. 40
+Travel speed in speed range II (forward, reverse)p. 40
Travel speed in speed range II (forward, reverse)p. 40
+km/hp. 40
km/hp. 40
+0 – 12p. 40
0 – 12p. 40
+0 – 12p. 40
0 – 12p. 40
+Gradability (soil dependent)p. 40
Gradability (soil dependent)p. 40
+%p. 40
%p. 40
+100p. 40
100p. 40
+100p. 40
100p. 40
+Max. pushing forcep. 40
Max. pushing forcep. 40
+kNp. 40
kNp. 40
+230p. 40
230p. 40
+259p. 40
259p. 40
+Drivep. 40
Drivep. 40
+Engine manufacturerp. 40
Engine manufacturerp. 40
+Deutzp. 40
Deutzp. 40
+Deutzp. 40
Deutzp. 40
+Typep. 40
Typep. 40
+TCD 2013 L06 2Vp. 40
TCD 2013 L06 2Vp. 40
+TCD 2013 L06 2Vp. 40
TCD 2013 L06 2Vp. 40
+Coolingp. 40
Coolingp. 40
+Waterp. 40
Waterp. 40
+Waterp. 40
Waterp. 40
+Number of cylindersp. 40
Number of cylindersp. 40
+6p. 40
6p. 40
+6p. 40
6p. 40
+Rated power ISO 9249p. 40
Rated power ISO 9249p. 40
+kWp. 40
kWp. 40
+190p. 40
190p. 40
+190p. 40
190p. 40
+Rated power acc. to SAE J 1349p. 40
Rated power acc. to SAE J 1349p. 40
+hpp. 40
hpp. 40
+261p. 40
261p. 40
+261p. 40
261p. 40
+Rated speedp. 40
Rated speedp. 40
+rpmp. 40
rpmp. 40
+2300p. 40
2300p. 40
+2300p. 40
2300p. 40
+Drive systemp. 40
Drive systemp. 40
+hydrostaticp. 40
hydrostaticp. 40
+hydrostaticp. 40
hydrostaticp. 40
+Operating voltagep. 40
Operating voltagep. 40
+Vp. 40
Vp. 40
+12p. 40
12p. 40
+12p. 40
12p. 40
+Compactor wheelsp. 40
Compactor wheelsp. 40
+Width (front/rear)p. 40
Width (front/rear)p. 40
+mmp. 40
mmp. 40
+900/900p. 40
900/900p. 40
+1125/900p. 40
1125/900p. 40
+Diameter, outer (front/rear)p. 40
Diameter, outer (front/rear)p. 40
+mmp. 40
mmp. 40
+1660/1660p. 40
1660/1660p. 40
+1660/1660p. 40
1660/1660p. 40
+Number of teeth (front/rear)p. 40
Number of teeth (front/rear)p. 40
+40/40p. 40
40/40p. 40
+50/40p. 40
50/40p. 40
+Compaction width per wheel sidep. 40
Compaction width per wheel sidep. 40
+mmp. 40
mmp. 40
+1013p. 40
1013p. 40
+1238p. 40
1238p. 40
+Brakep. 41
Brakep. 41
+Service brakep. 41
Service brakep. 41
+hydrostaticp. 41
hydrostaticp. 41
+hydrostaticp. 41
hydrostaticp. 41
+Parking brakep. 41
Parking brakep. 41
+mechanicalp. 41
mechanicalp. 41
+mechanicalp. 41
mechanicalp. 41
+Steeringp. 41
Steeringp. 41
+Type of steeringp. 41
Type of steeringp. 41
+Oscill.-articul.p. 41
Oscill.-articul.p. 41
+Oscill.-articul.p. 41
Oscill.-articul.p. 41
+Steering operationp. 41
Steering operationp. 41
+hydraulicp. 41
hydraulicp. 41
+hydraulicp. 41
hydraulicp. 41
+Steering/oscillation anglep. 41
Steering/oscillation anglep. 41
+± °p. 41
± °p. 41
+35/15p. 41
35/15p. 41
+35/15p. 41
35/15p. 41
+Inner track radiusp. 41
Inner track radiusp. 41
+mmp. 41
mmp. 41
+4116p. 41
4116p. 41
+3891p. 41
3891p. 41
+Dozer bladep. 41
Dozer bladep. 41
+Height adjustment above ground levelp. 41
Height adjustment above ground levelp. 41
+mmp. 41
mmp. 41
+1200p. 41
1200p. 41
+1200p. 41
1200p. 41
+Height adjustment below ground levelp. 41
Height adjustment below ground levelp. 41
+mmp. 41
mmp. 41
+120p. 41
120p. 41
+120p. 41
120p. 41
+Filling capacitiesp. 41
Filling capacitiesp. 41
+Fuel (diesel)p. 41
Fuel (diesel)p. 41
+lp. 41
lp. 41
+approx. 375p. 41
approx. 375p. 41
+approx. 375p. 41
approx. 375p. 41
+Engine oilp. 41
Engine oilp. 41
+lp. 41
lp. 41
+approx. 21,5p. 41
approx. 21,5p. 41
+approx. 21,5p. 41
approx. 21,5p. 41
+Coolantp. 41
Coolantp. 41
+lp. 41
lp. 41
+approx. 32p. 41
approx. 32p. 41
+approx. 32p. 41
approx. 32p. 41
+Hydraulic oilp. 41
Hydraulic oilp. 41
+lp. 41
lp. 41
+approx. 280p. 41
approx. 280p. 41
+approx. 280p. 41
approx. 280p. 41
Fig. 14p. 42
+Dimensions in mmp. 42
Dimensions in mmp. 42
+Ap. 42
Ap. 42
+Bp. 42
Bp. 42
+B2p. 42
+Bp. 42
2p. 42
+B3p. 42
+Bp. 42
3p. 42
+Dp. 42
Dp. 42
+Hp. 42
Hp. 42
+H4p. 42
+Hp. 42
4p. 42
+Kp. 42
Kp. 42
+Lp. 42
Lp. 42
+BC 472 RSp. 42
BC 472 RSp. 42
+3500p. 42
3500p. 42
+2998p. 42
2998p. 42
+2885p. 42
2885p. 42
+2660p. 42
2660p. 42
+1660p. 42
1660p. 42
+3390p. 42
3390p. 42
+2125p. 42
2125p. 42
+600p. 42
600p. 42
+8840p. 42
8840p. 42
+Subject to technical alterations.p. 42
Subject to technical alterations.p. 43
+BC 472 RSp. 42
BC 472 RSp. 42
+Weightsp. 42
Weightsp. 42
+Operating weight (CECE)p. 42
Operating weight (CECE)p. 42
+kgp. 42
kgp. 42
+25000p. 42
25000p. 42
+Front axle load (CECE)p. 42
Front axle load (CECE)p. 42
+kgp. 42
kgp. 42
+12000p. 42
12000p. 42
+Rear axle load (CECE)p. 42
Rear axle load (CECE)p. 42
+kgp. 42
kgp. 42
+13000p. 42
13000p. 42
+Max. operating weightp. 42
Max. operating weightp. 42
+kgp. 42
kgp. 42
+26000p. 42
26000p. 42
+Dimensionsp. 42
Dimensionsp. 42
+Rear overhangp. 42
Rear overhangp. 42
+mmp. 42
mmp. 42
+1460p. 42
1460p. 42
+Travel characteristicsp. 42
Travel characteristicsp. 42
+Travel speed range I (forward/reverse)p. 42
Travel speed range I (forward/reverse)p. 42
+km/hp. 42
km/hp. 42
+0 – 4.5p. 42
0 – 4.5p. 42
+Travel speed range II (forward/reverse)p. 42
Travel speed range II (forward/reverse)p. 42
+km/hp. 42
km/hp. 42
+0 – 12p. 42
0 – 12p. 42
+Gradability (soil dependent)p. 42
Gradability (soil dependent)p. 42
+%p. 42
%p. 42
+100p. 42
100p. 42
+Max. pushing forcep. 42
Max. pushing forcep. 42
+kNp. 42
kNp. 42
+272p. 42
272p. 42
+Drivep. 42
Drivep. 42
+Engine manufacturerp. 42
Engine manufacturerp. 42
+Deutzp. 42
Deutzp. 42
+Typep. 42
Typep. 42
+TCD 2013 L06 2Vp. 42
TCD 2013 L06 2Vp. 42
+Coolingp. 42
Coolingp. 42
+Waterp. 42
Waterp. 42
+Number of cylindersp. 42
Number of cylindersp. 42
+6p. 42
6p. 42
+Rated power ISO 9249p. 42
Rated power ISO 9249p. 42
+kWp. 42
kWp. 42
+190p. 42
190p. 42
+Rated power acc. to SAE J 1349p. 42
Rated power acc. to SAE J 1349p. 42
+hpp. 42
hpp. 42
+261p. 42
261p. 42
+Rated speedp. 42
Rated speedp. 42
+rpmp. 42
rpmp. 42
+2300p. 42
2300p. 42
+Drive systemp. 42
Drive systemp. 42
+hydrostaticp. 42
hydrostaticp. 42
+Operating voltagep. 42
Operating voltagep. 42
+Vp. 42
Vp. 42
+12p. 42
12p. 42
+Compactor wheelsp. 42
Compactor wheelsp. 42
+Width (front/rear)p. 42
Width (front/rear)p. 42
+mmp. 42
mmp. 42
+900/900p. 42
900/900p. 42
+Diameter, outer (front/rear)p. 42
Diameter, outer (front/rear)p. 42
+mmp. 42
mmp. 42
+1660/1660p. 42
1660/1660p. 42
+Number of teeth (front/rear)p. 42
Number of teeth (front/rear)p. 42
+40/40p. 42
40/40p. 42
+Compaction width per wheel sidep. 42
Compaction width per wheel sidep. 42
+mmp. 42
mmp. 42
+1013p. 42
1013p. 42
+Brakep. 43
Brakep. 43
+Service brakep. 43
Service brakep. 43
+hydrostaticp. 43
hydrostaticp. 43
+Parking brakep. 43
Parking brakep. 43
+mechanicalp. 43
mechanicalp. 43
+Steeringp. 43
Steeringp. 43
+Type of steeringp. 43
Type of steeringp. 43
+Oscill.-articul.p. 43
Oscill.-articul.p. 43
+Steering operationp. 43
Steering operationp. 43
+hydraulicp. 43
hydraulicp. 43
+Steering/oscillation anglep. 43
Steering/oscillation anglep. 43
+± °p. 43
± °p. 43
+35/15p. 43
35/15p. 43
+Inner track radiusp. 43
Inner track radiusp. 43
+mmp. 43
mmp. 43
+4116p. 43
4116p. 43
+Filling capacitiesp. 43
Filling capacitiesp. 43
+Fuel (diesel)p. 43
Fuel (diesel)p. 43
+lp. 43
lp. 43
+approx. 375p. 43
approx. 375p. 43
+Engine oilp. 43
Engine oilp. 43
+lp. 43
lp. 43
+approx. 21,5p. 43
approx. 21,5p. 43
+Coolantp. 43
Coolantp. 43
+lp. 43
lp. 43
+approx. 32p. 43
approx. 32p. 43
+Hydraulic oilp. 43
Hydraulic oilp. 43
+lp. 43
lp. 43
+approx. 300p. 43
approx. 300p. 43
Fig. 15p. 44
+Dimensions in mmp. 44
Dimensions in mmp. 44
+Ap. 44
Ap. 44
+Bp. 44
Bp. 44
+B2p. 44
+Bp. 44
2p. 44
+B3p. 44
+Bp. 44
3p. 44
+Dp. 44
Dp. 44
+Hp. 44
Hp. 44
+H4p. 44
+Hp. 44
4p. 44
+Kp. 44
Kp. 44
+Lp. 44
Lp. 44
+BC 462 EBp. 44
BC 462 EBp. 44
+3500p. 44
3500p. 44
+2998p. 44
2998p. 44
+2885p. 44
2885p. 44
+2660p. 44
2660p. 44
+1580p. 44
1580p. 44
+3390p. 44
3390p. 44
+1050p. 44
1050p. 44
+600p. 44
600p. 44
+8230p. 44
8230p. 44
+Subject to technical alterations.p. 44
Subject to technical alterations.p. 45
+BC 462 EBp. 44
BC 462 EBp. 44
+Weightsp. 44
Weightsp. 44
+Operating weight (CECE)p. 44
Operating weight (CECE)p. 44
+kgp. 44
kgp. 44
+21300p. 44
21300p. 44
+Front axle load (CECE)p. 44
Front axle load (CECE)p. 44
+kgp. 44
kgp. 44
+10300p. 44
10300p. 44
+Rear axle load (CECE)p. 44
Rear axle load (CECE)p. 44
+kgp. 44
kgp. 44
+11000p. 44
11000p. 44
+Dimensionsp. 44
Dimensionsp. 44
+Rear overhangp. 44
Rear overhangp. 44
+mmp. 44
mmp. 44
+1460p. 44
1460p. 44
+Travel characteristicsp. 44
Travel characteristicsp. 44
+Travel speed range I (forward, reverse)p. 44
Travel speed range I (forward, reverse)p. 44
+km/hp. 44
km/hp. 44
+0 to 4.5p. 44
0 to 4.5p. 44
+Travel speed range II (forward, reverse)p. 44
Travel speed range II (forward, reverse)p. 44
+km/hp. 44
km/hp. 44
+0 to 12p. 44
0 to 12p. 44
+Gradability (soil dependent)p. 44
Gradability (soil dependent)p. 44
+%p. 44
%p. 44
+100p. 44
100p. 44
+Enginep. 44
Enginep. 44
+Engine manufacturerp. 44
Engine manufacturerp. 44
+Deutzp. 44
Deutzp. 44
+Typep. 44
Typep. 44
+TCD 2013 L06 2Vp. 44
TCD 2013 L06 2Vp. 44
+Coolingp. 44
Coolingp. 44
+Waterp. 44
Waterp. 44
+Number of cylindersp. 44
Number of cylindersp. 44
+6p. 44
6p. 44
+Rated power ISO 9249p. 44
Rated power ISO 9249p. 44
+kWp. 44
kWp. 44
+190p. 44
190p. 44
+Rated power acc. to SAE J 1349p. 44
Rated power acc. to SAE J 1349p. 44
+hpp. 44
hpp. 44
+261p. 44
261p. 44
+Rated speedp. 44
Rated speedp. 44
+rpmp. 44
rpmp. 44
+2300p. 44
2300p. 44
+Drive systemp. 44
Drive systemp. 44
+hydrostaticp. 44
hydrostaticp. 44
+Driven compactor wheelsp. 44
Driven compactor wheelsp. 44
+4p. 44
4p. 44
+Operating voltagep. 44
Operating voltagep. 44
+Vp. 44
Vp. 44
+12p. 44
12p. 44
+Compactor wheelsp. 44
Compactor wheelsp. 44
+Width (front/rear)p. 44
Width (front/rear)p. 44
+mmp. 44
mmp. 44
+900/900p. 44
900/900p. 44
+Diameter, outer (front/rear)p. 44
Diameter, outer (front/rear)p. 44
+mmp. 44
mmp. 44
+1580/1580p. 44
1580/1580p. 44
+Number of teeth (front/rear)p. 44
Number of teeth (front/rear)p. 44
+40/40p. 44
40/40p. 44
+Compaction width per wheel sidep. 44
Compaction width per wheel sidep. 44
+mmp. 44
mmp. 44
+1013p. 44
1013p. 44
+Brakep. 45
Brakep. 45
+Service brakep. 45
Service brakep. 45
+hydrostaticp. 45
hydrostaticp. 45
+Parking brakep. 45
Parking brakep. 45
+mechanicalp. 45
mechanicalp. 45
+Emergency brakep. 45
Emergency brakep. 45
+hydro-mechanicalp. 45
hydro-mechanicalp. 45
+Steeringp. 45
Steeringp. 45
+Type of steeringp. 45
Type of steeringp. 45
+Oscill.-articul.p. 45
Oscill.-articul.p. 45
+Steering operationp. 45
Steering operationp. 45
+hydraulicp. 45
hydraulicp. 45
+Steering anglep. 45
Steering anglep. 45
+± °p. 45
± °p. 45
+35p. 45
35p. 45
+Oscillation anglep. 45
Oscillation anglep. 45
+± °p. 45
± °p. 45
+15p. 45
15p. 45
+Inner track radiusp. 45
Inner track radiusp. 45
+mmp. 45
mmp. 45
+4116p. 45
4116p. 45
+Dozer bladep. 45
Dozer bladep. 45
+Height adjustment above ground levelp. 45
Height adjustment above ground levelp. 45
+mmp. 45
mmp. 45
+1200p. 45
1200p. 45
+Height adjustment below ground levelp. 45
Height adjustment below ground levelp. 45
+mmp. 45
mmp. 45
+120p. 45
120p. 45
+Filling capacitiesp. 45
Filling capacitiesp. 45
+Fuel (diesel)p. 45
Fuel (diesel)p. 45
+lp. 45
lp. 45
+approx. 375p. 45
approx. 375p. 45
+Engine oilp. 45
Engine oilp. 45
+lp. 45
lp. 45
+approx. 21,5p. 45
approx. 21,5p. 45
+Coolantp. 45
Coolantp. 45
+lp. 45
lp. 45
+approx. 32p. 45
approx. 32p. 45
+Hydraulic oilp. 45
Hydraulic oilp. 45
+lp. 45
lp. 45
+approx. 280p. 45
approx. 280p. 45
+Additional engine datap. 46
Additional engine datap. 46
+Combustion principlep. 46
Combustion principlep. 46
+4-stroke dieselp. 46
4-stroke dieselp. 46
+Low idle speedp. 46
Low idle speedp. 46
+rpmp. 46
rpmp. 46
+700 – 900p. 46
700 – 900p. 46
+High idle speedp. 46
High idle speedp. 46
+rpmp. 46
rpmp. 46
+2300 – 2350p. 46
2300 – 2350p. 46
+Specific fuel consumptionp. 46
Specific fuel consumptionp. 46
+g/kWhp. 46
g/kWhp. 46
+240p. 46
240p. 46
+Valve clearance intakep. 46
Valve clearance intakep. 46
+°p. 46
°p. 46
+90°p. 46
90°p. 46
+Valve clearance exhaustp. 46
Valve clearance exhaustp. 46
+°p. 46
°p. 46
+150°p. 46
150°p. 46
+Starter powerp. 46
Starter powerp. 46
+kWp. 46
kWp. 46
+5.4p. 46
5.4p. 46
+Hydraulic pumpp. 46
Hydraulic pumpp. 46
+Typep. 46
Typep. 46
+AZPS/16p. 46
AZPS/16p. 46
+Systemp. 46
Systemp. 46
+Gear pumpp. 46
Gear pumpp. 46
+Max. displacementp. 46
Max. displacementp. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+16p. 46
16p. 46
+Pressure limitationp. 46
Pressure limitationp. 46
+barp. 46
barp. 46
+25p. 46
25p. 46
+Travel pumpp. 46
Travel pumpp. 46
+Bosch-Rexrothp. 46
Bosch-Rexrothp. 46
+Type frontp. 46
+Type frontp. 46
Type frontp. 46
+Series 40, A4VG110DA, Automatic control speed dependentp. 46
Series 40, A4VG110DA, Automatic control speed dependentp. 46
+Systemp. 46
Systemp. 46
+Axial piston machinep. 46
Axial piston machinep. 46
+Max. displacementp. 46
Max. displacementp. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+110p. 46
110p. 46
+High pressure limitationp. 46
High pressure limitationp. 46
+barp. 46
barp. 46
+directly controlled, fixed to a differential pressure of 475 barp. 46
directly controlled, fixed to a differential pressure of 475 barp. 46
+Pressure override valvep. 46
Pressure override valvep. 46
+barp. 46
barp. 46
+set to 425 bar absolutep. 46
set to 425 bar absolutep. 46
+Charge pressure, high idlep. 46
Charge pressure, high idlep. 46
+barp. 46
barp. 46
+25 bar, control run at 1000 rpm at least 23 barp. 46
25 bar, control run at 1000 rpm at least 23 barp. 46
+Control start when acceleratingp. 46
Control start when acceleratingp. 46
+50 bar at 11000 min-1p. 46
+50 bar at 11000 minp. 46
-1p. 46
+Control start at high pressurep. 46
Control start at high pressurep. 46
+400 bar at 2000 min-1p. 46
+400 bar at 2000 minp. 46
-1p. 46
+Q-characteristic control startp. 46
Q-characteristic control startp. 46
+2000 min-1 at high pressure 230 barp. 46
+2000 minp. 46
-1p. 46
+Integrated charge pumpp. 46
Integrated charge pumpp. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+31p. 46
31p. 46
+Type rearp. 46
+Type rearp. 46
Type rearp. 46
+Series 40, A4VG 110HT, Control hydraulic, directly controlledp. 46
Series 40, A4VG 110HT, Control hydraulic, directly controlledp. 46
+Systemp. 46
Systemp. 46
+Axial piston machinep. 46
Axial piston machinep. 46
+Max. displacementp. 46
Max. displacementp. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+110p. 46
110p. 46
+High pressure limitationp. 46
High pressure limitationp. 46
+barp. 46
barp. 46
+directly controlled, fixed to a differential pressure of 475 barp. 46
directly controlled, fixed to a differential pressure of 475 barp. 46
+Pressure override valvep. 46
Pressure override valvep. 46
+barp. 46
barp. 46
+set to 425 bar absolutep. 46
set to 425 bar absolutep. 46
+Charge pressure, high idlep. 46
Charge pressure, high idlep. 46
+barp. 46
barp. 46
+25 bar, control run at 1000 rpm at least 23 barp. 46
25 bar, control run at 1000 rpm at least 23 barp. 46
+Integrated charge pumpp. 46
Integrated charge pumpp. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+31p. 46
31p. 46
+travel motorsp. 46
travel motorsp. 46
+Bosch-Rexrothp. 46
Bosch-Rexrothp. 46
+Typep. 46
Typep. 46
+Series 63, A6VM170HA2T, automatic control high pressure dependent with pressure increase spring 100 barp. 46
Series 63, A6VM170HA2T, automatic control high pressure dependent with pressure increase spring 100 barp. 46
+Quantityp. 46
Quantityp. 46
+4p. 46
4p. 46
+Systemp. 46
Systemp. 46
+Axial piston/bent axlep. 46
Axial piston/bent axlep. 46
+Displacement (stage 1)p. 46
Displacement (stage 1)p. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+107p. 46
107p. 46
+Displacement (stage 2)p. 46
Displacement (stage 2)p. 46
+cm3/revp. 46
+cmp. 46
3p. 46
+45p. 46
45p. 46
+Control startp. 46
Control startp. 46
+230 bar at minimum displacement 45 cm3/revp. 46
+230 bar at minimum displacement 45 cmp. 46
3p. 46
+Perm. leak oil ratep. 46
Perm. leak oil ratep. 46
+l/minp. 46
l/minp. 46
+2p. 46
2p. 46
+Wheel drivep. 46
Wheel drivep. 46
+BC 472 RB/RSp. 46
BC 472 RB/RSp. 46
Reduction ratiop. 46
+715C3Bp. 46
715C3Bp. 46
82p. 46
+BC 462 RB/EBp. 46
BC 462 RB/EBp. 46
Reduction ratiop. 46
+713C3Bp. 46
713C3Bp. 46
81,3 RB / 74 EBp. 46
+Steering/working pumpp. 46
Steering/working pumpp. 46
+Bosch-Rexrothp. 46
Bosch-Rexrothp. 46
+Typep. 47
Typep. 47
+A10 VO85 DFR1p. 47
A10 VO85 DFR1p. 47
+Systemp. 47
Systemp. 47
+Axial piston/swash platep. 47
Axial piston/swash platep. 47
+Max. displacementp. 47
Max. displacementp. 47
+cm3/revp. 47
+cmp. 47
3p. 47
+85p. 47
85p. 47
+Max. dozer plate pressurep. 47
Max. dozer plate pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Max. bucket pressurep. 47
Max. bucket pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Max. steering pressurep. 47
Max. steering pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Stand-by pressurep. 47
Stand-by pressurep. 47
+barp. 47
barp. 47
+20p. 47
20p. 47
+Max. working pressurep. 47
Max. working pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Valve block, working hydraulicsp. 47
Valve block, working hydraulicsp. 47
+Typep. 47
Typep. 47
+STB – LVSp. 47
STB – LVSp. 47
+Max. steering pressurep. 47
Max. steering pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Max. dozer plate pressurep. 47
Max. dozer plate pressurep. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Max. pressure bucket up/downp. 47
Max. pressure bucket up/downp. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+Max. pressure bucket tiltp. 47
Max. pressure bucket tiltp. 47
+barp. 47
barp. 47
+250p. 47
250p. 47
+LS-pressure limitationp. 47
LS-pressure limitationp. 47
+barp. 47
barp. 47
+230p. 47
230p. 47
+Flow dividerp. 47
Flow dividerp. 47
+Bosch-Rexrothp. 47
Bosch-Rexrothp. 47
+Typep. 47
Typep. 47
+RTM25S2Ap. 47
RTM25S2Ap. 47
+Steering valvep. 47
Steering valvep. 47
+Typep. 47
Typep. 47
+STB – LVSp. 47
STB – LVSp. 47
+Systemp. 47
Systemp. 47
+Control block, hydraulicp. 47
Control block, hydraulicp. 47
+Steering joystickp. 47
Steering joystickp. 47
+Typep. 47
Typep. 47
+Hydraulicp. 47
Hydraulicp. 47
+Front axle, drivenp. 47
Front axle, drivenp. 47
+Typep. 47
Typep. 47
+Flow divider 2-foldp. 47
Flow divider 2-foldp. 47
+Differentialp. 47
Differentialp. 47
+Front, right-leftp. 47
Front, right-leftp. 47
+Rear axlep. 47
Rear axlep. 47
+Typep. 47
Typep. 47
+Flow divider 2-foldp. 47
Flow divider 2-foldp. 47
+Differentialp. 47
Differentialp. 47
+Rear, right-leftp. 47
Rear, right-leftp. 47
+Charge circuit filterp. 47
Charge circuit filterp. 47
+micronp. 47
micronp. 47
+12p. 47
12p. 47
+Return flow filterp. 47
Return flow filterp. 47
+micronp. 47
micronp. 47
+80p. 47
80p. 47
The following noise and vibration data acc. top. 48
– EC Machine Regulation edition 2006/42/ECp. 48
– the noise regulation 2000/14/EG, noise protection guideline 2003/10/ECp. 48
– Vibration Protection Regulation 2002/44/ECp. 48
were determined during conditions typical for this type of equipment and by application of harmonized standards.p. 48
During operation these values may vary because of the existing operating conditions.p. 48
+Noise valuep. 48
Noise valuep. 48
Sound pressure level on the place of the operator:p. 48
+Lp. 48
pAp. 48
Guaranteed sound power level:p. 48
+WA = 103 dB(A), determined acc. to ISO 3744 and EN 500p. 48
WAp. 48
+Vibration valuep. 48
Vibration valuep. 48
Vibration of the entire body (driver’s seat)p. 48
+The weighted effective acceleration value determined according to ISO 7096 isp. 48
£p. 48
2p. 48
Hand-arm vibration valuesp. 48
+The weighted effective acceleration value determined according to ISO 5349 isp. 48
£p. 48
2p. 48
+4 Maintenancep. 49
4 Maintenancep. 49
+4.1 General notes on maintenancep. 50
4.1 General notes on maintenancep. 50
+When performing maintenance work always comply with the appropriate safety regulations.p. 50
When performing maintenance work always comply with the appropriate safety regulations.p. 50
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. 50
The terms right/left correspond with travel direction forward.p. 50
+l Always clean machine and engine thoroughly before starting maintenance work.p. 50
l Always clean machine and engine thoroughly before starting maintenance work.p. 50
l For maintenance work stand the machine on level ground.p. 50
l Always remove the main battery switch for all maintenance work.p. 50
l Perform maintenance work only with the engine shut down.p. 50
l Relieve hydraulic pressures before working on hydraulic lines.p. 50
l Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 50
l When working in the area of the articulated joint attach the articulation lock (transport lock).p. 50
+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. 50
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. 50
Keep used filters in a separate waste container and dispose of environmentally.p. 50
Catch biodegradable oils separately.p. 50
+Notes on the fuel systemp. 50
Notes on the fuel systemp. 50
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 50
+l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 50
l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 50
l Drums with inside zinc lining are not suitable to store fuel.p. 50
l When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.p. 50
l Do not let the hose stir up the slurry at the bottom of the drum.p. 50
l The fuel drum must rest for a longer period of time before drawing off fuel.p. 50
l The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 50
+Notes on the performance of the enginep. 50
Notes on the performance of the enginep. 50
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. 50
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. 50
+Notes on the cooling systemp. 50
Notes on the cooling systemp. 50
Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 50
Coolant is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water.p. 50
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. 50
+Notes on the hydraulic systemp. 50
Notes on the hydraulic systemp. 50
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. 50
+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. 50
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. 50
l Seal external leaks immediately. If necessary inform the responsible customer service.p. 50
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. 50
l We recommend to use our filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.p. 50
l Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 50
l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 50
+Welding work on the refuse compactorp. 50
Welding work on the refuse compactorp. 50
+l Disconnect the main battery switchp. 50
l Disconnect the main battery switchp. 50
+l Pull the plugs off all control units, engine control unit (EMR), travel control (ESX) and additional control (DIOS).p. 50
l Pull the plugs off all control units, engine control unit (EMR), travel control (ESX) and additional control (DIOS).p. 50
+4.2 Fuels and lubricantsp. 51
4.2 Fuels and lubricantsp. 51
+Engine oilp. 51
Engine oilp. 51
Qualityp. 51
For use in DEUTZ engines the lubrication oils are classified in DEUTZ Lubrication Oil Quality Classes (DQC).p. 51
+Approved engine oilsp. 51
Approved engine oilsp. 51
+Deutzp. 51
Deutzp. 51
+ACEAp. 51
+ACEAp. 51
Association des Constructeurs European d’Automobilesp. 51
+APIp. 51
+APIp. 51
American Petroleum Institutep. 51
+DHDp. 51
DHDp. 51
+DQC II-05 or DQC II-10p. 51
DQC II-05 or DQC II-10p. 51
+E3-96, E5-02, E7-08, E4-07, E6-04, E9-08p. 51
E3-96, E5-02, E7-08, E4-07, E6-04, E9-08p. 51
+CG-4, CH-4, CI-4, CI-4 Plus, CJ-4p. 51
CG-4, CH-4, CI-4, CI-4 Plus, CJ-4p. 51
+DHD-1p. 51
DHD-1p. 51
+DQC III-05 or DQC II-10p. 51
DQC III-05 or DQC II-10p. 51
+–p. 51
–p. 51
+–p. 51
–p. 51
+–p. 51
–p. 51
+DQC IV-05 or DQC II-10p. 51
DQC IV-05 or DQC II-10p. 51
+–p. 51
–p. 51
+–p. 51
–p. 51
+–p. 51
–p. 51
The list of approved lubrication oils is also available in the Internet under the following address:p. 51
+www.deutz.comp. 51
www.deutz.comp. 51
+dep. 51
dep. 51
+>>SERVICE >> Betriebsstoffe und Additive >> DeutzQualityClass >> DQC-Freigabelistep. 51
>>SERVICE >> Betriebsstoffe und Additive >> DeutzQualityClass >> DQC-Freigabelistep. 51
Consult your local service station if in doubt.p. 51
+l Use winter grade engine oil for winter operation!p. 51
l Use winter grade engine oil for winter operation!p. 51
Oil viscosityp. 51
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. 51
Too high viscosity can cause starting difficulties, too low ´viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption.p. 51
Fig. 16p. 51
+Optimal operating conditions can be achieved by using the oil viscosity chartp. 51
(Fig. 16)p. 51
At ambient temperatures below -40 °C (-58 °F) the lubrication oil must be pre-heated (e.g. by parking the machine indoors).p. 51
The viscosity is classified acc. to SAE. Multi-purpose oils should generally be used.p. 51
Oil change intervalsp. 51
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. 51
DQC II, DQC III, DQC IV: 500 operating hoursp. 51
+When using fuels with a sulphur content of more than 0.5% to 1% or under permanent ambient temperatures below -10 °C (14 °F) and when using biodegradable diesel fuel the oil change intervals must be halved.p. 51
When using fuels with a sulphur content of more than 0.5% to 1% or under permanent ambient temperatures below -10 °C (14 °F) and when using biodegradable diesel fuel the oil change intervals must be halved.p. 51
+Fuelsp. 51
Fuelsp. 51
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. 51
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. 52
Qualityp. 52
The following fuel specifications are permitted:p. 52
+l EN 590p. 52
l EN 590p. 52
l DIN 51628p. 52
l ASTM D975 Grade-No. 1-D and 2-D.p. 52
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication properties acc. to EN 590p. 52
Winter fuelp. 52
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates. At very low temperatures disturbing paraffin separ…p. 52
The admixture of petroleum and the addition of "flow enhancing additives" (fuel additives) is not permitted.p. 52
+Coolantp. 52
Coolantp. 52
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. 52
This prevents damage caused by corrosion, cavitation, freezing and overheating.p. 52
Fresh water qualityp. 52
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. 52
+Fresh water analysis valuesp. 52
Fresh water analysis valuesp. 52
+pH-value at 20 °C (68 °F)p. 52
pH-value at 20 °C (68 °F)p. 52
+6.5 – 8.5p. 52
6.5 – 8.5p. 52
+Chloride ion content (mg/l) (ppm)p. 52
Chloride ion content (mg/l) (ppm)p. 52
+max. 100p. 52
max. 100p. 52
+Sulphate ion content (mg/l) (ppm)p. 52
Sulphate ion content (mg/l) (ppm)p. 52
+max. 100p. 52
max. 100p. 52
+Water hardness (ion content of calcium and magnesium ) (mmol/l)]p. 52
Water hardness (ion content of calcium and magnesium ) (mmol/l)]p. 52
+max. 3.56p. 52
max. 3.56p. 52
Conversion to other units:p. 52
+– German degree (°dH)]p. 52
– German degree (°dH)]p. 52
+max. 20p. 52
max. 20p. 52
+– English degree (°eH)]p. 52
– English degree (°eH)]p. 52
+max. 25p. 52
max. 25p. 52
+– French degree (°fH)]p. 52
– French degree (°fH)]p. 52
+max. 36.5p. 52
max. 36.5p. 52
+corresponds with the content of CaCO3 (mg/l) (ppm)p. 52
+corresponds with the content of CaCOp. 52
3p. 52
+max. 356p. 52
max. 356p. 52
Information concerning the water quality can be obtained from the waterworks.p. 52
If the fresh water analysis values are unknown, these must be determined with the help of a water analysis.p. 52
If the values of the analysis deviate, the water must be treated accordingly.p. 52
+l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 52
l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 52
l Water hardness too high: Mix with soft, distilled or fully demineralized waterp. 52
l Chlorides and/or sulphates too high: Mix with distilled or fully demineralized waterp. 52
l Total hardness or carbonate hardness too low: Mix with hardened water (harder water is in most cases available in the form of drinking water).p. 52
+Another analysis must be made after the fresh water has been prepared.p. 52
Another analysis must be made after the fresh water has been prepared.p. 52
Cooling system protection agentp. 52
As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.p. 52
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. 52
We therefore highly recommend our BOMAG cooling system protection agent.p. 52
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. 52
The list of approved cooling system protection agents is also available in the Internet under the following address:p. 52
+>>SERVICE >> Operating Liquids and Additives >> Cooling System Conditioner >> Flyer Cooling System Conditioner Technical Circularp. 53
>>SERVICE >> Operating Liquids and Additives >> Cooling System Conditioner >> Flyer Cooling System Conditioner Technical Circularp. 53
Products of the same product group (see Deutz Technical Circular Cooling System Protection Agents) can be mixed with each other.p. 53
The BOMAG cooling system protection agent corresponds with product group A.p. 53
+Do not mix different coolants and additives of any other kind.p. 53
Do not mix different coolants and additives of any other kind.p. 53
Before changing the product you must clean the entire cooling system.p. 53
Consult your local service station if in doubt.p. 53
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. 53
+Mixing ratiop. 53
Mixing ratiop. 53
+Cooling system protection agentp. 53
Cooling system protection agentp. 53
+Fresh waterp. 53
Fresh waterp. 53
+Cold protection down top. 53
Cold protection down top. 53
+min. 35%p. 53
min. 35%p. 53
+65%p. 53
65%p. 53
+-22 °C (-8 °F)p. 53
-22 °C (-8 °F)p. 53
+40%p. 53
40%p. 53
+60%p. 53
60%p. 53
+-28 °C (-18 °F)p. 53
-28 °C (-18 °F)p. 53
+45%p. 53
45%p. 53
+55%p. 53
55%p. 53
+-35 °C (-31 °F)p. 53
-35 °C (-31 °F)p. 53
+max. 50%p. 53
max. 50%p. 53
+50%p. 53
50%p. 53
+-41 °C (-42 °F)p. 53
-41 °C (-42 °F)p. 53
+A proportion of more than 50% of cooling system protection agent causes a drop in cooling power.p. 53
A proportion of more than 50% of cooling system protection agent causes a drop in cooling power.p. 53
The use of corrosion protection oils as cooling system protection agents is not permitted.p. 53
+When working at temperature below -41 °C(-42 °F) you should consult our local service representative.p. 53
When working at temperature below -41 °C(-42 °F) you should consult our local service representative.p. 53
+Coolant must be disposed of environmentally.p. 53
Coolant must be disposed of environmentally.p. 53
+Mineral oil based hydraulic oilp. 53
Mineral oil based hydraulic oilp. 53
+The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mmp. 53
2p. 53
2p. 53
+Bio-degradable hydraulic oilp. 53
Bio-degradable hydraulic oilp. 53
The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.p. 53
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. 53
In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up.p. 53
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. 53
+Check the filter more frequently after this change.p. 53
Check the filter more frequently after this change.p. 53
Perform regular oil analyses for content of water and mineral oil.p. 53
Replace the hydraulic oil filter element every 500 operating hours.p. 53
+Gear oilp. 53
Gear oilp. 53
Qualityp. 53
For the gearboxes use only multi-purpose gear oils of API-GL5-class, SAE 90.p. 53
This is a hypoid lubricant of highest quality class for extremely loaded transmissions.p. 53
The additives in this oil ensure low wear lubrication under all operating conditions.p. 53
+Lubrication greasep. 53
Lubrication greasep. 53
For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G.p. 53
4.3 Table of fuels and lubricantsp. 54
+Assemblyp. 54
Assemblyp. 54
+Fuel or lubricantp. 54
Fuel or lubricantp. 54
+Quantityp. 54
Quantityp. 54
+Summerp. 54
Summerp. 54
+Winterp. 54
Winterp. 54
+Attentionp. 54
+Attentionp. 54
Attentionp. 54
Observe the level marksp. 54
+Enginep. 54
Enginep. 54
+– Engine oilp. 54
– Engine oilp. 54
+Specification see "Fuels and lubricants – engine oil"p. 54
Specification see "Fuels and lubricants – engine oil"p. 54
+approx. 21,5 litres incl. oil filterp. 54
approx. 21,5 litres incl. oil filterp. 54
+SAE 10W-40 (-20 °C to +40 °C)p. 54
SAE 10W-40 (-20 °C to +40 °C)p. 54
(BOMAG PN 009 920 06; 20 l)p. 54
+SAE 15W-40 (-5 °C to +40 °C)p. 54
SAE 15W-40 (-5 °C to +40 °C)p. 54
+SAE 5W-40 (-30 °C to +40 °C)p. 54
SAE 5W-40 (-30 °C to +40 °C)p. 54
+SAE 5W-30 (-30 °C to +30 °C)p. 54
SAE 5W-30 (-30 °C to +30 °C)p. 54
+– Fuelp. 54
– Fuelp. 54
+Dieselp. 54
Dieselp. 54
+Winter diesel fuelp. 54
Winter diesel fuelp. 54
+approx. 375 litresp. 54
approx. 375 litresp. 54
+– Coolantp. 54
– Coolantp. 54
+Mixture of water and anti-freeze agentp. 54
Mixture of water and anti-freeze agentp. 54
BOMAG PN 009 940 08; 20l)p. 54
Specification see "Fuels and lubricants – coolant"p. 54
+approx. 32 litresp. 54
approx. 32 litresp. 54
+Hydraulic systemp. 54
Hydraulic systemp. 54
+Hydraulic oil (ISO), HLP 46p. 54
Hydraulic oil (ISO), HLP 46p. 54
(BOMAG PN 009 930 09; 20 l) or ester based biodegradable hydraulic oilp. 54
+approx. 200 litresp. 54
approx. 200 litresp. 54
+Travel gearp. 54
Travel gearp. 54
+Gear oil SAE 80W-140, API GL-5p. 54
Gear oil SAE 80W-140, API GL-5p. 54
(BOMAG PN 009 925 07; 20 l)p. 54
+approx. 5 l (462)p. 54
approx. 5 l (462)p. 54
approx. 6 l (472)p. 54
+Lubrication pointsp. 54
Lubrication pointsp. 54
Central lubrication systemp. 54
+High pressure grease (lithium saponified)p. 54
High pressure grease (lithium saponified)p. 54
+as requiredp. 54
as requiredp. 54
2.0 kg automatic lubricationp. 54
+Air conditioning systemp. 54
Air conditioning systemp. 54
+Refrigerant R134ap. 54
Refrigerant R134ap. 54
+approx. 1500 gp. 54
approx. 1500 gp. 54
4.4 Running-in instructionsp. 55
+The following service work must be performed when taking new machines into operation.p. 55
The following service work must be performed when taking new machines into operation.p. 55
+Up to approx. 250 operating hours check the engine oil level twice every day.p. 55
Up to approx. 250 operating hours check the engine oil level twice every day.p. 55
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. 55
After a running time of 15 minutes retighten the V- belts for generator and air conditioning compressor.p. 55
Maintenance after 50 operating hoursp. 55
+l Changing engine oil and oil filterp. 55
l Changing engine oil and oil filterp. 55
l Change the oil in the drive gears.p. 55
l Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.p. 55
l Retighten all bolted connections on the machine.p. 55
Maintenance after 500 operating hoursp. 55
+l Change the oil in the drive gears.p. 55
l Change the oil in the drive gears.p. 55
Special intervalsp. 55
+l Switch the air conditioning on every month for about 10 minutes.p. 55
l Switch the air conditioning on every month for about 10 minutes.p. 55
4.5 Maintenance tablep. 56
+No.p. 56
No.p. 56
+Maintenance workp. 56
Maintenance workp. 56
+Commentp. 56
Commentp. 56
+every 10 operating hours, dailyp. 56
every 10 operating hours, dailyp. 56
+every 500 oper. hoursp. 56
every 500 oper. hoursp. 56
+every 1000 oper. hoursp. 56
every 1000 oper. hoursp. 56
+every 2000 oper. hoursp. 56
every 2000 oper. hoursp. 56
+every 3000 oper. hoursp. 56
every 3000 oper. hoursp. 56
+every 6000 oper. hoursp. 56
every 6000 oper. hoursp. 56
+as requiredp. 56
as requiredp. 56
+5.6p. 56
5.6p. 56
+Check the engine oil levelp. 56
Check the engine oil levelp. 56
+Dipstick markp. 56
Dipstick markp. 56
+Xp. 56
Xp. 56
+5.7p. 56
5.7p. 56
+Check the fuel levelp. 56
Check the fuel levelp. 56
+Instrument clusterp. 56
Instrument clusterp. 56
+Xp. 56
Xp. 56
+5.8p. 56
5.8p. 56
+Check the hydraulic oil levelp. 56
Check the hydraulic oil levelp. 56
+Inspection glassp. 56
Inspection glassp. 56
+Xp. 56
Xp. 56
+5.9p. 56
5.9p. 56
+Check the coolant levelp. 56
Check the coolant levelp. 56
+Inspection glassp. 56
Inspection glassp. 56
+Xp. 56
Xp. 56
+5.10p. 56
5.10p. 56
+Visual inspection of the machine for damage and leaksp. 56
Visual inspection of the machine for damage and leaksp. 56
+Xp. 56
Xp. 56
+5.11p. 56
5.11p. 56
+Lubricate the machine (RB)p. 56
Lubricate the machine (RB)p. 56
+Xp. 56
Xp. 56
+5.12p. 56
5.12p. 56
+Lubricate the machine (RS)p. 56
Lubricate the machine (RS)p. 56
+Xp. 56
Xp. 56
+5.13p. 56
5.13p. 56
+Change engine oil and oil filter cartridgep. 56
+Change engine oil and oil filter cartridgep. 56
oil change after 50 and 500 operating hours, then every 500 operating hoursp. 58
+at least 1x per yearp. 56
at least 1x per yearp. 56
see foot notep. 56
+Xp. 56
Xp. 56
+5.14p. 56
5.14p. 56
+Check, clean the water separatorp. 56
Check, clean the water separatorp. 56
+when the "water in fuel" warning light lights upp. 56
when the "water in fuel" warning light lights upp. 56
+Xp. 56
Xp. 56
+5.15p. 56
5.15p. 56
+Check the anti-freeze concentration and the condition of the coolantp. 56
Check the anti-freeze concentration and the condition of the coolantp. 56
+Xp. 56
Xp. 56
+5.16p. 56
5.16p. 56
+Check condition, tension of ribbed V- belts and compressor V-beltp. 56
Check condition, tension of ribbed V- belts and compressor V-beltp. 56
+Xp. 56
Xp. 56
+5.17p. 56
5.17p. 56
+Battery service, check the main battery switchp. 56
Battery service, check the main battery switchp. 56
+pole greasep. 56
pole greasep. 56
+Xp. 56
Xp. 56
+5.18p. 56
5.18p. 56
+Service the air conditioningp. 56
Service the air conditioningp. 56
+Xp. 56
Xp. 56
+5.19p. 56
5.19p. 56
+Clean the circulation air filter for the heatingp. 56
Clean the circulation air filter for the heatingp. 56
+Xp. 56
Xp. 56
+5.20p. 56
5.20p. 56
+Clean the cooling fins on engine and hydraulic oil coolerp. 56
Clean the cooling fins on engine and hydraulic oil coolerp. 56
+Xp. 56
Xp. 56
+5.21p. 56
5.21p. 56
+Check the fastening of the scrapersp. 56
Check the fastening of the scrapersp. 56
+Xp. 56
Xp. 56
+5.22p. 56
5.22p. 56
+Check the oil level in the travel gearp. 56
Check the oil level in the travel gearp. 56
+Xp. 56
Xp. 56
+5.23p. 56
5.23p. 56
+Check the central lubrication system, top upp. 56
Check the central lubrication system, top upp. 56
+Xp. 56
Xp. 56
+5.24p. 56
5.24p. 56
+Change the fresh air filterp. 56
Change the fresh air filterp. 56
+Xp. 56
Xp. 56
+5.25p. 56
5.25p. 56
+Replace the fuel filter cartridgesp. 56
Replace the fuel filter cartridgesp. 56
+Xp. 56
Xp. 56
+5.26p. 57
5.26p. 57
+Replace the fuel pre-filter cartridge, bleed the fuel systemp. 57
Replace the fuel pre-filter cartridge, bleed the fuel systemp. 57
+Xp. 57
Xp. 57
+5.27p. 57
5.27p. 57
+Check fastening of engine/turbo charger/combustion air hosesp. 57
Check fastening of engine/turbo charger/combustion air hosesp. 57
+Xp. 57
Xp. 57
+5.28p. 57
5.28p. 57
+Check the engine mountsp. 57
Check the engine mountsp. 57
+Xp. 57
Xp. 57
+5.29p. 57
5.29p. 57
+Oil change in travel gearp. 57
+Oil change in travel gearp. 57
Running-in instructions: oil change after 50, 500 and 1000 operating hours, then every 1000 operating hoursp. 58
+see foot notep. 57
see foot notep. 57
+Xp. 57
Xp. 57
+5.30p. 57
5.30p. 57
+Change the hydraulic oil fine filterp. 57
+Change the hydraulic oil fine filterp. 57
Also after repairs in the hydraulic system.p. 58
+see foot notep. 57
see foot notep. 57
+Xp. 57
Xp. 57
+5.31p. 57
5.31p. 57
+Check the ROPSp. 57
Check the ROPSp. 57
+Xp. 57
Xp. 57
+5.32p. 57
5.32p. 57
+Check, adjust the valve clearancep. 57
Check, adjust the valve clearancep. 57
+Intake = 90°p. 57
Intake = 90°p. 57
Exhaust = 150°p. 57
on cold enginep. 57
+Xp. 57
Xp. 57
+5.33p. 57
5.33p. 57
+Change hydraulic oil and breather filter***p. 57
Change hydraulic oil and breather filter***p. 57
+see foot notep. 57
see foot notep. 57
at least every 2 yearsp. 57
+Xp. 57
Xp. 57
+5.34p. 57
5.34p. 57
+Change the coolantp. 57
Change the coolantp. 57
+at least every 2 yearsp. 57
at least every 2 yearsp. 57
+Xp. 57
Xp. 57
+5.35p. 57
5.35p. 57
+Check condition of oscillating articulated jointp. 57
Check condition of oscillating articulated jointp. 57
+at least every 2 yearsp. 57
at least every 2 yearsp. 57
+Xp. 57
Xp. 57
+5.36p. 57
5.36p. 57
+Check the fire extinguisherp. 57
Check the fire extinguisherp. 57
+at least every 2 yearsp. 57
at least every 2 yearsp. 57
only by authorized and qualified personnelp. 57
+Xp. 57
Xp. 57
+5.37p. 57
5.37p. 57
+Replace ribbed V-belt and idler pulleyp. 57
Replace ribbed V-belt and idler pulleyp. 57
+at least every 2 yearsp. 57
at least every 2 yearsp. 57
+Xp. 57
Xp. 57
+5.38p. 57
5.38p. 57
+Replace the crankcase ventilation valvep. 57
Replace the crankcase ventilation valvep. 57
+Xp. 57
Xp. 57
+5.39p. 57
5.39p. 57
+Change the injection valvesp. 57
Change the injection valvesp. 57
+only by authorized service personnelp. 57
only by authorized service personnelp. 57
+Xp. 57
Xp. 57
+5.40p. 57
5.40p. 57
+Service the combustion air filterp. 57
Service the combustion air filterp. 57
+at least 1x every year, safety cartridge at least every 2 yearsp. 57
at least 1x every year, safety cartridge at least every 2 yearsp. 57
+Xp. 57
Xp. 57
+5.41p. 57
5.41p. 57
+Adjust scrapers and edge cuttersp. 57
Adjust scrapers and edge cuttersp. 57
+Xp. 57
Xp. 57
+5.42p. 57
5.42p. 57
+Replace the wheel capsp. 57
Replace the wheel capsp. 57
+Xp. 57
Xp. 57
+5.43p. 57
5.43p. 57
+Check the condition of the cutting blades, replace the cutting blades if necessaryp. 57
Check the condition of the cutting blades, replace the cutting blades if necessaryp. 57
+Xp. 57
Xp. 57
+5.44p. 57
5.44p. 57
+Fill the provision tank for the windscreen washer systemp. 57
Fill the provision tank for the windscreen washer systemp. 57
+Xp. 57
Xp. 57
+5.45p. 58
5.45p. 58
+Drain off dirty fluids from front and rear framep. 58
Drain off dirty fluids from front and rear framep. 58
+Xp. 58
Xp. 58
+5.46p. 58
5.46p. 58
+Tighten all bolted connectionsp. 58
Tighten all bolted connectionsp. 58
+Xp. 58
Xp. 58
+5.47p. 58
5.47p. 58
+Engine conservationp. 58
Engine conservationp. 58
+Xp. 58
Xp. 58
+5 E-Plan wiring diagramsp. 59
+5 E-Plan wiring diagramsp. 59
5.1 Understanding wiring diagramsp. 60
+Electric circuit diagramsp. 60
Electric circuit diagramsp. 60
+Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics.p. 60
Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics.p. 60
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 60
+l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 60
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 60
l The sequence in which current flows through the individual elements in the electric circuit.p. 60
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.p. 60
l Pin assignment of plug-and-socket connections.p. 60
+Structure of a wiring diagramp. 60
Structure of a wiring diagramp. 60
+l Cover sheet, see section "Cover sheet"p. 60
l Cover sheet, see section "Cover sheet"p. 60
l Table of contents, see section "Table of contents"p. 60
l Structuring symbol overview, see section "Structuring symbol overview"p. 60
+The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 60
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 60
+l Sheets with illustration of function, see section"Sheets with illustration of function"p. 60
l Sheets with illustration of function, see section"Sheets with illustration of function"p. 60
l List of fuels and lubricants, see "List of fuels and lubricants"p. 60
l Terminal strip overview, see section "Terminal strip overview"p. 60
l Plug overview, see section "Plug overview"p. 60
l Pin overview, see section "Pin overview"p. 60
Cover sheetp. 61
+The cover sheet, see examplep. 61
(Fig. 17)p. 61
Fig. 17 Example: Cover sheetp. 61
Table of contentsp. 62
+The table of contents, see examplep. 62
(Fig. 18)p. 62
Fig. 18 Example: Table of contentsp. 62
Sheets with representations of functionsp. 63
+l The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 63
l The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 63
l All sheets are successively numbered.p. 63
+l BOMAG used the resolved type of representation. In this case parts and components with different functions, which belong to the same components (e.g. relay coil and relay contact), can be represented on different sheets. Cross-references, which ref…p. 63
(Fig. 19)p. 63
Fig. 19 Example: Sheet with functionsp. 63
+Current pathsp. 63
+Current pathsp. 63
(Fig. 19)p. 63
+l Current paths are successively numbered from 0 to 9.p. 63
l Current paths are successively numbered from 0 to 9.p. 63
+Potential cross referencesp. 63
+Potential cross referencesp. 63
(Fig. 19)p. 63
+l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 63
l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 63
+Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current path 1.p. 63
Example: Potential 15_54 +SEAT/16.1p. 63
+SEATp. 63
+Relay cross referencesp. 64
+Relay cross referencesp. 64
(Fig. 19)p. 64
+l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta…p. 64
l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta…p. 64
+Example: The relay cross-reference (p. 64
Example:p. 64
-K61/4.2p. 64
List of componentp. 65
+The list of components, see examplep. 65
(Fig. 20)p. 65
Fig. 20 Example: List of componentsp. 65
An electric component is a part, assembly or device in an electrical installation.p. 65
+l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the …p. 65
l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the …p. 65
l The component identifications are alphabetically sorted in the list of components. Each component has the corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which installation location it is assigned t…p. 65
+Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 65
Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 65
Overview of terminal stripsp. 66
+The overview of terminal strips, see axamplep. 66
(Fig. 21)p. 66
Fig. 21 Example: Terminal strip overview X1p. 66
Overview of plugsp. 67
+The overview of plugs, see examplep. 67
(Fig. 22)p. 67
The following information is listed for each plug:p. 67
+l Contact numberingp. 67
l Contact numberingp. 67
l Structuring symbolsp. 67
l Function textp. 67
l Use in wiring diagram.p. 67
Fig. 22 Example: Plug overview X0p. 67
Overview of pinsp. 68
+The overview of pins, see examplep. 68
(Fig. 23)p. 68
Fig. 23 Example: Overview of pins, control A66p. 68
5.2 Circuit symbols in the circuit diagramp. 69
+Circuit symbolsp. 69
Circuit symbolsp. 69
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 compliance …p. 69
Fig. 24 Example: Circuit symbolp. 69
+1 Current sourcep. 69
1 Current sourcep. 69
2 Conductorp. 69
3 Switchp. 69
4 Groundp. 69
5 Filament lampp. 69
6 Filament lamp with two luminous elementsp. 69
7 Voltmeterp. 69
8 Amperemeterp. 69
9 Resistancep. 69
10 Fusep. 69
11 Terminal stripp. 69
12 Plugp. 69
+Different symbols are used to simplify the differentiation of terminal strips 11p. 69
(Fig. 24)p. 69
+Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug.p. 69
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug.p. 69
Representation of electric devicesp. 70
Electronic devices and components are increasingly used in the construction equipment industry. Controls with software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently used to represent and contro…p. 70
+Black-Box representationp. 70
+Black-Box representationp. 70
(Fig. 25)p. 70
The Black-Box representation shows the device as a Box with the connections required for the machine function. Connections which are not needed do not need to be represented.p. 70
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is available.p. 70
Fig. 25 Example: Central lubrication systemp. 70
+Identification of externally supplied documentationp. 70
(Fig. 26)p. 70
In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the projecting of machines. These systems may be composed of various components and wirings. For easier differentiation of BOMAG designati…p. 70
Fig. 26 Example: Identification of externally supplied documentationp. 70
+PLC representationp. 70
+PLC representationp. 70
(Fig. 27)p. 70
The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections which are not needed do not n…p. 70
Fig. 27 PLC representationp. 71
The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which were specified accordingly, and where information on the assignment of signals is available.p. 71
Identification of similar, adjacent switching symbolsp. 71
In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are arranged just next to each other. In such cases it is common practice to reduce the identification on the subsequent symbol to the criteri…p. 71
+Example: -X0 36 and -X0 37p. 71
(Fig. 27)p. 71
In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol.p. 71
5.3 Identification of switch blocks in the wiring diagramp. 72
+Switches of modular designp. 72
Switches of modular designp. 72
+l For normally open contacts the contact symbols "_3/_4" are used.p. 72
l For normally open contacts the contact symbols "_3/_4" are used.p. 72
l For normally closed contacts the contact symbols "_1/_2" are used.p. 72
In combination with the contact block numbering described above each individual connection is clearly defined.p. 72
Fig. 28p. 72
Example:p. 72
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" / "42" if it is a normally closed contact.p. 72
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it is a normally closed contact.p. 72
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it is a normally closed contact.p. 72
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it is a normally closed contact.p. 72
+6 Electricsp. 73
+6 Electricsp. 73
6.1 Designation of components in the wiring diagramp. 74
+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. 74
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. 74
Control lights, warning buzzer, warning lightp. 74
+Kp. 74
Kp. 74
+Relaysp. 74
Relaysp. 74
+Mp. 74
Mp. 74
+Starter, pumps, motorsp. 74
Starter, pumps, motorsp. 74
+Pp. 74
Pp. 74
+Operating hour meter, general gaugesp. 74
Operating hour meter, general gaugesp. 74
+Rp. 74
Rp. 74
+Transducers, resistorsp. 74
Transducers, resistorsp. 74
+Sp. 74
Sp. 74
+Switches, momentary contact switchesp. 74
Switches, momentary contact switchesp. 74
+Vp. 74
Vp. 74
+Diodep. 74
Diodep. 74
+Xp. 74
Xp. 74
+Terminalp. 74
Terminalp. 74
+Yp. 74
Yp. 74
+Solenoid valvesp. 74
Solenoid valvesp. 74
6.2 Terminal designations in wiring diagramp. 75
+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. 75
+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. 75
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. 75
+Terminal designationp. 75
Terminal designationp. 75
+Meaningp. 75
Meaningp. 75
+15p. 75
15p. 75
+Switch plus (after battery) : Output of ignition switchp. 75
Switch plus (after battery) : Output of ignition switchp. 75
+15ap. 75
15ap. 75
+Output from dropping resistor to ignition coil and starterp. 75
Output from dropping resistor to ignition coil and starterp. 75
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 75
Battery changeover relay 12V / 24V return line to battery 2 minusp. 75
+31bp. 75
31bp. 75
+Return line to battery minus or ground via switch or relay (switched minus)p. 75
Return line to battery minus or ground via switch or relay (switched minus)p. 75
+31cp. 75
31cp. 75
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 75
Battery changeover relay 12V / 24V return line to battery 1 minusp. 75
+49p. 75
49p. 75
+Input flasher relayp. 75
Input flasher relayp. 75
+49ap. 75
49ap. 75
+Output flasher relayp. 75
Output flasher relayp. 75
+49bp. 75
49bp. 75
+Flasher relay output 2nd flasher circuitp. 75
Flasher relay output 2nd flasher circuitp. 75
+49cp. 75
49cp. 75
+Flasher relay output 3rd flasher circuitp. 75
Flasher relay output 3rd flasher circuitp. 75
+50p. 75
50p. 75
+Starter, starter controlp. 75
Starter, starter controlp. 75
+50ap. 75
50ap. 75
+Battery changeover relay, output for starter controlp. 75
Battery changeover relay, output for starter controlp. 75
+53p. 75
53p. 75
+Wiper motor input (+)p. 75
Wiper motor input (+)p. 75
+53ap. 75
53ap. 75
+Wiper motor (+) end limit shut downp. 75
Wiper motor (+) end limit shut downp. 75
+53bp. 75
53bp. 75
+Wiper shunt windingp. 75
Wiper shunt windingp. 75
+56p. 75
56p. 75
+Head lightp. 75
Head lightp. 75
+56ap. 75
56ap. 75
+Head light, travel light and travel light controlp. 75
Head light, travel light and travel light controlp. 75
+56bp. 75
56bp. 75
+Head lights, dimmed head lightp. 75
Head lights, dimmed head lightp. 75
+56dp. 75
56dp. 75
+Head lights, flash lightp. 75
Head lights, flash lightp. 75
+57p. 75
57p. 75
+Parking light for motor cycles (abroad also for cars and trucks)p. 75
Parking light for motor cycles (abroad also for cars and trucks)p. 75
+57ap. 75
57ap. 75
+Parking lightp. 75
Parking lightp. 75
+57Lp. 75
57Lp. 75
+Parking light leftp. 75
Parking light leftp. 75
+57Rp. 75
57Rp. 75
+Parking light rightp. 75
Parking light rightp. 75
+58p. 75
58p. 75
+Side lights, tail light, number plate light, dashboard lightp. 75
Side lights, tail light, number plate light, dashboard lightp. 75
+58bp. 75
58bp. 75
+Tail light changeover for single axle trailersp. 75
Tail light changeover for single axle trailersp. 75
+58cp. 75
58cp. 75
+Trailer plug for single core wired and trailer fused tail lightp. 75
Trailer plug for single core wired and trailer fused tail lightp. 75
+58dp. 75
58dp. 75
+Adjustable dashboard light, tail light and side lightp. 75
Adjustable dashboard light, tail light and side lightp. 75
+58Lp. 75
58Lp. 75
+Side light, leftp. 75
Side light, leftp. 75
+58Rp. 75
58Rp. 75
+Side light, rightp. 75
Side light, rightp. 75
+61p. 75
61p. 75
+Generator controlp. 75
Generator controlp. 75
+75p. 75
75p. 75
+Radio, cigarette lighterp. 75
Radio, cigarette lighterp. 75
+76p. 75
76p. 75
+Loudspeakerp. 75
Loudspeakerp. 75
+87p. 75
87p. 75
+Relay contact on breaker and two-way contact, inputp. 75
Relay contact on breaker and two-way contact, inputp. 75
+87ap. 76
87ap. 76
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 76
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 76
+87bp. 76
87bp. 76
+Relay contact on breaker and two-way contact, output 2p. 76
Relay contact on breaker and two-way contact, output 2p. 76
+87cp. 76
87cp. 76
+Relay contact on breaker and two-way contact, output 3p. 76
Relay contact on breaker and two-way contact, output 3p. 76
+87zp. 76
87zp. 76
+Relay contact on breaker and two-way contact, input 1p. 76
Relay contact on breaker and two-way contact, input 1p. 76
+87yp. 76
87yp. 76
+Relay contact on breaker and two-way contact, input 2p. 76
Relay contact on breaker and two-way contact, input 2p. 76
+87xp. 76
87xp. 76
+Relay contact on breaker and two-way contact, input 3p. 76
Relay contact on breaker and two-way contact, input 3p. 76
+88p. 76
88p. 76
+Relay contact for makerp. 76
Relay contact for makerp. 76
+88ap. 76
88ap. 76
+Relay contact on maker and two-way contact, (maker side) output 1p. 76
Relay contact on maker and two-way contact, (maker side) output 1p. 76
+88bp. 76
88bp. 76
+Relay contact on maker and two-way contact, (maker side) output 2p. 76
Relay contact on maker and two-way contact, (maker side) output 2p. 76
+88cp. 76
88cp. 76
+Relay contact on maker and two-way contact, (maker side) output 3p. 76
Relay contact on maker and two-way contact, (maker side) output 3p. 76
+88zp. 76
88zp. 76
+Relay contact on maker, input 1p. 76
Relay contact on maker, input 1p. 76
+88yp. 76
88yp. 76
+Relay contact on maker, input 2p. 76
Relay contact on maker, input 2p. 76
+88xp. 76
88xp. 76
+Relay contact on maker, input 3p. 76
Relay contact on maker, input 3p. 76
+B+p. 76
B+p. 76
+Battery positivep. 76
Battery positivep. 76
+B-p. 76
B-p. 76
+Battery minusp. 76
Battery minusp. 76
+D+p. 76
D+p. 76
+Dynamo Plusp. 76
Dynamo Plusp. 76
+D-p. 76
D-p. 76
+Dynamo Minusp. 76
Dynamo Minusp. 76
+DFp. 76
DFp. 76
+Dynamo field (generator excitation current)p. 76
Dynamo field (generator excitation current)p. 76
+DF1p. 76
DF1p. 76
+Dynamo field 1 (generator excitation current)p. 76
Dynamo field 1 (generator excitation current)p. 76
+DF2p. 76
DF2p. 76
+Dynamo field 2 (generator excitation current)p. 76
Dynamo field 2 (generator excitation current)p. 76
+DTM Seriesp. 77
6.3 Battery ground and analog groundp. 77
+GND, battery groundp. 77
GND, battery groundp. 77
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. 77
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. 77
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. 77
Terminal designation for GND = terminale 31p. 77
+AGND, analog groundp. 77
AGND, analog groundp. 77
Apart from the "normal" battery ground there is also the analog ground, which is solely reserved for sensors.p. 77
+DTM Seriesp. 77
6.4 Current and voltagep. 77
+Generalp. 77
Generalp. 77
If one wants to describe electric current, this can most simply be accomplished by means of a comparison:p. 77
One simply compares electric current with water.p. 77
+Voltagep. 77
Voltagep. 77
Fig. 1p. 77
+1 (Fig. 1) Chargep. 77
+1 (Fig. 1) Chargep. 77
1 (Fig. 1)p. 77
2 Voltagep. 77
3 Currentp. 77
+The equalization attempt between different electric charges is referred to as electric voltage.p. 77
The equalization attempt between different electric charges is referred to as electric voltage.p. 77
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. 77
Fig. 2p. 77
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.p. 77
Plus pole= lack of electronsp. 77
Minus pole = excess of electronsp. 77
The following statements concerning electric voltage can be madep. 78
+l electric voltage is the pressure or force applied to free electrons.p. 78
l electric voltage is the pressure or force applied to free electrons.p. 78
l the electric voltage is the cause of electric currentp. 78
l electric voltage is a result of the equalization attempt of electric charges.p. 78
Voltage is measured with a Voltmeter.p. 78
Unit, Voltp. 78
The electric voltage (U) is measured in Volt (V).p. 78
Currentp. 78
+Electric current generally describes the directed movement of charge carriers.p. 78
Electric current generally describes the directed movement of charge carriers.p. 78
+l The charge carriers may either be electrons or ions.p. 78
l The charge carriers may either be electrons or ions.p. 78
l Electric current can only flow if there is a sufficient amount of free moving charge carriers.p. 78
l The higher the number of electrons flowing through a conductor per second, the higher the amperage.p. 78
Current is measured with an ammeter.p. 78
Unit, Amperep. 78
The electric amperage (I) is measured in Ampere (A).p. 78
The technical flow direction is specified from PLUS to MINUS.p. 78
+Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 78
Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 78
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. 78
+Circuitp. 78
Circuitp. 78
Fig. 3 Circuitp. 78
+A simple circuit consists of a current source 1p. 78
(Fig. 3)p. 78
When the circuit is closed, current can flow.p. 78
The circuit can be interrupted or closed with a switch (2).p. 78
The system is protected by a fuse (4).p. 78
Types of currentp. 79
+Direct current (D.C.)p. 79
Direct current (D.C.)p. 79
Fig. 1 Direct current (D.C.)p. 79
Direct current flows with steady voltage and amperage from the plus to the minus pole.p. 79
Pure D.C.-voltages are only delivered by accumulators or batteries.p. 79
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. 79
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off.p. 79
+Alternating current (A.C.)p. 79
Alternating current (A.C.)p. 79
Fig. 2 Alternating current (A.C.)p. 79
Alternating current not only changes its direction, but also its amperage.p. 79
+DTM Seriesp. 79
6.5 Resistancep. 79
+Resistance and voltage dropp. 79
Resistance and voltage dropp. 79
+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. 79
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. 79
Fig. 1 Various size resistorsp. 79
+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. 79
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. 79
The resistance can only be measured with a Multimeter.p. 79
Symbol, Rp. 79
+Unit, Ohmp. 79
Wp. 79
+The electric resistance (R) is measured in Ohmp. 79
Wp. 79
Rule of thumb:p. 79
+l The thicker the cable cross-section, the lower the voltage loss.p. 79
l The thicker the cable cross-section, the lower the voltage loss.p. 79
l The shorter the cable, the better the current.p. 79
l The cleaner the contacts, the better the current.p. 80
l The quality of the ground cable is of the same importance as the supply line.p. 80
+Unnecessary resistancesp. 80
Unnecessary resistancesp. 80
+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. 80
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. 80
Badp. 80
Fig. 1 Screw-type terminalsp. 80
Copper wires are squashed and thus become faulty.p. 80
+Betterp. 80
Betterp. 80
Fig. 2 Spring clampsp. 80
Connecting clamps for flexible conductorsp. 80
BOMAG No. 057 565 72p. 80
Ampacity up to 20 Amp.p. 80
Cable cross-section 0.08 to 2.5 qmmp. 80
Fig. 3p. 80
+In many cases it is better to replace the contact. Soiled or oxidized contacts should be cleaned with Ballistolp. 80
(Fig. 4)p. 80
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. 80
Fig. 4 Balistol oilp. 80
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. 81
Fig. 5p. 81
Hint for practice:p. 81
A tool you cannot buy. The pliers were converted, the nail is permanently present.p. 81
+DTM Seriesp. 81
6.6 Series / parallel connectionp. 81
+Series connectionp. 81
Series connectionp. 81
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. 81
Fig. 1 Series connectionp. 81
Currentp. 81
In series connection the current is identical at every point.p. 81
Itotal = I1 = I2 = I3p. 81
Voltagep. 81
The sum of all partial voltages is identical with the total voltage.p. 81
Utotal = U1 + U2 + U3p. 81
Resistancep. 81
The sum of all partial resistances is identical with the total resistance.p. 81
Rtotal = R1 + R2 + R3p. 81
+Series connection of batteriesp. 81
Series connection of batteriesp. 81
Fig. 2p. 81
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. 81
+l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 82
l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 82
l The sum of all individual voltages is applied to the free poles.p. 82
l The total capacity (Ah) is identical with the capacity of the individual battery.p. 82
+Parallel connection of batteriesp. 82
Parallel connectionp. 82
In parallel connection all resistances (consumers) are connected between feed and return line.p. 82
+l All resistances (consumers) are supplied with the same voltage.p. 82
l All resistances (consumers) are supplied with the same voltage.p. 82
l Each of the resistances (consumers) draws as much current as required.p. 82
Fig. 3 Parallel connectionp. 82
Currentp. 82
The total current is the sum of all currents.p. 82
Itotal = I1 + I2 + I3p. 82
Voltagep. 82
The voltage values are identical at every resistance (consumer).p. 82
Utotal = U1 = U2 = U3p. 82
Resistancep. 82
The total resistance is less than the lowest individual resistance.p. 82
+Parallel connection of batteriesp. 82
Parallel connection of batteriesp. 82
Fig. 4p. 82
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. 82
+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. 83
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. 83
l Plus and minus poles have the voltage of the single battery applied.p. 83
l The total capacity (Ah) is identical with the sum of all battery capacities.p. 83
The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of charging.p. 83
+DTM Seriesp. 83
6.7 Ohm's lawp. 83
+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. 83
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. 83
Fig. 1p. 83
+According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohmp. 83
Wp. 83
Advicep. 83
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. 83
Voltage U = I multiplied with Rp. 83
Resistance R = U divided by Ip. 83
Amperage I = U divided by Rp. 83
U = Voltage in Voltp. 83
I = Current in Amperep. 83
+R = Resistance in OHMp. 83
Wp. 83
+DTM Seriesp. 84
6.8 Electrical energyp. 84
Fig. 1p. 84
In a closed electric circuit current and voltage generate energy.p. 84
If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced.p. 84
Advicep. 84
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. 84
Energy P = I multiplied with Up. 84
Amperage I = P divided by Up. 84
Voltage U = P divided by Ip. 84
U = Voltage in Voltp. 84
I = Current in Amperep. 84
P = Power in Wattp. 84
+DTM Seriesp. 85
6.9 Formula diagramp. 85
+Description:p. 85
Description:p. 85
+l Select the desired value from the inner circle.p. 85
l Select the desired value from the inner circle.p. 85
l Determine the formula variables in the quarter circlep. 85
l Calculatep. 85
Example:p. 85
P = 150 Wattp. 85
U = 24 Voltp. 85
Sought for = Current in Amperep. 85
I = P : U = 150 W : 24 Volt = 6.25 Amperep. 85
Fig. 1 Formula diagramp. 85
+Resistance, R Ohmp. 85
Wp. 85
Voltage, U Voltp. 85
Current, I Amperep. 85
Power, P Wattp. 85
+DTM Seriesp. 86
6.10 Metrologyp. 86
+Test lampsp. 86
Test lampsp. 86
+Test lampp. 86
Test lampp. 86
Fig. 1 Test lampp. 86
+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. 86
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. 86
+Diode test lampp. 86
Diode test lampp. 86
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. 86
Fig. 2 Diode test lampp. 86
If voltage is present, the corresponding light emitting diode will light up.p. 86
Multimeterp. 86
+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. 86
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. 86
Fig. 1 Multimeterp. 86
In order to avoid damage:p. 86
+l the range selector switch must be correctly set for the corresponding measurement.p. 86
l the range selector switch must be correctly set for the corresponding measurement.p. 86
l the test cable must be plugged into the correct socket.p. 86
l the voltage type (AC/DC) must be set.p. 86
l In case of direct voltage the correct polarity must be assured.p. 86
l the measuring range should be chosen higher at the beginning of the test.p. 86
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. 86
Resistance and continuity measurement with multimeterp. 87
Fig. 2p. 87
The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points.p. 87
Fig. 3p. 87
The following information should be observed when measuring resistance and continuity:p. 87
+l The component to be measured must not be connected to the power supply during the measurement.p. 87
l The component to be measured must not be connected to the power supply during the measurement.p. 87
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. 87
l Polarity is of no significance.p. 87
Voltage and voltage drop measurement with multimeterp. 87
Fig. 4 Measuring voltagep. 87
+l Measurement at the voltage source measures the currently available Voltage.p. 87
l Measurement at the voltage source measures the currently available Voltage.p. 87
l The meter is always connected parallel to consumer, component or power source.p. 87
Fig. 5 Voltage measurementp. 87
+l A measurement at the consumer measures the voltage drop at this component.p. 87
l A measurement at the consumer measures the voltage drop at this component.p. 87
Current measurement with the multimeterp. 88
Fig. 6 Measuring currentp. 88
+l The meter is connected in series with the consumer.p. 88
l The meter is connected in series with the consumer.p. 88
l During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened.p. 88
Fig. 7 Current measurementp. 88
Advicep. 88
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. 88
The current value can then be calculated with the help of Ohm's law.p. 88
Clip-on measuring instrumentp. 88
+The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 88
The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 88
Fig. 1 Clip-on measuring instrumentp. 88
Fig. 2p. 88
+l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 88
l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 88
Magnet testerp. 89
Fig. 1 Magnet testerp. 89
The magnet tester is used to test solenoid valves and magnetic coils.p. 89
The test lamp responds to the magnetic fields of A.C- voltage, D.C.-voltage and permanent magnets.p. 89
+l The component to be tested does not need to be removed.p. 89
l The component to be tested does not need to be removed.p. 89
l The magnetic coil can also be tested under a protective cap.p. 89
Power measurementp. 89
The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage.p. 89
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. 89
Fig. 2p. 89
+DTM Seriesp. 90
6.11 Diodes, relays, fusesp. 90
+Diodesp. 90
Diodesp. 90
Fig. 1p. 90
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. 90
Plus-voltage on diode:p. 90
+l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 90
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 90
Negative voltage on diode:p. 90
+l The diode does not allow current to pass through.p. 90
l The diode does not allow current to pass through.p. 90
Fig. 2 Marking of the cathodep. 90
Diodes are used:p. 90
+l For rectifying A.C. voltage.p. 90
l For rectifying A.C. voltage.p. 90
l For absorbing voltage peaks (free-wheeling diode).p. 90
l For construction of logical circuits.p. 90
+Diode logics and free-wheeling diodep. 90
Diode logics and free-wheeling diodep. 90
Fig. 3 Diode circuitryp. 90
+l The solenoid valve Y48p. 90
+l The solenoid valve Y48p. 90
(Fig. 3)p. 90
l Solenoid valve Y20 is supplied, if the switch is in position "1".p. 90
l Solenoid valve Y21 is supplied, if the switch is in position "2".p. 90
The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.p. 90
+Light emitting diodesp. 91
Light emitting diodesp. 91
Fig. 4 LEDp. 91
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. 91
Relaysp. 91
Fig. 1 Relaysp. 91
Relays are commonly used to realize switching processes.p. 91
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. 91
With the possibility of using breaker – maker contacts the effect of an information can be reversed.p. 91
Fig. 2 Relay circuitryp. 91
+The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric currentp. 91
(Fig. 2)p. 91
86 = Positive supply for coilp. 91
85 = Ground supply for coilp. 92
30 = Supply voltagep. 92
87 = Normally open contactp. 92
87a= Normally closed contactp. 92
Fusesp. 92
Fig. 1p. 92
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. 92
+Fuses must not be repaired or bridged.p. 92
Fuses must not be repaired or bridged.p. 92
The melting time at 23 °C is:p. 92
+l approx. 1 hour with 1.5 times the rated currentp. 92
l approx. 1 hour with 1.5 times the rated currentp. 92
l approx. 1 minute with 2.5 times the rated current.p. 92
A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours.p. 92
Yellow = 5 Ap. 92
Brown = 7.5 Ap. 92
White = 8 Ap. 92
Red = 16 Ap. 92
Blue = 25 Ap. 92
+DTM Seriesp. 93
6.12 Telemecanique switchp. 93
+Disassemblyp. 93
Disassemblyp. 93
Fig. 1 Disassemblyp. 93
+l Lift up the interlock (5).p. 93
l Lift up the interlock (5).p. 93
Fig. 2 Folding down the switch blockp. 93
+l Fold down the switch block (4).p. 93
l Fold down the switch block (4).p. 93
l Loosen screw (1).p. 93
Fig. 3 Pulling out the front elementp. 93
+l Lift up the interlock (2) and pull out the front element (3).p. 93
l Lift up the interlock (2) and pull out the front element (3).p. 93
Assemblyp. 94
Fig. 4 Assemblyp. 94
+l Insert the front element (3) into the bore in the control panel.p. 94
l Insert the front element (3) into the bore in the control panel.p. 94
Fig. 5 Observe the marks.p. 94
+l Clip the fastening adapter (6) onto the front element (3).p. 94
l Clip the fastening adapter (6) onto the front element (3).p. 94
+Watch the marls on front elementp. 94
+Watch the marls on front elementp. 94
(Fig. 5)p. 94
+l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 94
l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 94
Fig. 6 Assemble the switch blockp. 94
+l Clip on the switch block (4).p. 94
l Clip on the switch block (4).p. 94
+Hook in the switch block at the bottom firstp. 94
+Hook in the switch block at the bottom firstp. 94
(Fig. 6)p. 94
+DTM Seriesp. 95
6.13 Plug connectorsp. 95
+Duties and requirementsp. 95
Duties and requirementsp. 95
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. 95
+Examples for these loads are:p. 95
Examples for these loads are:p. 95
+l Vibration accelerationp. 95
l Vibration accelerationp. 95
l Temperature fluctuations, high and low temperaturesp. 95
l Dampnessp. 95
l Micro movements of the contact with resulting friction corrosion.p. 95
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. 95
+l Low transition resistances of the conductive parts.p. 95
l Low transition resistances of the conductive parts.p. 95
l High insulation strength between conductive parts with different voltage potentials.p. 95
l Excellent leak tightness against water and moisture.p. 95
+DTM Seriesp. 95
6.14 Magnetic coil plugp. 95
+Magnetic coil plug with LED and suppressor diodep. 95
Magnetic coil plug with LED and suppressor diodep. 95
The plug is equipped with a polarized function display and a suppressor diode as protection against overvoltages.p. 95
Fig. 7p. 95
The plug is reverse polarity protected, 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. 95
Fig. 8p. 95
Fig. 9 Switching symbol in circuit diagramp. 95
+Magnetic coil plug without LED and without supressor diodep. 95
Magnetic coil plug without LED and without supressor diodep. 95
The plug has no LED and no suppressor diode as protection against overvoltages.p. 95
+Assembly of magnetic coil plugsp. 96
Assembly of magnetic coil plugsp. 96
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. 96
Fig. 10 Solenoid valve plug with pointed cablep. 96
Fig. 11p. 96
+l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 96
l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 96
Fig. 12p. 96
+l Fasten the screw with a suitable screwdriver.p. 96
l Fasten the screw with a suitable screwdriver.p. 96
Fig. 13p. 96
+l Press the plug firmly on again.p. 96
l Press the plug firmly on again.p. 96
Fig. 14p. 96
+l Retighten the screw.p. 96
l Retighten the screw.p. 96
Fig. 15p. 97
+There should be no gap between plug and solenoid coil!p. 97
There should be no gap between plug and solenoid coil!p. 97
Fig. 16 Correctly installed plug without gapp. 97
+DTM Seriesp. 97
6.15 Deutsch plug, series DT and DTMp. 97
+Generalp. 97
Generalp. 97
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. 97
Fig. 17 Crimp connectionsp. 97
+Do not crimp more than one lead per pin or per socket.p. 97
Do not crimp more than one lead per pin or per socket.p. 97
Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics).p. 97
When connecting sockets and plugs these must engage with a noticeable click when both halves interlock.p. 97
The plug connection should not be separable (without loosening the interlock).p. 97
Pulling testp. 97
This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing.p. 97
+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. 97
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. 97
+DT Seriesp. 98
DT Seriesp. 98
Fig. 1 DT plug connectionp. 98
Fig. 2 DT Seriesp. 98
Fig. 3 Sectional drawingp. 98
+DTM Seriesp. 99
DT Seriesp. 99
+Installing DT contactsp. 99
Installing DT contactsp. 99
Fig. 4p. 99
+l Insert the contacts through the rubber grommet until they click into place.p. 99
l Insert the contacts through the rubber grommet until they click into place.p. 99
l Insert the orange wedge in direction of arrow.p. 99
+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. 99
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. 99
+Use the same method when assembling the socket.p. 99
Use the same method when assembling the socket.p. 99
+Disassembling DT contactsp. 99
Disassembling DT contactsp. 99
Fig. 5p. 99
+l Pull the orange wedge out with long nose pliers.p. 99
l Pull the orange wedge out with long nose pliers.p. 99
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 99
l Pull the contact out of the socket.p. 99
+Use the same method when assembling the socket.p. 99
Use the same method when assembling the socket.p. 99
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 99
+DTM Seriesp. 100
DTM Seriesp. 100
Fig. 6 DTM Seriesp. 100
Fig. 7 Sectional drawingp. 100
+Installing DTM contactsp. 100
Installing DTM contactsp. 100
Fig. 8p. 100
+l Insert the contacts through the rubber grommet until they click into place.p. 100
l Insert the contacts through the rubber grommet until they click into place.p. 100
l Insert the orange wedge, until it clicks into place.p. 100
+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. 101
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. 101
+Use the same method when assembling the socket.p. 101
Use the same method when assembling the socket.p. 101
+Removing DTM contactsp. 101
Removing DTM contactsp. 101
Fig. 9p. 101
+l Pull the orange wedge (interlock) out with long nose pliers.p. 101
l Pull the orange wedge (interlock) out with long nose pliers.p. 101
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 101
l Pull the contact out of the socket.p. 101
+Use the same method when assembling the socket.p. 101
Use the same method when assembling the socket.p. 101
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 101
+6.19 Battery service, checking the main battery switchp. 102
6.16 Plugs and terminals in spring clamping technologyp. 102
+Generalp. 102
Generalp. 102
Fig. 1p. 102
+The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 102
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 102
+Spring clamp technologyp. 102
(Fig. 1)p. 102
+Connecting terminal for quick repairsp. 102
Connecting terminal for quick repairsp. 102
Fig. 2 That's how it worksp. 102
BOMAG part-no.: 057 565 72p. 102
+The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mmp. 102
2p. 102
2p. 102
2p. 102
(Fig. 2)p. 102
That's how it worksp. 102
+l Strip 9-10 mm of the lead.p. 102
l Strip 9-10 mm of the lead.p. 102
l Open the actuating lever and insert the strand.p. 102
l Return the actuating lever to initial position.p. 102
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 102
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 102
+X-COM plug clampp. 103
Series clampp. 103
Fig. 3 That's how it worksp. 103
That's how it worksp. 103
+l Insert a screw driver into the actuating opening until it bottoms.p. 103
l Insert a screw driver into the actuating opening until it bottoms.p. 103
l Strip 9-10 mm of the lead and insert it into the clamp.p. 103
l Pull out the screw driver.p. 103
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 103
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 103
Measuring signalsp. 103
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. 103
Fig. 4 Test adapterp. 103
+X-COM plug clampp. 104
X-COM Systemp. 104
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. 104
+X-COM plug clampp. 104
X-COM plug clampp. 104
Fig. 5 That's how it worksp. 104
That's how it worksp. 104
+l Insert a screw driver into the actuating opening until it bottoms.p. 104
l Insert a screw driver into the actuating opening until it bottoms.p. 104
l Strip 9-10 mm of the lead and insert it into the plug.p. 104
l Pull out the screw driver.p. 104
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 104
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 104
Fig. 6 X-COM plug with measuring cablep. 104
+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. 104
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. 104
Measuring signalsp. 105
Fig. 7 X-COM plug plugged onto the series clampp. 105
+6.19 Battery service, checking the main battery switchp. 106
6.17 Inductive proximity switchesp. 106
+Generalp. 106
Generalp. 106
In all automated sequences the use of sensors as a source of information for the electronic control is indispensable. The sensors deliver the necessary signals about positions, end positions, filling levels or serve as pulse transducers for counting …p. 106
+Working principlep. 106
Working principlep. 106
Fig. 8p. 106
The working principle is based on the principle of the dampened LC-oscillator. The coil of the oscillation circuit forms a high-frequency magnetic stray field.p. 106
This stray field leaks out from the active area of the proximity switch. If metal or non-ferrous metal enters into the response range energy is absorbed. The oscillator is thus dampened and the resulting change in current consumption is evaluated.p. 106
+PNP circuitryp. 106
PNP circuitryp. 106
Fig. 9 PNP circuitryp. 106
On sensors with PNP-circuitry the output stage contains a PNP-transistor, which switches the load against the positive operating voltage. The load is connected between the output and the negative operating voltage. The switch is designed with a norma…p. 106
+NPN circuitryp. 106
NPN circuitryp. 106
Fig. 10 NPN circuitryp. 106
On sensors with NPN-circuitry the output stage contains a NPN-transistor, which switches the load against the negative operating voltage. The load is connected between the output and the positive operating voltage.p. 106
+Breaking and making contactsp. 106
Breaking and making contactsp. 106
Fig. 11p. 106
Proximity switches are used as breaking or making contacts. Depending on the design the switching distances are 2 or 4 mm. The maximum amperage is 300 mA.p. 106
+The LEDp. 106
(Fig. 11)p. 106
Fig. 12 Circuit diagram, making contactp. 107
+The circuit diagramp. 107
(Fig. 12)p. 107
Brown = voltage supplyp. 107
Blue = ground supplyp. 107
Black = switching outputp. 107
The initiator switches the relay (K05)p. 107
+6.19 Battery service, checking the main battery switchp. 107
6.18 Batteriesp. 107
+Battery – accumulatorp. 107
Battery – accumulatorp. 107
Fig. 1p. 107
In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries.p. 107
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.p. 107
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. 107
All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.p. 107
Fig. 2p. 107
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.p. 107
Capacityp. 107
is a synonym for the amount of current taken up and discharged by a battery over a specified period of time.p. 107
+Battery maintenancep. 108
Battery maintenancep. 108
+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. 108
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. 108
If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself.p. 108
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. 108
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.p. 108
The following therefore applies for longer downtimes:p. 108
+l Remove the battery and store it in a cool, dry and frost protected room.p. 108
l Remove the battery and store it in a cool, dry and frost protected room.p. 108
l Check the open circuit voltage on the battery at regular intervals (at least once every month).p. 108
l Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).p. 108
+The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 108
The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 108
+Battery test in generalp. 108
Battery test in generalp. 108
+l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 108
l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 108
l Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar.p. 108
+6.19 Battery service, checking the main battery switchp. 108
Batteries with screw plugsp. 108
+Checking the electrolyte levelp. 108
Checking the electrolyte levelp. 108
Fig. 3p. 108
+1 Upper filling level markp. 108
1 Upper filling level markp. 108
2 Lower filling level markp. 108
+l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 108
l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 108
Checking the electrolyte densityp. 109
Fig. 4p. 109
+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. 109
3p. 109
3p. 109
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. 109
Fig. 5 Checking the electrolyte density:p. 109
1) correctp. 109
2) poorp. 109
3) poorp. 109
+(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 109
(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 109
Do not draw too much electrolyte into the pipe.p. 109
Make sure that the float is not obstructed in its movement and hold the electrolyte tester at eye level.p. 109
The electrolyte tester must be read at the highest electrolyte level.p. 109
+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. 109
+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. 109
(reference)p. 109
Referencep. 109
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. 109
+l Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 109
l Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 109
l Specific weight at 68 °F = measuring value + 0,0004 × (electrolyte temperature: 68 °F)p. 109
+Acid density at 27 °C in kg/dmp. 109
3p. 109
+l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 109
l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 109
l 1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary.p. 109
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. 109
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. 109
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. 109
+6.19 Battery service, checking the main battery switchp. 110
Testing batteries without screw plugsp. 110
On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:p. 110
Fig. 6 Battery and generator testerp. 110
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) integrated thermal printer.p. 110
+Before testing clean the poles and ensure good connection between clamps and poles.p. 110
Before testing clean the poles and ensure good connection between clamps and poles.p. 110
The test program calculates the text messages "good" or "replace" on the basis of the charge condition (derived from the battery voltage) and the currently available starting power of the battery. A battery with 45% starting power may thus be rated g…p. 110
The starting power can exceed 100%.p. 110
+6.19 Battery service, checking the main battery switchp. 110
6.19 Battery service, checking the main battery switchp. 110
+Danger of cauterisation ! Danger of explosion!p. 110
+Danger of cauterisation ! Danger of explosion!p. 110
Danger of cauterisation ! Danger of explosion!p. 110
When working on the battery do not use open fire, do not smoke!p. 110
The battery contains acid. Do not let acid come in contact with skin or clothes!p. 110
Wear protective clothing!p. 110
Do not lay any tools on the battery!p. 110
For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.p. 110
+Dispose of the old batteries environmentally.p. 110
Dispose of the old batteries environmentally.p. 110
+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. 110
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. 110
The following therefore applies for the service life:p. 110
+l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 110
l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 110
l Check open-circuit voltage of the battery at regular intervals. At least once per month.p. 110
Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.p. 110
+l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 110
l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 110
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.p. 110
+l After each charging process allow the battery to rest for one hour before taking it into service.p. 110
l After each charging process allow the battery to rest for one hour before taking it into service.p. 110
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. 110
+Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 110
Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 110
+l Disassemble the battery compartment cover.p. 110
l Disassemble the battery compartment cover.p. 110
Fig. 7p. 111
+l Clean battery and battery compartmentp. 111
+l Clean battery and battery compartmentp. 111
(Fig. 7)p. 111
l Clean battery poles and pole clamps and grease them with pole grease (Vaseline).p. 111
l Check the fastening of the battery.p. 111
l On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.p. 111
+Checking the main battery switchp. 111
Checking the main battery switchp. 111
Fig. 8p. 111
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 111
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 111
+l Turn the switchp. 111
+l Turn the switchp. 111
(Fig. 8)p. 111
+6.20 Starting the engine with jump leadsp. 111
6.20 Starting the engine with jump leadsp. 111
+When using external starting aid two external batteries are required, one for each on-board battery.p. 111
+When using external starting aid two external batteries are required, one for each on-board battery.p. 111
When using external starting aid two external batteries are required, one for each on-board battery.p. 111
+l Open the maintenance door to the battery compartment.p. 111
l Open the maintenance door to the battery compartment.p. 111
Fig. 9p. 111
+A wrong connection will cause severe damage in the electric system.p. 111
A wrong connection will cause severe damage in the electric system.p. 111
+l When starting with external batteries connect the positive polesp. 111
+l When starting with external batteries connect the positive polesp. 111
(Fig. 9)p. 111
+l Start as described under "Starting the engine".p. 111
l Start as described under "Starting the engine".p. 111
+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. 111
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. 111
+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. 111
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. 111
+l Once the engine is running switch on a powerful consumer (working light, etc.).p. 111
l Once the engine is running switch on a powerful consumer (working light, etc.).p. 111
l After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 111
l Switch off the consumer.p. 111
+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. 111
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. 111
6.21 Main battery switchp. 112
Fig. 10p. 112
+No. 1 = Main battery switchp. 112
No. 1 = Main battery switchp. 112
+Position "0"p. 112
Position "0"p. 112
Disconnects the batteries from the vehicle electrics in case of burning cables and fire in the engine compartment, protection against unauthorized use during welding work on the machine. Can be removed.p. 112
Position "I"p. 112
Operating position, engine can be started.p. 112
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 112
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 112
6.22 Main fusep. 112
Fig. 11p. 112
+No. 2 = Fuses in battery compartmentp. 112
No. 2 = Fuses in battery compartmentp. 112
+80Ap. 112
80Ap. 112
(F48) Fuse for glow plugsp. 112
125Ap. 112
(F00) main fuse for batteryp. 112
6.23 Hydraulic oil temperaturep. 113
+Temperature sensorp. 113
+Temperature sensorp. 113
Optional equipmentp. 113
The sensor is installed in the hydraulic oil tank. The analog sensor is a variable resistance to ground.p. 113
Fig. 12 Temperature sensorp. 113
+Temperature displayp. 113
+Temperature displayp. 113
Optional equipmentp. 113
Fig. 13 Temperature displayp. 113
The display shows the temperature of the hydraulic oil.p. 113
+Hydraulic oil temperature warning lightp. 113
Temperature switch, B20p. 113
+The temperature switch is installed in the hydraulic oil tank, it switches on at 86°Cp. 113
±3°Cp. 113
±3°Cp. 113
Fig. 14 Temperature switchp. 113
+Hydraulic oil temperature warning lightp. 113
Hydraulic oil temperature warning lightp. 113
+The switch contact connects the monitoring board (A15, Pin13) to ground. The hydraulic oil temperature warning lampp. 113
ip. 113
(Fig. 15)p. 113
Fig. 15 Monitoring board, A15p. 113
+Temperature too highp. 113
Temperature too highp. 113
The hydraulic oil temperature warning light "i" in the instrument cluster lights up, the warning buzzer sounds and the engine is shut down after 2 minutes.p. 113
+The warning buzzer is activated by the monitoring board (Pin23).p. 113
The warning buzzer is activated by the monitoring board (Pin23).p. 113
The engine is shut down by the monitoring board via relay (K22).p. 113
6.24 Pressure switch, hydraulic oil filterp. 114
+Differential pressure switches, B21, B22 and B121p. 114
Differential pressure switches, B21, B22 and B121p. 114
+The differential pressure switches 1p. 114
+The differential pressure switches 1p. 114
(Fig. 1)p. 114
Dp. 114
Dp. 114
Fig. 1 Differential pressure switch on charge oil filterp. 114
+Pressure switch in return flow filter block, B122p. 114
Pressure switch in return flow filter block, B122p. 114
+Pressure switch 1p. 114
(Fig. 2)p. 114
±0,5p. 114
Fig. 2 Pressure switch on return flow filter blockp. 114
+Hydraulic oil filter warning lightp. 114
Hydraulic oil filter warning lightp. 114
+Switching of one or more of the pressure switches connects the monitoring board (A15, Pin17) to ground. The warning lightp. 114
mp. 114
(Fig. 15)p. 114
Fig. 3 Monitoring board, A15p. 114
+m yellowp. 114
+m yellowp. 114
mp. 114
Hydraulic oil filter warning light Lights when the hydraulic oil filter is contaminated, the warning buzzer sounds, the engine is shut down after 2 minutes.p. 114
+The warning buzzer is activated by the monitoring board (Pin23).p. 114
The warning buzzer is activated by the monitoring board (Pin23).p. 114
The engine is shut down by the monitoring board via relay (K22).p. 114
6.25 Magnetic sensor, hydraulic oilp. 115
+Magnetic sensor, B19p. 115
Magnetic sensor, B19p. 115
+The sensor is installed in the return flow filter block. The sensor switches when it has picked up metal chips.p. 115
The sensor is installed in the return flow filter block. The sensor switches when it has picked up metal chips.p. 115
Fig. 1 Hydraulic oil return frlo filterp. 115
+Warning light for magnetic sensorp. 115
Warning light for magnetic sensorp. 115
+The switch contacts connect the monitoring board (A15, Pin14) to ground. The warning lampp. 115
jp. 115
(Fig. 15)p. 115
Fig. 2 Monitoring board, A15p. 115
+j yellowp. 115
+j yellowp. 115
jp. 115
Warning light to indicate metal chips in the hydraulic circuit. Lights when the sensor has picked up metal chipsp. 115
6.26 Pressure switch for brakep. 115
+Pressure switch, B05p. 115
Pressure switch, B05p. 115
+Below 15p. 115
+Below 15p. 115
±1.5p. 115
Fig. 1p. 115
+Parking brake warning lightp. 115
Parking brake warning lightp. 115
+The switch contacts connect the monitoring board (A15, Pin4) to ground. The warning lampp. 115
np. 115
(Fig. 15)p. 115
Fig. 2 Monitoring board, A15p. 115
+n redp. 115
+n redp. 115
np. 115
Parking brake warning light Lights when the hydraulic pressure on the brake valve drops below the setpoint.p. 115
6.27 Fuel gaugep. 116
+Float switch, R03p. 116
Float switch, R03p. 116
The float switch is installed in the fuel tank. The analog sensor is a variable resistance to ground.p. 116
Fig. 3 Float switchp. 116
+Fuel gaugep. 116
Fuel gaugep. 116
Fig. 4 Monitoring board, A15p. 116
The gauge shows the fuel filling level.p. 116
+pp. 116
+pp. 116
pp. 116
Fuel level gaugep. 116
Cab electrics
Fig. 5p. 118
+1 Rotary switch for cabin heaterp. 118
+1 Rotary switch for cabin heaterp. 118
1 Rotary switch for cabin heaterp. 118
+2 S00, ignition switchp. 118
2 S00p. 118
+3 P02, hydraulic oil temperature gaugep. 118
3 P02p. 118
Optional equipmentp. 118
+4 P14, coolant temperature gaugep. 118
4 P14p. 118
+5 A15, instrument clusterp. 118
5 A15p. 118
+6 A108, rotary switch for cabin fanp. 118
6 A108p. 118
+7 A108, rotary switch for air conditioning*p. 118
7 A108p. 118
8 Air distribution nozzlesp. 118
9 Lever for dozer blade controlp. 118
+10p. 118
S64p. 118
+11p. 118
S31p. 118
+12p. 118
S03p. 118
+13p. 118
S02p. 118
+14p. 118
S01p. 118
+15p. 118
S04p. 118
+16p. 118
S119p. 118
+17p. 118
S161p. 118
+18p. 118
R94p. 118
+19p. 118
S160p. 118
+20p. 118
S27p. 118
21p. 118
+22p. 118
S53p. 118
+23p. 119
H04 / S118p. 119
24 Steering leverp. 119
+Cabin lightp. 119
Control panel cabin, topp. 119
Fig. 6p. 119
+ap. 119
ap. 119
+S20, Toggle switch for front windscreen wipersp. 119
S20p. 119
bp. 119
+S22, Toggle switch for front washerp. 119
S22p. 119
cp. 119
+S21, Toggle switch/push button for rear windscreen wiper/washerp. 119
S21p. 119
dp. 119
+S163, Toggle switch for rear windscreen heatingp. 119
S163p. 119
ep. 119
+S38, Toggle switch for flashing beaconp. 119
S38p. 119
+Cabin lightp. 119
Cabin lightp. 119
Fig. 7p. 119
+ap. 119
ap. 119
+S45, Switch for interior lightp. 119
S45p. 119
bp. 119
+S158, Switch for night lightp. 119
S158p. 119
6.29 Fuse, cabinp. 120
Fig. 8p. 120
+No. 3 = Fuse box, cabinp. 120
No. 3 = Fuse box, cabinp. 120
+Fire hazard!p. 120
Fire hazard!p. 120
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 120
+(1) 15Ap. 120
(1) 15Ap. 120
(F43) Rear windscreen wiper motorp. 120
(2) 15Ap. 120
(F44) Front windscreen wiper motorp. 120
(3) 10Ap. 120
(F130) Night lightp. 120
(4) 25Ap. 120
(F31) Cabin ventilatorp. 120
(5) 10Ap. 120
(F41) Flashing beaconp. 120
(6) 15Ap. 120
(F144) Cab socketp. 120
(7) 15Ap. 120
(F143) Rear windscreen heatingp. 120
(8) 10Ap. 120
(F42) Cabin lightp. 120
6.30 Fusesp. 120
Fig. 9p. 120
Fusesp. 120
+Fire hazard!p. 120
Fire hazard!p. 120
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 120
Terminalp. 120
+X1:10 (30A)p. 120
X1:10 (30A)p. 120
(F13) Ignition switchp. 120
X1:11 (5A)p. 120
(F68) Anti-theft protectionp. 120
X1:12 (25A)p. 120
(F93) Engine control unit (pot. 30)p. 120
X1:13 (5A)p. 120
(F243) BOMAG Telematicp. 120
X1:17 (15A)p. 120
(F22) Working headlights, rearp. 120
X1:18 (15A)p. 120
(F19) Working headlights, frontp. 120
X1:19 (15A)p. 120
(F05) 12V Socketp. 120
X1:20 (10A)p. 120
(F95) Engine contgrol unitp. 120
X1:21 (10A)p. 120
(F23) Warning hornsp. 120
X1:22 (15A)p. 120
(F24) Instrumentsp. 120
X1:23 (10A)p. 120
(F26) Travel speed range selectionp. 120
X1:24 (10A)p. 120
(F25) Driving, brakingp. 120
X1:25 (10A)p. 120
(F18) Working lightsp. 120
X1:27 (10A)p. 120
(F16) Central lubricationp. 120
X1:28 (25A)p. 120
(F124) Fuel pre-heatingp. 120
X1:29 (20A)p. 120
(F29) Seat heating/air suspensionp. 120
X1:30 (15A)p. 120
(F196) Reversible fanp. 120
Fig. 10p. 121
Main fuse for cabinp. 121
+80Ap. 121
80Ap. 121
(F39) Main fuse for cabinp. 121
Machine related electricsp. 122
+1p. 122
1p. 122
+Wiring loom starter (M01) – main battery fuse (F00)p. 122
Wiring loom starter (M01) – main battery fuse (F00)p. 122
+17p. 122
17p. 122
+Wiring loom battery (G01) – main battery fuse (F00)p. 122
Wiring loom battery (G01) – main battery fuse (F00)p. 122
+2p. 122
2p. 122
+Wiring loom charge line (G02) – main battery fuse (F00)p. 122
Wiring loom charge line (G02) – main battery fuse (F00)p. 122
+18p. 122
18p. 122
+Wiring loom battery (G03) – main battery fuse (F00)p. 122
Wiring loom battery (G03) – main battery fuse (F00)p. 122
+3p. 122
3p. 122
+Wiring loom central electrics – main battery fuse (F00)p. 122
Wiring loom central electrics – main battery fuse (F00)p. 122
+19p. 122
19p. 122
+Wiring loom battery (G01) – main battery switch (S30)p. 122
Wiring loom battery (G01) – main battery switch (S30)p. 122
+4p. 122
4p. 122
+Wiring loom central electrics – groundp. 122
Wiring loom central electrics – groundp. 122
+20p. 122
20p. 122
+Wiring loom battery (G03) – main battery switch (S30)p. 122
Wiring loom battery (G03) – main battery switch (S30)p. 122
+8p. 122
8p. 122
+Wiring loom engine groundp. 122
Wiring loom engine groundp. 122
+21p. 122
21p. 122
+Wiring loom main battery switch (S30) – groundp. 122
Wiring loom main battery switch (S30) – groundp. 122
+Wiring loom preheating relay (K14) – central electricsp. 123
Wiring loom preheating relay (K14) – central electricsp. 123
+1p. 124
1p. 124
+Wiring loom engine compartment – central electricsp. 124
Wiring loom engine compartment – central electricsp. 124
+1p. 125
1p. 125
+Wiring loom rear frame – central electricsp. 125
Wiring loom rear frame – central electricsp. 125
+7 Engine electricsp. 127
7 Engine electricsp. 127
+7.22 Diagnostics interfacep. 128
7.1 EMR3 system componentsp. 128
+Engine control unitp. 128
Engine control unitp. 128
+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. 128
+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. 128
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. 128
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. 128
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. 128
+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. 128
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. 128
+l excellent exhaust gas characteristics,p. 128
l excellent exhaust gas characteristics,p. 128
l low fuel consumption,p. 128
l smooth running of engine,p. 128
l long lifetime of engine,p. 128
l efficient servicingp. 128
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. 128
+l exact control of the injection process (among others the number, start and duration of injections),p. 128
l exact control of the injection process (among others the number, start and duration of injections),p. 128
l idle speed regulation,p. 128
l regulation of exhaust gas recirculation,p. 128
l optimization of smooth running (by means of injection quantity correction),p. 128
l engine monitoring,p. 128
l system diagnose.p. 128
+Replacing the control unitp. 128
Replacing the control unitp. 128
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. 128
+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. 128
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. 128
Replacing the EMR or DCR componentsp. 128
+l On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control uni…p. 128
l On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control uni…p. 128
l Any other EMR components (sensors etc) must under no circumstances be repaired, but must be replaced if they are defective.p. 128
Fig. 11p. 129
+The EMR3-S (TCD 2012 and TCD 2013)p. 129
(Fig. 11)p. 129
+l socket D2.1 to connect the engine wiring loom,p. 129
l socket D2.1 to connect the engine wiring loom,p. 129
l socket D2.2 to connect the vehicle wiring loom.p. 129
Fig. 12p. 129
+The EMR3-E (TCD 2015)p. 129
(Fig. 12)p. 129
+l socket D2.1 to connect the vehicle wiring loom,p. 129
l socket D2.1 to connect the vehicle wiring loom,p. 129
l socket D2.2 to connect the engine wiring loom for sensors and actuators,p. 129
l socket D2.3 to connect the engine wiring loom for fuel metering unit and injection valves.p. 129
EMR-3 system in connection with injection system and electricsp. 130
Fig. 1p. 130
+1 Fuel tankp. 130
1 Fuel tankp. 130
2 Pre-filterp. 130
3 Fuel lift pumpp. 130
4 Fuel filterp. 130
5 High pressure fuel pumpp. 130
6 Fuel control unit FCUp. 130
7 Control unitp. 130
8 High pressure accumulator, Railp. 130
9 Injectorp. 130
10 Rail pressure sensorp. 130
11 Exhaust gas turbochargerp. 130
12 Engine transfer plugp. 130
13 Exhaust gas recirculation, optionp. 130
14 Engine sensorsp. 130
15 Diagnostics lampp. 130
16 Ignition switchp. 130
17 Pedalp. 130
18 Diagnostics buttonp. 130
19 Pressure relief valvep. 130
20 Battery terminal 31 and 30p. 130
21 Connecting line control unit-enginep. 130
22 Wiring loom connecting cablep. 130
23 Engine wiring harnessp. 130
24 Sensor, water in fuelp. 130
Sensors TCD 2012/2013p. 131
Fig. 1p. 131
+1 Fuel control unit FCUp. 131
1 Fuel control unit FCUp. 131
2 Coolant temperature sensorp. 131
3 Sensor for charge air temperature and charge air pressurep. 131
4 Wiring loom connecting cablep. 131
5 Engine control unitp. 131
6 Crankshaft speed sensorp. 131
7 Rail pressure sensorp. 131
8 Oil level sensor, optionp. 131
9 Oil pressure sensorp. 131
10 Fuel pressure sensorp. 131
11 Camshaft speed sensorp. 131
12 Central plugp. 131
Sensors TCD 2015p. 131
Fig. 1p. 131
+1 Oil pressure sensorp. 131
1 Oil pressure sensorp. 131
2 Fuel temperature sensorp. 131
3 Sensor for charge air temperature and charge air pressurep. 131
4 Engine control unitp. 131
5 Coolant temperature sensorp. 131
6 Oil level sensor, optionp. 131
7 Central plugp. 131
8 Crankshaft speed sensorp. 131
9 Camshaft speed sensorp. 131
10 Wiring loom connecting cablep. 131
Shut down the engine.p. 132
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. The injectors are closed immediately, the Rail pressure is discharged in an orderly manner and the counter readings are saved in the non-volatile memo…p. 132
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. The injectors are closed immediately, the Rail pressure is discharged in an orderly manner and the counter readings are saved in the non-volatile memo…p. 132
battp. 132
+The main relay serves the purpose of releasing the vehicle energy supply for the EMR3 system.p. 132
The main relay serves the purpose of releasing the vehicle energy supply for the EMR3 system.p. 132
+l The EMR3 engine control unit requires an external main relay (relay K41, in single drum rollers and tandem rollers), (relay E8 in road finishers), see machine related circuit diagram.p. 132
l The EMR3 engine control unit requires an external main relay (relay K41, in single drum rollers and tandem rollers), (relay E8 in road finishers), see machine related circuit diagram.p. 132
l The EMR3-E engine control unit has an internal electronic main relay.p. 132
The following applies for both control units: when terminal 15 is no longer connected to battery (+) (i.e. after the ignition has been switched off), the main relay is switched off after approx. 10 seconds.p. 132
The main relay thereby disconnects the control unit from terminal 30 battery (+), whereby it becomes de- energized.p. 132
On the EMR3-S the fault state of the main relay can be examined directly on Pin72, on the EMR3-E on Pin13.p. 132
+7.22 Diagnostics interfacep. 133
7.2 Pin assignment of engine control EDC16 / EMR3p. 133
+7.22 Diagnostics interfacep. 138
7.3 Rotary speed sensor for camshaftp. 138
+Speed sensor, B114p. 138
Speed sensor, B114p. 138
+l Inductive sensorp. 138
l Inductive sensorp. 138
l Determination of TDCp. 138
l Limp-home function in case of crankshaft sensor failurep. 138
Fig. 2p. 138
+Disassembling the speed sensorp. 138
Disassembling the speed sensorp. 138
Fig. 3p. 138
+l Remove the cable strapp. 138
+l Remove the cable strapp. 138
(Fig. 3)p. 138
l Disconnect the cable plug.p. 138
Fig. 4p. 138
+l Unscrew the screwp. 138
+l Unscrew the screwp. 138
(Fig. 4)p. 138
l Remove the speed sensorp. 138
+Installing the speed sensorp. 138
Installing the speed sensorp. 138
Fig. 5p. 138
+l Clean the sealing faces on speed transducer and timing gear cover.p. 138
l Clean the sealing faces on speed transducer and timing gear cover.p. 138
+l Assemble a new O-ringp. 138
(Fig. 5)p. 138
l Cover the O-ring slightly with oil.p. 138
Fig. 6p. 139
+l Insert the speed sensorp. 139
+l Insert the speed sensorp. 139
(Fig. 6)p. 139
l Tighten the screw.p. 139
+Assemble the screw with screw retention agent.p. 139
Assemble the screw with screw retention agent.p. 139
Fig. 7p. 139
+l Plug in the cable plugp. 139
+l Plug in the cable plugp. 139
(Fig. 7)p. 139
l Route the cable.p. 139
l Fasten the cable with cable straps.p. 139
+7.22 Diagnostics interfacep. 139
7.4 Rotary speed sensor for crankshaftp. 139
+Speed sensor, B130p. 139
Speed sensor, B130p. 139
+l Inductive sensorp. 139
l Inductive sensorp. 139
l Exact determination of engine speedp. 139
l Limp-home function in case of camshaft sensor failurep. 139
+Disassembling the speed sensorp. 139
Disassembling the speed sensorp. 139
Fig. 8p. 139
+l Disconnect the cable plugp. 139
+l Disconnect the cable plugp. 139
(Fig. 8)p. 139
Fig. 9p. 139
+l Unscrew both screwsp. 139
+l Unscrew both screwsp. 139
(Fig. 9)p. 139
l Remove the bracket with speed sensorp. 139
Fig. 10p. 140
+l Unscrew the screwp. 140
+l Unscrew the screwp. 140
(Fig. 10)p. 140
l Pull the speed sensor out of the bracketp. 140
+Installing the speed sensorp. 140
Installing the speed sensorp. 140
Fig. 11p. 140
+l Press the speed sensor into the bracketp. 140
+l Press the speed sensor into the bracketp. 140
(Fig. 11)p. 140
+Clean the threads on screw and in bore hole. Assemble the screw with screw retention agent.p. 140
Clean the threads on screw and in bore hole. Assemble the screw with screw retention agent.p. 140
+l Tighten the screw with 9 Nm.p. 140
l Tighten the screw with 9 Nm.p. 140
Fig. 12p. 140
+l Attach the bracket with speed sensorp. 140
+l Attach the bracket with speed sensorp. 140
(Fig. 12)p. 140
+Insert the screws with screw retention agent and check the gap, adjust as necessary.p. 140
Insert the screws with screw retention agent and check the gap, adjust as necessary.p. 140
Fig. 13p. 140
+l Plug in the cable plugp. 140
+l Plug in the cable plugp. 140
(Fig. 13)p. 140
+Adjusting the gap measurementp. 141
Checking the gap measurementp. 141
Fig. 14p. 141
+l Check the gap measurement with a feeler gaugep. 141
+l Check the gap measurement with a feeler gaugep. 141
(Fig. 14)p. 141
+Nominal value: 0,6p. 141
± 0.1p. 141
+The feeler gauge must fit through the gap been toothed disc and speed sensor (crankshaft) with only little resistance.p. 141
The feeler gauge must fit through the gap been toothed disc and speed sensor (crankshaft) with only little resistance.p. 141
+Adjusting the gap measurementp. 141
Adjusting the gap measurementp. 141
Fig. 15p. 141
+l Unscrew both screwsp. 141
+l Unscrew both screwsp. 141
(Fig. 15)p. 141
+Assemble the screw with screw retention agent.p. 141
Assemble the screw with screw retention agent.p. 141
+Watch out for different screw lengthsp. 141
Watch out for different screw lengthsp. 141
Fig. 16p. 141
+l Insert the feeler gauge between the toothed disc and the speed sensor.p. 141
l Insert the feeler gauge between the toothed disc and the speed sensor.p. 141
l Slightly press the speed sensor against the feeler gauge and tighten the screws.p. 141
+Tightening torque: 20 Nmp. 141
Tightening torque: 20 Nmp. 141
+7.22 Diagnostics interfacep. 142
7.5 Rail pressure sensorp. 142
+Pressure sensor, B93p. 142
Pressure sensor, B93p. 142
+l Pressure sensorp. 142
l Pressure sensorp. 142
l Monitoring the injection pressurep. 142
Fig. 17p. 142
+Disassembling the pressure sensorp. 142
Disassembling the pressure sensorp. 142
+After shutting down the engine wait 30 seconds, before starting work in the fuel system.p. 142
After shutting down the engine wait 30 seconds, before starting work in the fuel system.p. 142
+Ensure strict cleanliness when working on the fuel system.p. 142
Ensure strict cleanliness when working on the fuel system.p. 142
Thoroughly clean the areas around the affected components. Dry off moist locations with compressed air.p. 142
Do not allow foreign particles to enter into the rail.p. 142
Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 142
Follow the safety regulations and the country specific instructions concerning the handling of fuel.p. 142
Close any opened connection immediately with new and clean plugs/caps.p. 142
Remove plugs/caps only just before assembly.p. 142
Do not touch the pin contacts of the rail pressure sensor with bare hands to avoid electrostatic discharge.p. 142
+Catch running out fuel and dispose of environmentally.p. 142
Catch running out fuel and dispose of environmentally.p. 142
Fig. 18p. 142
+l Unlock and pull out the cable plugp. 142
+l Unlock and pull out the cable plugp. 142
(Fig. 18)p. 142
l Unscrew the rail pressure sensor with a socket wrenchp. 142
Fig. 19p. 142
+l Visually examine the thread and the sealing edge (arrows)p. 142
+l Visually examine the thread and the sealing edge (arrows)p. 142
(Fig. 19)p. 142
+Installing the rail pressure sensorp. 143
Installing the rail pressure sensorp. 143
Fig. 20p. 143
+Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 143
Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 143
+l Apply a little bit of grease to the thread and the sealing edge of the rail pressure sensor.p. 143
l Apply a little bit of grease to the thread and the sealing edge of the rail pressure sensor.p. 143
+l Turn in the rail pressure sensor (2)p. 143
(Fig. 20)p. 143
+Tightening torque: 40p. 143
+Tightening torque: 40p. 143
+ 5p. 143
+l Plug on the cable plug.p. 143
l Plug on the cable plug.p. 143
+7.22 Diagnostics interfacep. 143
7.6 Fuel pressure sensorp. 143
+Pressure sensor, B145p. 143
Pressure sensor, B145p. 143
+l Pressure sensorp. 143
l Pressure sensorp. 143
l Monitoring of input pressurep. 143
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 143
Fig. 21p. 143
+Disassembling the pressure sensorp. 143
Disassembling the pressure sensorp. 143
+Ensure strict cleanliness when working on the fuel system.p. 143
Ensure strict cleanliness when working on the fuel system.p. 143
Thoroughly clean the areas around the affected components. Dry off moist locations with compressed air.p. 143
Follow the safety regulations and the country specific instructions concerning the handling of fuel.p. 143
Close any opened connection immediately with new and clean plugs/caps.p. 143
Remove plugs/caps only just before assembly.p. 143
+Catch running out fuel and dispose of environmentally.p. 143
Catch running out fuel and dispose of environmentally.p. 143
Fig. 22p. 144
+l Unscrew the locking ringp. 144
+l Unscrew the locking ringp. 144
(Fig. 22)p. 144
l Pull out the cable plug.p. 144
l Unscrew the fuel pressure sensor with a socket wrench.p. 144
+Assembling the pressure sensorp. 144
Assembling the pressure sensorp. 144
Fig. 23p. 144
+l Install and tighten the fuel pressure sensor with a new seal ringp. 144
+l Install and tighten the fuel pressure sensor with a new seal ringp. 144
(Fig. 23)p. 144
+Tightening torque: 30p. 144
+Tightening torque: 30p. 144
± 5p. 144
Fig. 24p. 144
+l Push the cable plug onto the fuel level sensorp. 144
+l Push the cable plug onto the fuel level sensorp. 144
(Fig. 24)p. 144
l Screw in the locking ring, until it locks in place.p. 144
+Ensure matching of the contacts.p. 144
Ensure matching of the contacts.p. 144
Bleed the fuel system via the manual fuel pump on the fuel pre-filter.p. 144
+7.22 Diagnostics interfacep. 145
7.7 Fuel control unitp. 145
+Control unit, Y137p. 145
Control unit, Y137p. 145
Fig. 25p. 145
+Functionp. 145
Functionp. 145
Here the fuel flowing into the pump elements is metered by a infinitely controllable solenoid valve (referred to as fuel control unit).p. 145
This valve is mounted on the control block FCU (Fuel Control Unit) and adapts the fuel quantity delivered to the Rail to the system requirements. The solenoid valve is triggered by means of a pulse width modulated signal (PWM-signal). When the valve …p. 145
+The injectors are installed in the cylinder head. They have the same function as nozzle and nozzle holder in conventional injection systems. The injectors are connected with the pressure accumulator (Rail) by high pressure linesp. 146
(Fig. 29)p. 146
A valve determines the start of injection and the end of injection of the nozzle. The actuating forces to open and close the valve are generated by an solenoid. The injectors work with 50 to 70 V instead of the 12 V on- board voltage, which opens the…p. 146
+The forces required to open and close the nozzle needle cannot be generated by a solenoid valve on its own. The nozzle needle is therefore indirectly triggered via an hydraulic power booster system in the injectorp. 146
(Fig. 30)p. 146
Fig. 29p. 147
Fig. 30p. 147
+7.22 Diagnostics interfacep. 147
7.9 Oil pressure sensorp. 147
+Pressure sensor, B88p. 147
Pressure sensor, B88p. 147
Oil pressure monitoringp. 147
The operator is warned ifp. 147
+l the oil pressure falls short of the warning limit and/orp. 147
l the oil pressure falls short of the warning limit and/orp. 147
l the power is reduced by the EMR after a pre-warning time, orp. 147
l the oil pressure falls short of the shut-down limit and the engine is shut down after a pre-warning time.p. 147
Fig. 31 Oil pressure sensorp. 147
+Warning light, engine oil pressurep. 147
Warning light, engine oil pressurep. 147
+During cold starting the EMR-control switches (Pin71 ground, Pin51 plus) and the coil of relay (K60) is excited. The switch contact of relay (K60) connects the monitoring board (A15, Pin11) to ground. The engine oil pressure warning lightp. 147
fp. 147
(Fig. 32)p. 147
Fig. 32 Monitoring board, A15p. 147
+f redp. 147
+f redp. 147
fp. 147
Warning light, engine oil pressure Flashes when the engine oil pressure is too low, the warning buzzer soundsp. 147
+The warning buzzer is activated by the monitoring board (Pin23).p. 147
The warning buzzer is activated by the monitoring board (Pin23).p. 147
+Disassembling the pressure sensorp. 148
Disassembling the pressure sensorp. 148
+Ensure strict cleanliness when working on the lubrication oil system.p. 148
Ensure strict cleanliness when working on the lubrication oil system.p. 148
Thoroughly clean the areas around the affected components. Dry off moist locations with compressed air.p. 148
Close any opened connection immediately with new and clean plugs/caps.p. 148
Remove plugs/caps only just before assembly.p. 148
+Catch running out engine oil and dispose of environmentally.p. 148
Catch running out engine oil and dispose of environmentally.p. 148
Fig. 33p. 148
+l Unlock and pull out the cable plugp. 148
+l Unlock and pull out the cable plugp. 148
(Fig. 33)p. 148
l Unscrew the oil pressure sensor.p. 148
+Assembling the pressure sensorp. 148
Assembling the pressure sensorp. 148
Fig. 34p. 148
+l Install and tighten the oil pressure sensor with a new seal ring.p. 148
l Install and tighten the oil pressure sensor with a new seal ring.p. 148
+Tightening torque: 20 Nmp. 148
Tightening torque: 20 Nmp. 148
+7.22 Diagnostics interfacep. 149
7.10 Sensor for charge air temperature and charge air pressurep. 149
+Sensor, B133p. 149
Sensor, B133p. 149
+Combined charge air pressure / temperature sensorp. 149
Combined charge air pressure / temperature sensorp. 149
Fig. 35p. 149
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. 149
+With a faulty sensor the engine continues to run with charge pressure simulation.p. 149
With a faulty sensor the engine continues to run with charge pressure simulation.p. 149
With a defective temperature sensor the engine also carries on running.p. 149
Charge air temperature monitoringp. 149
The operator is warned ifp. 149
+l the temperature exceeds the warning limit and/orp. 149
l the temperature exceeds the warning limit and/orp. 149
l the power is reduced by the EMR 3 after a pre- warning time, orp. 149
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 149
+Disassembling the sensorp. 149
Disassembling the sensorp. 149
Fig. 36p. 149
+l Unscrew fastening screw 1p. 149
+l Unscrew fastening screw 1p. 149
(Fig. 36)p. 149
l Remove the cover plate.p. 149
Fig. 37p. 149
+l Unlock and pull out the cable plugp. 149
+l Unlock and pull out the cable plugp. 149
(Fig. 37)p. 149
l Remove the pressure/temperature sensor.p. 149
+Assembling the sensorp. 150
Assembling the sensorp. 150
Fig. 38p. 150
+l Assemble a new O-ringp. 150
+l Assemble a new O-ringp. 150
(Fig. 38)p. 150
l Slightly cover the O-ring with grease.p. 150
Fig. 39p. 150
+l Carefully insert the pressure/temperature sensorp. 150
+l Carefully insert the pressure/temperature sensorp. 150
(Fig. 39)p. 150
l Plug in and lock the cable plug.p. 150
Fig. 40p. 150
+l Attach the cover platep. 150
+l Attach the cover platep. 150
(Fig. 40)p. 150
l Tighten the screw (1).p. 150
+7.22 Diagnostics interfacep. 151
7.11 EMR coolant temperature sensorp. 151
+Temperature sensor, B113p. 151
Temperature sensor, B113p. 151
The coolant temperature sensor influences the calculated injection quantity and the preheating behaviour of the glow plugs.p. 151
Coolant temperature monitoringp. 151
The operator is warned ifp. 151
+l the temperature exceeds the warning limit and/orp. 151
l the temperature exceeds the warning limit and/orp. 151
l the power is reduced by the EMR after a pre-warning time, orp. 151
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 151
Fig. 41 Coolant temperature sensorp. 151
+Warning light, overheating of enginep. 151
Warning light, overheating of enginep. 151
+If the permissible coolant temperature is exceeded, the EMR-control switches (Pin70 ground, Pin29 plus) and the coil of relay (K146) is excited. The switch contact of relay (K146) connects the monitoring board (A15, Pin8) to ground. The warning light…p. 151
cp. 151
(Fig. 42)p. 151
Fig. 42 Monitoring board, A15p. 151
+c redp. 151
+c redp. 151
cp. 151
Warning light, overheating of engine flashes if the engine overheats, warning buzzer sounds.p. 151
+The warning buzzer is activated by the monitoring board (Pin23).p. 151
The warning buzzer is activated by the monitoring board (Pin23).p. 151
+Disassembling the temperature sensorp. 151
Disassembling the temperature sensorp. 151
+Catch running out fuels and lubricants with suitable vessels and and follow the waste disposal regulations.p. 151
Catch running out fuels and lubricants with suitable vessels and and follow the waste disposal regulations.p. 151
+Please follow the corresponding documentation in the operating instructions when emptying and filling the cooling system.p. 151
Please follow the corresponding documentation in the operating instructions when emptying and filling the cooling system.p. 151
Fig. 43p. 151
+l Unlock and pull out the cable plugp. 151
+l Unlock and pull out the cable plugp. 151
(Fig. 43)p. 151
Fig. 44p. 151
+l Screw out the coolant temperature sensorp. 151
+l Screw out the coolant temperature sensorp. 151
(Fig. 44)p. 151
+Counter the adapter piece.p. 152
Counter the adapter piece.p. 152
+Assembling the temperature sensorp. 152
Assembling the temperature sensorp. 152
Fig. 45p. 152
+l Tighten the coolant temperature sensorp. 152
+l Tighten the coolant temperature sensorp. 152
(Fig. 45)p. 152
+Make sure that the seal ring is present.p. 152
Make sure that the seal ring is present.p. 152
+Tightening torque: 22p. 152
±2p. 152
Fig. 46p. 152
+l Insert the cable plugp. 152
+l Insert the cable plugp. 152
(Fig. 46)p. 152
+7.22 Diagnostics interfacep. 152
7.12 Glow plugsp. 152
+R81 to R86p. 152
R81 to R86p. 152
+The engines are equipped with glow plugs for cold starting as standard. These on the one hand ensure reliable cold starting by preheating the glow plugs in the combustion chamber of the engine, and on the other hand after-heating of the glow plugs in…p. 152
The engines are equipped with glow plugs for cold starting as standard. These on the one hand ensure reliable cold starting by preheating the glow plugs in the combustion chamber of the engine, and on the other hand after-heating of the glow plugs in…p. 152
+Pre-heating control lightp. 152
Pre-heating control lightp. 152
+During cold starting the EMR-control switches (Pin92 ground, Pin29 plus) and the coil of relay (K15) is excited. The switch contact of relay (K15) connects the monitoring board (A15, Pin3) to ground. The preheating control lightp. 152
dp. 152
(Fig. 47)p. 152
Fig. 47 Monitoring board, A15p. 152
+d yellowp. 152
+d yellowp. 152
dp. 152
Pre-heating control light Lights when temperatures are low (pre- heating for starting)p. 152
+Fuse for glow plugsp. 153
Control of the glow plugsp. 153
During cold starting the EMR-control switches (Pin24 ground, Pin34 plus) and the coil of relay (K14) is excited. The switching contact of relay (K14) supplies the glow plugs with battery power.p. 153
+Fuse for glow plugsp. 153
Fuse for glow plugsp. 153
Fig. 48p. 153
+80Ap. 153
80Ap. 153
(F48) Fuse for glow plugsp. 153
125Ap. 153
(F00) main fuse for central electricsp. 153
+The fuse for the glow plugs and the main fuse for the central electrics are located in the battery box above the batteries.p. 153
The fuse for the glow plugs and the main fuse for the central electrics are located in the battery box above the batteries.p. 153
+7.22 Diagnostics interfacep. 153
7.13 Sensor, water in fuelp. 153
+Sensor, B124p. 153
Sensor, B124p. 153
Fig. 49p. 153
+1 Water separator sensor connection (B124)p. 153
1 Water separator sensor connection (B124)p. 153
+2 Fuel pre-heating connectionp. 153
Optionp. 153
+Warning light water in fuel filterp. 153
Warning light water in fuel filterp. 153
+If water is detected in the fuel filter the EMR-control switches (Pin68 ground) and the coil of relay (K150) is excited. The switch contact of relay (K150) connects the monitoring board (A15, Pin20) to ground. The water in fuel warning lightp. 153
bap. 153
(Fig. 50)p. 153
Fig. 50 Monitoring board, A15p. 153
+a yellowp. 153
+a yellowp. 153
ap. 153
Warning light water in fuel filter Lights when the water content in the fuel pre-cleaner reaches the sensor contacts. The warning buzzer sounds.p. 153
+The warning buzzer is activated by the monitoring board (Pin23).p. 154
The warning buzzer is activated by the monitoring board (Pin23).p. 154
+7.22 Diagnostics interfacep. 154
7.14 Fuel pre-heatingp. 154
+Fuel pre-heating (option)p. 154
Fuel pre-heating (option)p. 154
+The preheating system is not monitored by the engine control unit.p. 154
+The preheating system is not monitored by the engine control unit.p. 154
The preheating system is not monitored by the engine control unit.p. 154
In diesel engines the pre-heating of the fuel prevents malfunctions caused by the formation of jelly (paraffin separation) in the fuel under low temperatures.p. 154
The heater is activated when the ignition is switched on, this should take place at least 5 minutes before starting the engine.p. 154
The generated heat works directly under the filter element and melts the wax crystals that have formed, so that the fuel can flow through the filter element without restriction. The 200W heating is supplied with 12V D.C-current.p. 154
+7.22 Diagnostics interfacep. 155
7.15 Air filter vacuum switchp. 155
+Vacuum switch, B03p. 155
Vacuum switch, B03p. 155
+The vacuum is not monitored by the engine control unit.p. 155
+The vacuum is not monitored by the engine control unit.p. 155
The vacuum is not monitored by the engine control unit.p. 155
Fig. 52p. 155
+Air filter warning lightp. 155
Air filter warning lightp. 155
The vacuum switch switches at a vacuum of > 50 mbar.p. 155
+The switch contact connects the monitoring board (A15, Pin16) to ground. The air filter warning lampp. 155
hkp. 155
(Fig. 53)p. 155
Fig. 53 Monitoring board, A15p. 155
+k yellowp. 155
+k yellowp. 155
kp. 155
Air filter warning light Lights when the combustion air filter is contaminated. Clean or replace, as necessary.p. 155
+7.22 Diagnostics interfacep. 155
7.16 Float switch in coolant containerp. 155
+Float switch, B55p. 155
Float switch, B55p. 155
+The float switch is not monitored by the engine control unit.p. 155
+The float switch is not monitored by the engine control unit.p. 155
The float switch is not monitored by the engine control unit.p. 155
Fig. 54p. 155
+Coolant level warning lightp. 155
Coolant level warning lightp. 155
The float switch switches when the coolant level is too low.p. 155
+The switch contact connects the monitoring board (A15, Pin15) to ground. The coolant level warning lightp. 155
gp. 155
(Fig. 55)p. 155
Fig. 55 Monitoring board, A15p. 155
+g redp. 155
+g redp. 155
gp. 155
Coolant level warning light Flashes if the coolant level is too low, the warning buzzer sounds, the engine is shut down after 10 seconds. Check coolant level. Check cooling system for leaks, repair if necessary.p. 155
+The warning buzzer is activated by the monitoring board (Pin23).p. 156
The warning buzzer is activated by the monitoring board (Pin23).p. 156
The engine is shut down by the monitoring board via relay (K22).p. 156
+7.22 Diagnostics interfacep. 156
7.17 Coolant temperature gaugep. 156
+Temperature sensor, B152p. 156
Temperature sensor, B152p. 156
+The temperature is not monitored by the engine control unit.p. 156
The temperature is not monitored by the engine control unit.p. 156
The sensor is installed in the radiator. The analog sensor is a variable resistance to ground.p. 156
Fig. 56 Temperature sensorp. 156
+Temperature display, P14p. 156
Temperature display, P14p. 156
Fig. 57 Temperature displayp. 156
The display shows the coolant temperature of the engine.p. 156
+7.22 Diagnostics interfacep. 157
7.18 Charge control light, engine rpm-meterp. 157
+The generator is not monitored by the engine control unit.p. 157
+The generator is not monitored by the engine control unit.p. 157
The generator is not monitored by the engine control unit.p. 157
Fig. 1 Generatorp. 157
+1 Terminal B+p. 157
1 Terminal B+p. 157
2 Terminal Wp. 157
3 Terminal D+p. 157
+Charge control lightp. 157
Charge control lightp. 157
+If the battery is not being charged, a ground signal is applied to D+ terminal 3p. 157
+If the battery is not being charged, a ground signal is applied to D+ terminal 3p. 157
(Fig. 1)p. 157
hp. 157
(Fig. 1)p. 157
Fig. 1 Monitoring board, A15p. 157
+h yellowp. 157
+h yellowp. 157
hp. 157
Charge control light Lights if the battery is not being charged.p. 157
+op. 157
op. 157
Engine PRM-meter Shows the engine speed x 100 per minute.p. 157
+Engine PRM-meterp. 157
Engine PRM-meterp. 157
+Terminal "W" on the generator delivers pulsating direct voltage, which can be used to determine the engine speed.p. 157
Terminal "W" on the generator delivers pulsating direct voltage, which can be used to determine the engine speed.p. 157
+7.22 Diagnostics interfacep. 158
7.19 System faults indicated by flashing codep. 158
+Engine protection function of the electric engine controller EMR3p. 158
Engine protection function of the electric engine controller EMR3p. 158
+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. 158
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. 158
Depending on the engine configuration the flashing fault lamp can have the following meaning:p. 158
+l Shut-down request for the operatorp. 158
l Shut-down request for the operatorp. 158
l Attention: Loss of warranty if disregarded!p. 158
l Automatic engine shut-down after a short pre-warning time, possibly in connection with a restarting prevention.p. 158
l Forced engine operation at low idle speed to cool the engine, possible in connection with automatic shut-down.p. 158
l Start prevention.p. 158
+Indication of system faultp. 158
Indication of system faultp. 158
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. 158
Fig. 2p. 158
+1 Diagnostics button, S118p. 158
1 Diagnostics button, S118p. 158
2 Fault lamp, H04p. 158
3 EMR3 control unitp. 158
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. 158
Fig. 3p. 158
The following steps are required to read out the flashing codes for saved system faults:p. 158
+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. 158
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. 158
l After approx. 2 s watch the flashing code or the first or the next active fault.p. 159
l Wait until the fault lamp shows the original flashing or permanent light again after about 5 seconds.p. 159
+Example: 1x short flashing,p. 159
Example: 1p. 159
2p. 159
8p. 159
1-2-8p. 159
(Fig. 3)p. 159
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. 159
+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. 159
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. 159
Deleting the fault logp. 159
+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. 159
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. 159
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. 159
The following describes the steps for clearing fault log 1:p. 159
+l Ignition OFF, press and hold the diagnostics button.p. 159
l Ignition OFF, press and hold the diagnostics button.p. 159
l Switch the ignition on.p. 159
l Only release the diagnostics button after approx. 10 seconds.p. 159
l All passive faults in fault log 1 will be deleted.p. 159
l The deleting process is confirmed by three short flashing pulses.p. 159
+7.22 Diagnostics interfacep. 160
7.20 Diagnose with SERDIAp. 160
+SERDIAp. 160
SERDIAp. 160
+With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 160
With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 160
Fig. 1 Service-Software TCD 2012 / 2013p. 160
The SERDIA software is first choice for any diagnostics task.p. 160
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. 160
This displays information onp. 160
+l Location of fault (e.g. ’coolant temperature sensor’)p. 160
l Location of fault (e.g. ’coolant temperature sensor’)p. 160
l Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)p. 160
l Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)p. 160
l Number of fault locations and frequency of faultp. 160
l Fault status (active – fault present / passive- fault no longer present)p. 160
l Fault messages for non-present / rectified faults can be deleted with SERDIA.p. 160
Function testp. 160
The control outputs can be activated with the engine shut down.p. 160
Assignment of inputs/outputsp. 160
Display of the current input and output assignment of the EMR-control.p. 160
Representation of measuring valuesp. 161
Fig. 2p. 161
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. 161
Representation of fault logp. 162
Fig. 3p. 162
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. 162
7.22 Diagnostics interfacep. 162
+7.22 Diagnostics interfacep. 163
7.21 Diagnose with CAN-busp. 163
+The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 163
The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 163
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. 163
+l Analog displayp. 163
l Analog displayp. 163
l Digital datap. 163
l Multi data (a combination of analog and digital data)p. 163
l Alarm messages currently presentp. 163
The different diagnostic screens enable detailed examination of the engine data flowp. 163
Fig. 1p. 163
+Display for EMR controlp. 163
(Fig. 1)p. 163
+7.22 Diagnostics interfacep. 164
7.22 Diagnostics interfacep. 164
Fig. 1 Control unit in electric wiring boxp. 164
Fig. 2 Diagnostics interface in electric wiring boxp. 164
Fig. 3 Diagnostics socketp. 164
+Ap. 164
Ap. 164
Battery plus (+)p. 164
Bp. 164
Battery minus (-)p. 164
Fp. 164
CAN2 lowp. 164
Gp. 164
CAN1 lowp. 164
Hp. 164
CAN1 highp. 164
Kp. 164
K-linep. 164
Mp. 164
CAN2 highp. 164
SERDIA connectionp. 165
Fig. 4p. 165
+The KWP2000 protocol with encrypted data flow is used through the K-line. For this purpose the PC or laptopp. 165
(Fig. 4)p. 165
Operation of SERDIA is described in a separate operation manual.p. 165
Connection CAN-bus displayp. 165
Operation of the display is described in a separate operating manual.p. 165
Fig. 5p. 165
+Display for EMR controlp. 165
(Fig. 5)p. 165
BOMAG part-no.: 057 189 94p. 165
Fig. 6p. 165
The display is connected to the diagnostics interface by means of a special cable.p. 165
+Wiring loom for displayp. 165
(Fig. 6)p. 165
BOMAG part-no.: 079 900 19p. 165
Flashing codep. 166
+Flashing codep. 166
Flashing codep. 166
+Function / componentp. 166
Function / componentp. 166
+Faultp. 166
Faultp. 166
+Short (0.4s)p. 166
Short (0.4s)p. 166
+Long (0.8s)p. 166
Long (0.8s)p. 166
+Short 0.4sp. 166
Short 0.4sp. 166
+1p. 166
1p. 166
+2p. 166
2p. 166
+3p. 166
3p. 166
+Output to coolant temperature indicator lampp. 166
Output to coolant temperature indicator lampp. 166
Signal implausible, pressure deviation beyond permissible rangep. 166
+2p. 166
2p. 166
+1p. 166
1p. 166
+2p. 166
2p. 166
+Monitoring of camshaft / crankshaftp. 166
Monitoring of camshaft / crankshaftp. 166
+No camshaft signal, no crankshaft signalp. 166
No camshaft signal, no crankshaft signalp. 166
+2p. 166
2p. 166
+1p. 166
1p. 166
+3p. 166
3p. 166
+Monitoring of camshaft / crankshaftp. 166
Monitoring of camshaft / crankshaftp. 166
+Discrepancy between camshaft and crankshaft signalsp. 166
Discrepancy between camshaft and crankshaft signalsp. 166
+2p. 166
2p. 166
+1p. 166
1p. 166
+4p. 166
4p. 166
+Motor protectionp. 166
Motor protectionp. 166
+Status of overspeed/override implausiblep. 166
Status of overspeed/override implausiblep. 166
+2p. 166
2p. 166
+1p. 166
1p. 166
+6p. 166
6p. 166
+Fuel low pressure sensorp. 166
Fuel low pressure sensorp. 166
+Signal faultyp. 166
Signal faultyp. 166
+Fuel low pressure monitoringp. 166
Fuel low pressure monitoringp. 166
+Fuel low pressure outside nominal rangep. 166
Fuel low pressure outside nominal rangep. 166
+2p. 166
2p. 166
+1p. 166
1p. 166
+9p. 166
9p. 166
+Output to actuator for exhaust damper engine brakep. 166
Output to actuator for exhaust damper engine brakep. 166
+Signal faulty, control unit overheatingp. 166
Signal faulty, control unit overheatingp. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+Throttle pedal input 1 (PWM)p. 166
Throttle pedal input 1 (PWM)p. 166
+PWM signal faultyp. 166
PWM signal faultyp. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+3p. 166
3p. 166
+Charge air pressure sensorp. 166
Charge air pressure sensorp. 166
+Signal faultyp. 166
Signal faultyp. 166
+Charge air pressure monitoringp. 166
Charge air pressure monitoringp. 166
+Charge air pressure outside nominal rangep. 166
Charge air pressure outside nominal rangep. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+4p. 166
4p. 166
+Oil pressure sensorp. 166
Oil pressure sensorp. 166
+Signal faulty / implausiblep. 166
Signal faulty / implausiblep. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+5p. 166
5p. 166
+Coolant temperature sensorp. 166
Coolant temperature sensorp. 166
+Signal faulty / implausible in comparison to oil temperature, CAN-signal invalidp. 166
Signal faulty / implausible in comparison to oil temperature, CAN-signal invalidp. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+6p. 166
6p. 166
+Input throttle pedal 1 (analog)p. 166
Input throttle pedal 1 (analog)p. 166
+Signal faulty / implausiblep. 166
Signal faulty / implausiblep. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+7p. 166
7p. 166
+Fuel temperature sensorp. 166
Fuel temperature sensorp. 166
+Signal faultyp. 166
Signal faultyp. 166
+2p. 166
2p. 166
+2p. 166
2p. 166
+8p. 166
8p. 166
+Water level sensor in fuel filterp. 166
Water level sensor in fuel filterp. 166
+Signal faultyp. 166
Signal faultyp. 166
+Fuel filter water level monitoringp. 166
Fuel filter water level monitoringp. 166
+Max. water level exceededp. 166
Max. water level exceededp. 166
+2p. 166
2p. 166
+3p. 166
3p. 166
+1p. 166
1p. 166
+Monitoring of lubrication oil pressurep. 166
Monitoring of lubrication oil pressurep. 166
+Pressure outside the nominal rangep. 166
Pressure outside the nominal rangep. 166
+2p. 166
2p. 166
+3p. 166
3p. 166
+2p. 166
2p. 166
+Monitoring of coolant temperaturep. 166
Monitoring of coolant temperaturep. 166
+Temperature above nominal rangep. 166
Temperature above nominal rangep. 166
+2p. 167
2p. 167
+3p. 167
3p. 167
+3p. 167
3p. 167
+Monitoring of intake air temperaturep. 167
Monitoring of intake air temperaturep. 167
+Temperature above nominal rangep. 167
Temperature above nominal rangep. 167
+2p. 167
2p. 167
+3p. 167
3p. 167
+5p. 167
5p. 167
+Monitoring of coolant levelp. 167
Monitoring of coolant levelp. 167
+Level below nominal rangep. 167
Level below nominal rangep. 167
+2p. 167
2p. 167
+3p. 167
3p. 167
+7p. 167
7p. 167
+Monitoring of fuel temperaturep. 167
Monitoring of fuel temperaturep. 167
+Temperature outside nominal rangep. 167
Temperature outside nominal rangep. 167
+2p. 167
2p. 167
+3p. 167
3p. 167
+8p. 167
8p. 167
+Output to fan actuator 1 / 2p. 167
Output to fan actuator 1 / 2p. 167
+Signal faulty, control unit overheatingp. 167
Signal faulty, control unit overheatingp. 167
+Monitoring of fan speedp. 167
Monitoring of fan speedp. 167
+Speed outside nominal rangep. 167
Speed outside nominal rangep. 167
+2p. 167
2p. 167
+4p. 167
4p. 167
+1p. 167
1p. 167
+Monitoring of combustionp. 167
Monitoring of combustionp. 167
+Misfiring detected in one or several cylindersp. 167
Misfiring detected in one or several cylindersp. 167
+2p. 167
2p. 167
+6p. 167
6p. 167
+1p. 167
1p. 167
+Monitoring of output to actuatorsp. 167
Monitoring of output to actuatorsp. 167
+Relay does not open or is delayed, short circuit to groundp. 167
Relay does not open or is delayed, short circuit to groundp. 167
+2p. 167
2p. 167
+6p. 167
6p. 167
+3p. 167
3p. 167
+Output to cold starting aidp. 167
Output to cold starting aidp. 167
+Signal faulty, relay defective, jammed or incorrectly connected, short circuitp. 167
Signal faulty, relay defective, jammed or incorrectly connected, short circuitp. 167
+2p. 167
2p. 167
+7p. 167
7p. 167
+1p. 167
1p. 167
+CAN-Busp. 167
CAN-Busp. 167
+Time-Out for one or several sent messages, bus inactivep. 167
Time-Out for one or several sent messages, bus inactivep. 167
+2p. 167
2p. 167
+8p. 167
8p. 167
+2p. 167
2p. 167
+Sensor supply voltage 1 / 2 / 3p. 167
Sensor supply voltage 1 / 2 / 3p. 167
+Voltage outside nominal rangep. 167
Voltage outside nominal rangep. 167
+2p. 167
2p. 167
+9p. 167
9p. 167
+2p. 167
2p. 167
+Atmospheric pressure sensorp. 167
Atmospheric pressure sensorp. 167
+Signal faulty / implausiblep. 167
Signal faulty / implausiblep. 167
+3p. 167
3p. 167
+1p. 167
1p. 167
+4p. 167
4p. 167
+Hydraulic oil temperature sensorp. 167
Hydraulic oil temperature sensorp. 167
+Signal faultyp. 167
Signal faultyp. 167
+Hydraulic oil temperature monitoringp. 167
Hydraulic oil temperature monitoringp. 167
+Temperature outside nominal rangep. 167
Temperature outside nominal rangep. 167
+3p. 167
3p. 167
+1p. 167
1p. 167
+8p. 167
8p. 167
+Battery monitoringp. 167
Battery monitoringp. 167
+Voltage outside nominal rangep. 167
Voltage outside nominal rangep. 167
+3p. 167
3p. 167
+2p. 167
2p. 167
+8p. 167
8p. 167
+Output to cold starting aid control lampp. 167
Output to cold starting aid control lampp. 167
+Signal faulty, control unit overheatingp. 167
Signal faulty, control unit overheatingp. 167
+4p. 167
4p. 167
+1p. 167
1p. 167
+4p. 167
4p. 167
+Output to external exhaust gas recirculation actuatorp. 167
Output to external exhaust gas recirculation actuatorp. 167
+Signal faultyp. 167
Signal faultyp. 167
+4p. 167
4p. 167
+1p. 167
1p. 167
+5p. 167
5p. 167
+Output to external exhaust gas recirculation actuatorp. 167
Output to external exhaust gas recirculation actuatorp. 167
+Signal faulty, control unit overheatingp. 167
Signal faulty, control unit overheatingp. 167
+4p. 167
4p. 167
+1p. 167
1p. 167
+6p. 167
6p. 167
+Output to external exhaust gas recirculation actuatorp. 167
Output to external exhaust gas recirculation actuatorp. 167
+Signal faultyp. 167
Signal faultyp. 167
+4p. 167
4p. 167
+1p. 167
1p. 167
+7p. 167
7p. 167
+Lubrication oil wear time meterp. 167
Lubrication oil wear time meterp. 167
+Critical time reachedp. 167
Critical time reachedp. 167
+5p. 167
5p. 167
+1p. 167
1p. 167
+2p. 167
2p. 167
+Output to start relayp. 167
Output to start relayp. 167
+Signal faulty, control unit overheatingp. 167
Signal faulty, control unit overheatingp. 167
+5p. 167
5p. 167
+1p. 167
1p. 167
+3p. 167
3p. 167
+Output to fault lampp. 167
Output to fault lampp. 167
+Signal faulty, control unit overheatingp. 167
Signal faulty, control unit overheatingp. 167
+5p. 167
5p. 167
+1p. 167
1p. 167
+4p. 167
4p. 167
+Monitoring of terminal 15p. 167
Monitoring of terminal 15p. 167
+No signal detectedp. 167
No signal detectedp. 167
+5p. 167
5p. 167
+1p. 167
1p. 167
+5p. 167
5p. 167
+Monitoring of terminal 50p. 167
Monitoring of terminal 50p. 167
+Permanent signal detectedp. 167
Permanent signal detectedp. 167
+5p. 167
5p. 167
+2p. 167
2p. 167
+1p. 167
1p. 167
+Speed measurementp. 167
Speed measurementp. 167
+Travel speed implausiblep. 167
Travel speed implausiblep. 167
+5p. 167
5p. 167
+2p. 167
2p. 167
+8p. 167
8p. 167
+Output to internal engine brakep. 167
Output to internal engine brakep. 167
+Signal faultyp. 167
Signal faultyp. 167
EMR3 List of fault codesp. 168
CAN-bus, Controller Area Networkp. 239
+created by Bosch at the end of the eighties for automobile applications.p. 239
created by Bosch at the end of the eighties for automobile applications.p. 239
Development objectives:p. 239
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. 239
Fig. 7p. 239
Why CAN?p. 239
+l Networking of control units for the realization of complex functions.p. 239
+l Networking of control units for the realization of complex functions.p. 239
l Networking of control units for the realization of complex functions.p. 239
l Reduction of the extend of wiring and plug connections.p. 239
l Better diagnostic possibilities (central diagnostics socket).p. 239
Characteristics of CANp. 239
+It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 239
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 239
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. 239
Wire (+) = cable colour bluep. 239
Wire (-) = cable colour yellowp. 239
+Measuring on the CANp. 239
Measuring on the CANp. 239
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. 239
7.25 Generatorp. 239
+Generalp. 239
Generalp. 239
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. 239
Terminal designationsp. 239
+l B61, L = charge controlp. 239
l B61, L = charge controlp. 239
l B+, B = battery plus, also with the designation "30"p. 239
l B- = battery minus, also with the designation "31"p. 239
l D+ = dynamo plus corresponds with terminal "61" and "L"p. 239
l D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed)p. 239
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. 239
l DF1 = dynamo field 1p. 239
l DF2 = dynamo field 2p. 239
l IG = "15" ignition switchp. 239
Three-phase generatorp. 240
+The AC-generator first of all produces AC-voltage / AC-current.p. 240
The AC-generator first of all produces AC-voltage / AC-current.p. 240
Why does AC-current need to be rectified?p. 240
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. 240
This includes :p. 240
+l Incandescent lampsp. 240
l Incandescent lampsp. 240
l Fluorescent lampsp. 240
l Glow lampsp. 240
l Electric heating elements.p. 240
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. 240
This includes :p. 240
+l Electric motorsp. 240
l Electric motorsp. 240
l Relays.p. 240
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.p. 240
This includes :p. 240
+l Accumulatorsp. 240
l Accumulatorsp. 240
l Control unitsp. 240
l All electronicsp. 240
l Communication equipment.p. 240
+Design and functionp. 240
Design and functionp. 240
Fig. 8p. 240
+1 Fanp. 240
1 Fanp. 240
2 Holding platep. 240
3 Stator corep. 240
4 Stator windingp. 240
5 Brushp. 240
6 Brush holderp. 240
7 Rectifierp. 240
8 Bearing coverp. 240
9 Rotor windingp. 240
10 Rotorp. 240
11 V-belt pulleyp. 240
Fig. 9 Rotor with claw polesp. 240
+In the generator the armature windings are located inside the stationary statorp. 240
(Fig. 10)p. 240
(Fig. 9)p. 240
Fig. 10 Statorp. 240
+The three stator windingsp. 240
(Fig. 10)p. 240
Fig. 11 3-phase currentp. 241
+The wiring diagramp. 241
(Fig. 11)p. 241
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. 241
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. 241
Charge control lightp. 241
The charge control light has two duties:p. 241
+l Indication of the correct generator functionp. 241
l Indication of the correct generator functionp. 241
l External excitation of the generator during the starting phasep. 241
Fig. 12 plus controlled charging regulatorp. 241
+(Fig. 12) shows the current flow with the ignition switched on, engine stopped.p. 241
(Fig. 12)p. 241
Fig. 13 plus controlled charging regulatorp. 241
+(Fig. 13) shows the current flow with the ignition switched on, engine running.p. 241
(Fig. 13)p. 241
+1 Batteryp. 241
1 Batteryp. 241
2 Charge controllerp. 241
3 Ignition switchp. 241
4 Charge control lightp. 241
5 Rectifierp. 241
6 Rotorp. 241
7 Sliprings / carbon brushp. 241
8 Auxiliary rectifierp. 241
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. 241
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. 242
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. 242
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. 242
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. 242
Charge controllerp. 242
The charge controller has the following functionsp. 242
+l To regulate the voltage generated by the generatorp. 242
l To regulate the voltage generated by the generatorp. 242
l To protect against overloads caused by too high output currentp. 242
l Protection against reverse currentp. 242
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. 242
+Electronic charge regulatorp. 242
Electronic charge regulatorp. 242
Fig. 14p. 242
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. 242
Fig. 15 plus controlled regulatorp. 243
Fig. 16 minus controlled regulatorp. 243
Checking the generatorp. 243
+First one must check whether the generator is actually defective.p. 243
First one must check whether the generator is actually defective.p. 243
+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. 243
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. 243
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. 243
The following points allow to contain faults in the voltage supply within certain limits.p. 243
+l Cable connections on the generator OK?p. 243
l Cable connections on the generator OK?p. 243
l V-belt OK?p. 243
l Generator ground (engine ground) OK?p. 243
l Pre-excitation from vehicle electronics OK?p. 243
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. 243
Checking the pre-exciter circuit, D+ generatorp. 244
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. 244
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. 244
The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm.p. 244
In case of faults likep. 244
+l charge control light stays onp. 244
l charge control light stays onp. 244
l no voltage increase, e.g. from 12 V to 14 Vp. 244
one should check that the correct resistance is assured.p. 244
Fig. 17 Connections on the three-phase alternator (exemplary design)p. 244
If the charge control light or LED stays on when the engine is running, you should proceed as follows:p. 244
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 244
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 244
(Fig. 17)p. 244
If this measure does not clear the fault, the alternator must be defective.p. 244
+Measuring the charge currentp. 244
Measuring the charge currentp. 244
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 244
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 244
l The generator ground connection must be OK.p. 244
l During the measurement switch on as many consumers as possible.p. 244
+1 Attach the clip-on ammeter around the B+ line.p. 244
1 Attach the clip-on ammeter around the B+ line.p. 244
2 Gradually increase the engine speed.p. 244
3 The generator current must be at least as high as the total current of all switched on consumers.p. 244
Checking the rotorp. 245
+The rotor coils can only be measured in disassembled state.p. 245
The rotor coils can only be measured in disassembled state.p. 245
Fig. 18p. 245
+l Measure the resistance between the sliprings.p. 245
l Measure the resistance between the sliprings.p. 245
l If the resistance does not comply with the factory specification, replace the rotor.p. 245
l Use the resistance range of the continuity tester to check the continuity between slipring and core.p. 245
l Replace the rotor if no infinite value is indicated.p. 245
+Factory specification for resistance: 2.8 to 5 OHM.p. 245
Factory specification for resistance: 2.8 to 5 OHM.p. 245
Checking the statorp. 245
+The stator coils can only be measured in disassembled state.p. 245
The stator coils can only be measured in disassembled state.p. 245
Fig. 19p. 245
+l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 245
l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 245
l If the measuring value does not comply with the factory specification, replace the stator.p. 245
l Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core.p. 245
l Replace the stator if no infinite value is indicated.p. 245
+Factory specification for resistance: Less than 1 OHM.p. 245
Factory specification for resistance: Less than 1 OHM.p. 245
Checking the bearingsp. 246
Fig. 20p. 246
+l Check whether the bearing rotates without obstruction.p. 246
l Check whether the bearing rotates without obstruction.p. 246
l Replace the bearing if it does not rotate properly.p. 246
Checking the regulator voltage with the generator testerp. 246
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. 246
Fig. 21p. 246
The generator test assesses the regulator voltage and the ripple factor of the generator voltage.p. 246
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 246
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 246
l The generator ground connection must be OK.p. 246
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 246
l If possible switch off all consumers.p. 246
l Perform the measurement at raised engine speed.p. 246
Checking the regulator voltage with the multimeterp. 247
Fig. 22p. 247
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 247
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 247
l The generator ground connection must be OK.p. 247
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 247
l If possible switch off all consumers.p. 247
l Perform the measurement at raised engine speed.p. 247
l The voltage (B+) should adjust itself at 13 to 14 Volt.p. 247
Checking the regulator in disassembled statep. 247
+On ap. 247
Bosch generatorp. 247
+Thep. 247
Delco-Remy generatorp. 247
+When testing the regulator one should be aware that there are 2 different types of regulators:p. 247
When testing the regulator one should be aware that there are 2 different types of regulators:p. 247
+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. 247
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. 247
D+ (vehicle wiring system)p. 247
D- (ground contact, mostly located on one of the fastening screws)p. 247
DF (Dynamo Field)p. 247
Fig. 23p. 247
+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. 247
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. 247
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. 247
Fig. 24p. 248
E.g minus controlled regulatorp. 248
+One connects the regulatorp. 248
(Fig. 24)p. 248
With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-.p. 248
Fig. 25p. 248
Fig. 26p. 248
+The illustrationsp. 248
(Fig. 25)p. 248
(Fig. 26)p. 248
Replacing carbon brushesp. 248
+l On ap. 248
+l On ap. 248
Bosch generatorp. 248
5 mmp. 248
+l For replacing the carbon brushes in thep. 248
Delco- Remy generatorp. 248
7.26 Electric starterp. 249
+Generalp. 249
Generalp. 249
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. 249
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. 249
Duties of the starter:p. 249
+l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 249
l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 249
l establish the gear connection between starter and combustion engine.p. 249
l to maintain this connection.p. 249
l to switch on the starter current.p. 249
After starting the engine:p. 249
+l to return the starter pinion to initial position.p. 249
l to return the starter pinion to initial position.p. 249
l to switch off the starter current.p. 249
Directly acting electric starterp. 249
+This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 249
This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 249
Fig. 27p. 249
+1 Magnetic switchp. 249
1 Magnetic switchp. 249
2 Armaturep. 249
3 Actuating leverp. 249
4 Freewheeling clutchp. 249
5 Resetting springp. 249
6 Brushp. 249
7 Exciting windingp. 249
8 Armaturep. 249
9 Collectorp. 249
+Ignition switch in position "START"p. 249
Ignition switch in position "START"p. 249
Fig. 28 Magnetic switch openp. 249
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. 249
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. 249
+1 Armaturep. 249
1 Armaturep. 249
2 Holding windingp. 249
3 Pick-up windingp. 249
4 Magnetic switchp. 249
5 Ignition switchp. 250
6 Actuating leverp. 250
7 Ring gearp. 250
8 Pinionp. 250
9 Freewheeling clutchp. 250
10 (Batteryp. 250
+Pinion meshes with the ring gearp. 250
Pinion meshes with the ring gearp. 250
Fig. 29 Magnetic switch closedp. 250
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. 250
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. 250
+1 Pick-up windingp. 250
1 Pick-up windingp. 250
2 Magnetic switchp. 250
3 Pinionp. 250
4 Ring gearp. 250
5 Armaturep. 250
6 Exciting windingp. 250
7 Batteryp. 250
+Engine runningp. 250
Engine runningp. 250
Fig. 30p. 250
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. 250
+1 Pinionp. 250
1 Pinionp. 250
2 (Ring gearp. 250
3 Freewheeling clutchp. 250
4 Armaturep. 250
+Ignition switch releasedp. 250
Ignition switch releasedp. 250
Fig. 31p. 250
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. 250
This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops.p. 250
+1 Armaturep. 250
1 Armaturep. 250
2 Holding windingp. 250
3 Pick-up windingp. 250
4 Resetting springp. 251
5 Magnetic switchp. 251
6 Ignition switchp. 251
7 Pinionp. 251
8 Ring gearp. 251
9 Batteryp. 251
Magnetic switchp. 251
Fig. 32 Direct acting electric motorp. 251
Fig. 33 Geared motorp. 251
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. 251
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. 251
+1 Holding windingp. 251
1 Holding windingp. 251
2 Pick-up windingp. 251
3 Contact platep. 251
4 Armaturep. 251
5 Resetting springp. 251
6 Armature guidep. 251
Freewheeling clutchp. 252
Fig. 34 Freewheeling clutchp. 252
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. 252
This makes sure that the armature will only drive the ring gear, but can never be driven by the engine.p. 252
+1 Freewheeling ringp. 252
1 Freewheeling ringp. 252
2 Rollerp. 252
3 Roller springp. 252
4 Splined shaftp. 252
5 Pinionp. 252
6 Pinionp. 252
Trouble shooting "Starter"p. 252
+The most frequent fault is definitely a fully discharged battery.p. 252
+The most frequent fault is definitely a fully discharged battery.p. 252
The most frequent fault is definitely a fully discharged battery.p. 252
+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. 252
If the starter rotates too slowlyp. 252
+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. 252
If the starter only emits a clicking soundp. 252
Frequently a jammed return mechanism is the reason for a starter failure.p. 252
Occasionally worn contacts are found on the magnetic return switchp. 252
Defects on the actual starter motor including pinion and carbon brushes are very rare.p. 252
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. 252
+l Immobilizer deactivated?p. 252
l Immobilizer deactivated?p. 252
l Ignition switch OK?p. 252
l Travel lever in correct position?p. 252
l Emergency stop not actuated?p. 252
l Battery sufficiently charged?p. 252
l Battery poles OK?p. 252
l Main battery fuse OK?p. 252
l Main battery switch closed?p. 252
l Main starter cable (terminal 30) OK?p. 252
l Starter control cable (terminal 50) OK, voltage drop?p. 252
l Ground cable OK?p. 252
l Switching of magnetic switches OK?p. 252
The sequence of these tests is generally of no significance. It mainly depends on:p. 252
+l the experience of the specialistp. 252
l the experience of the specialistp. 252
l the failure probability of the component to be tested and the testing effort for the respective part.p. 252
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. 252
Testing and measuring the starterp. 253
+Function control with the starter removedp. 253
Function control with the starter removedp. 253
+Fasten the starter to make sure that it will not come loose during the test.p. 253
Fasten the starter to make sure that it will not come loose during the test.p. 253
Fig. 35p. 253
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 253
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 253
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 253
+If the motor does not start, the starter is defective. Repair or replace the starter.p. 253
If the motor does not start, the starter is defective. Repair or replace the starter.p. 253
+Checking the magnetic switchp. 253
Checking the magnetic switchp. 253
Fig. 36p. 253
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 253
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 253
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 253
+If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 253
If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 253
+Continuity test for the magnetic switchp. 253
Continuity test for the magnetic switchp. 253
Fig. 37p. 253
+l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 253
l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 253
l Replace the magnetic switch if no continuity is detected.p. 253
Removing and assembling the starterp. 254
+Removing the starterp. 254
Removing the starterp. 254
Fig. 38p. 254
+l Switch the main battery switch to position "0"p. 254
+l Switch the main battery switch to position "0"p. 254
(Fig. 38)p. 254
Fig. 39p. 254
+l Disconnect the cable connections (terminal 30 and 50).p. 254
l Disconnect the cable connections (terminal 30 and 50).p. 254
+l Unscrew the screws (arrows)p. 254
(Fig. 39)p. 254
l Take off the starter.p. 254
+Assembling the starterp. 254
Assembling the starterp. 254
Fig. 40p. 254
+l Insert the starter.p. 254
l Insert the starter.p. 254
+l Tighten the screws (arrows)p. 254
(Fig. 40)p. 254
l Connect the cables (terminal 30 and 50).p. 254
+Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 254
Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 254
+Terminal 30, 24p. 254
±4p. 254
Terminal 50, 1 – 1,3 Nmp. 254
To tightly tightened nuts can cause damage to starter components (e.g. cracks in the cover of the magnetic switch). Moisture entering into the starter can cause short circuit – or even cable fire.p. 254
Insufficiently tightened nuts can cause cable connections to come loose and thus short circuit – or even cable fire.p. 254
+8 Enginep. 255
+8 Enginep. 255
8.1 Diesel enginep. 256
+The new range of refuse and earth compactors in the 20 – 30 tonne weight class is powered by cylinder Deutz diesel engines type TCD 2013 with cylinders and 2 valves per cylinder.p. 256
The new range of refuse and earth compactors in the 20 – 30 tonne weight class is powered by cylinder Deutz diesel engines type TCD 2013 with cylinders and 2 valves per cylinder.p. 256
The engines are water cooled in-line engines with EMR3 engine electronics.p. 256
Furthermore, the engines are turbocharged and equipped with an intercooler. They are highly compact and come with a Deutz-Common-Rail "DCR" injection system and two-valve control.p. 256
All engines are designed with exhaust gas recirculation and thus reach emission values complying with EPA/ COM/ Tier/ stage lllp. 256
These engines are characterized by the following positive features:p. 256
+l compact designp. 256
l compact designp. 256
l low noise levelp. 256
l almost vibration free operationp. 256
l low fuel consumptionp. 256
l low exhaust emission EPA/COM IIlp. 256
l high power densityp. 256
l good access to all service points.p. 256
l high reliabilityp. 256
l low running costs,p. 256
l long lifetimep. 256
Fig. 1 Deutz diesel engine TCD 2012 and 2013p. 256
Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand sidep. 257
+1 Combustion air inlet (possibility to install a heating flange, optionally)p. 257
1 Combustion air inlet (possibility to install a heating flange, optionally)p. 257
2 Connection of cabin heater or compensation linep. 257
3 Fanp. 257
4 Generatorp. 257
5 Belt pulley on crankshaftp. 257
6 V-beltp. 257
7 Fuel lift pump drivep. 257
8 Fuel filterp. 257
9 Lubrication oil filterp. 257
10 Lubrication oil coolerp. 257
11 Possible installation of hydraulic pump or compressor (optional)p. 257
12 Lubrication oil return line crankcase ventilationp. 257
13 Central plug (for engine control)p. 257
14 Fuel control unitp. 257
15 High pressure pumpp. 257
16 Crankcase ventilation valvep. 257
17 Injectorp. 257
18 Lubrication oil filling neckp. 257
Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand sidep. 258
+1 Lubrication oil filling neck (optional)p. 258
1 Lubrication oil filling neck (optional)p. 258
2 Transmission connection (SAE)p. 258
3 Engine mountsp. 258
4 Lubrication oil drain plugp. 258
5 Lubrication oil sumpp. 258
6 Starter motorp. 258
7 Lubrication oil return line from exhaust gas turbo chargerp. 258
8 Exhaust turbo chargerp. 258
9 Coolant inletp. 258
10 Charge air connection to intercoolerp. 258
11 Coolant outletp. 258
12 Exhaust manifoldp. 258
13 Charge air linep. 258
14 Transport devicep. 258
Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand sidep. 259
+1 Combustion air inletp. 259
1 Combustion air inletp. 259
2 Lubrication oil filling neckp. 259
3 Transport devicep. 259
4 Fan hubp. 259
5 Generatorp. 259
6 Lubrication oil filterp. 259
7 Fuel filterp. 259
8 Lubrication oil sumpp. 259
9 Oil dipstickp. 259
10 Lubrication oil drain plugp. 259
11 Oil return line crankcase ventilationp. 259
12 Engine mountsp. 259
13 Transmission connection (SAE)p. 259
14 Central plug (for engine control)p. 259
15 High pressure pumpp. 259
16 Railp. 259
17 Crankcase ventilation valvep. 259
18 Injectorp. 259
Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand sidep. 260
+1 Exhaust turbo chargerp. 260
1 Exhaust turbo chargerp. 260
2 Exhaust manifoldp. 260
3 Starter motorp. 260
4 Lubrication oil flow to exhaust turbo chargerp. 260
5 Coolant drain plugp. 260
6 Coolant inletp. 260
7 Ribbed V-beltp. 260
8 Fan hubp. 260
9 Idler pulleyp. 260
10 Connection of cabin heater or compensation linep. 260
11 Ventilation line to compensation tankp. 260
12 Coolant line from engine to radiatorp. 260
8.3 Lubrication oil circuit TCD 2012 / 2013p. 261
Fig. 1 Lubrication oil schematicp. 261
+1 Lubrication oil sumpp. 261
1 Lubrication oil sumpp. 261
2 Lubrication oil suction pipep. 261
3 Lubrication oil pumpp. 261
4 Pressure relief valvep. 261
5 Lubrication oil coolerp. 261
6 Return flow check valve (only on 2012)p. 261
7 By-pass valvep. 261
8 By-pass valve lubrication oil filterp. 261
9 Pressure control valvep. 261
10 Lubrication oil filterp. 261
11 Main lubrication oil linesp. 261
12 Internally switched exhaust gas recirculationp. 261
13 Crankshaft bearingsp. 261
14 Conrod bearingsp. 261
15 Camshaft bearingsp. 261
16 Line to spray nozzlep. 261
17 Piston cooling nozzle with pressure maintaining valvep. 261
18 Plunger with rocker arm pulse lubricationp. 262
19 Push rod, lubrication oil supply for rocker arm lubricationp. 262
20 Rocker armp. 262
21 Return line to lubrication oil sumpp. 262
22 Lubrication oil flow to exhaust turbo chargerp. 262
23 Exhaust turbo chargerp. 262
24 Return line from compressor / hydraulic pump to crankcasep. 262
25 Compressor or hydraulic pumpp. 262
26 Lubrication oil line to crankshaft and camshaft, compressor / hydraulic pumpp. 262
27 Return flow from exhaust turbo chargerp. 262
8.4 Coolant circuit TCD 2012 / 2013p. 263
Fig. 1 Coolant circuitp. 263
+1 Coolant outlet on radiatorp. 263
1 Coolant outlet on radiatorp. 263
2 Thermostatp. 263
3 Coolant – supply to water pumpp. 263
4 Coolant pumpp. 263
5 Lubrication oil coolerp. 263
6 Cylinder coolingp. 263
7 Cylinder liner / head coolingp. 263
8 Coolant flow to heaterp. 263
9 Cabin heater (optional)p. 263
10 Coolant to thermostatp. 263
11 Connection for cabin heaterp. 263
12 Compensation linep. 263
13 Ventilation line to compensation tankp. 263
14 Coolant outlet to radiatorp. 263
15 Compensation tankp. 263
16 Compensation line to heat exchangerp. 263
8.5 Fuel system TCD 2012 / 2013p. 264
Fig. 1 Fuel circuitp. 264
+1 Fuel tank A= minimum distance 500 mmp. 264
1 Fuel tank A= minimum distance 500 mmp. 264
2 Fuel pre-filter with pre-pressure hand pump to fill the low pressure sectionp. 264
3 Line to fuel lift pumpp. 264
4 Fuel lift pumpp. 264
5 Fuel filterp. 264
6 Fuel supply line to fuel control unitp. 264
7 Railp. 264
8 High pressure pumpp. 264
9 Fuel supply line to injectorp. 264
10 Injectorp. 264
11 FCU (Fuel Control Unit)p. 264
12 Fuel return flow on cylinder headp. 264
13 Fuel return line to fuel tankp. 264
14 Fuel lines from fuel control unit to high pressure pumps and railp. 264
15 Fuel lift pump 2013p. 264
+Fuel pre-cleanerp. 265
Fuel pre-cleanerp. 265
Fig. 2 Fuel pre-cleanerp. 265
+1 Fuel supply to pumpp. 265
1 Fuel supply to pumpp. 265
2 Fuel return flow from FCU (Fuel Control Unit)p. 265
3 Manual fuel pump with bayonet lock to lock and unlockp. 265
4 Option, thermostat valve with shut-down leverp. 265
5 Filter cartridgep. 265
6 Possibility to connect an electric water level sensorp. 265
7 Drain tapp. 265
8 Water collecting bowlp. 265
9 Fuel inlet from fuel tankp. 265
10 Fuel return flow to fuel tankp. 265
A Electric water level sensor, B124p. 265
TCD 2013 Fuel filter systemp. 266
Fig. 3 TCD 2013 Fuel systemp. 266
+1 Fuel pre-cleanerp. 266
1 Fuel pre-cleanerp. 266
2 Hand pumpp. 266
3 Fuel pressure filter min. 3µmp. 266
4 Bleeding screwsp. 266
5 Water separator sensor, B124p. 266
8.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013p. 267
+The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" (DCR) injection system.p. 267
The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" (DCR) injection system.p. 267
The English term "Common Rail" indicates that the system is based on a common rail. It describes the use of a common high pressure fuel line with corresponding branches to supply all cylinders with fuel.p. 267
The "Common Rail" injection is an injection system for combustion engines, in which a high pressure pump pressurizes the fuel to a high pressure level. The pressurized fuel fills a piping system, which is permanently under pressure while the engine i…p. 267
The general idea is the total isolation of the pressure generation from the actual injection process. An injection solely controlled by mapping is only possible under this condition. Injection timing and injection quantity are controlled by the engin…p. 267
The electric control is accomplished by the electronic control unit (EDC16) with EMR3, in dependence on the operating parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a r…p. 267
Fig. 1 TCD 2012 and 2013p. 267
Fig. 2 Schematic of the Deutz Common Rail System "DCR"p. 268
11 Fuel pre-filter with water separator (B124)p. 268
12 Hand pumpp. 268
Under normal conditions the rail pressure is between 300 and 1350 barp. 269
The PRV is set to 1600 barp. 269
If the PRV is defective or always open, the pressure in the rail will only build up to max. 700 bar.p. 269
The rail pressure must be at least 1.5 bar to start the diesel enginep. 269
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 269
The solenoid valve of the Fuel Control Unit (FCU) is dead, open towards the tank.p. 269
The voltage applied to the injectors is normally approx. 40 V.p. 269
FCU Fuel Control Unit (Y137)p. 270
Fig. 3 Fuel Control Unit FCUp. 270
Two high pressure pumpsp. 270
Fig. 4 High pressure pumpp. 270
Injector ( Y148 )p. 271
Fig. 5 Injectorp. 271
Fig. 6 Excerpt from the wiring diagramp. 271
TCD 2013p. 272
Fig. 7 TCD 2013p. 272
+1 FCU Fuel Control Unit (Y137)p. 272
1 FCU Fuel Control Unit (Y137)p. 272
2 Railp. 272
3 Fuel low pressure sensor (B145)p. 272
4 Connecting plug EMR3p. 272
5 Rail pressure sensor (B93)p. 272
8.7 Exhaust gas recirculation TCD 2012 / 2013p. 273
+In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 273
In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 273
On 4-cylinder 2-valve engines TCD 2012/2013 the exhaust gas recirculation has been realized internally through the intake valves, on 6-cylinder 2-valve engines through the exhaust valves. For this purpose the camshaft has been manufactured with an ad…p. 273
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013p. 273
8.8 Engine problemsp. 274
+Faultp. 274
Faultp. 274
+Possible causep. 274
Possible causep. 274
+Remedyp. 274
Remedyp. 274
+Engine does not start or starts poorlyp. 274
Engine does not start or starts poorlyp. 274
+Fuel tank emptyp. 274
Fuel tank emptyp. 274
+Fill the fuel tank and bleed the fuel systemp. 274
Fill the fuel tank and bleed the fuel systemp. 274
+Temperature below starting limitp. 274
Temperature below starting limitp. 274
+Checkp. 274
Checkp. 274
+Cold starting aidp. 274
Cold starting aidp. 274
+Check/replacep. 274
Check/replacep. 274
+Engine oil with wrong SAE viscosity classp. 274
Engine oil with wrong SAE viscosity classp. 274
+Change the lubrication oilp. 274
Change the lubrication oilp. 274
+Fuel quality not as specified in the operating instructionsp. 274
Fuel quality not as specified in the operating instructionsp. 274
+Change the fuelp. 274
Change the fuelp. 274
+Battery defective or not chargedp. 274
Battery defective or not chargedp. 274
+Check the batteryp. 274
Check the batteryp. 274
+Cable to starter loose or oxidizedp. 274
Cable to starter loose or oxidizedp. 274
+Check cable connectionp. 274
Check cable connectionp. 274
+Starter defective or pinion does not engagep. 274
Air filter clogged / exhaust turbocharger defectivep. 276
+Check/replacep. 276
Check/replacep. 276
+Air filter service switch / indicator defectivep. 276
Air filter service switch / indicator defectivep. 276
+Check/replacep. 276
Check/replacep. 276
+Incorrect valve clearancep. 276
Incorrect valve clearancep. 276
+Check, adjust the valve clearancep. 276
Check, adjust the valve clearancep. 276
+Charge air pipe leakingp. 276
Charge air pipe leakingp. 276
+Check charge air linep. 276
Check charge air linep. 276
+Injection valve defectivep. 276
Injection valve defectivep. 276
+Check / replace the injection valvep. 276
Check / replace the injection valvep. 276
+8.10 Adjust the valve clearancep. 277
8.9 Wastegate – charge pressure controller on TCD-enginesp. 277
+The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 277
The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 277
The Wastegate (exhaust gas bypass valve) is used to control the charge pressurep. 277
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. 277
The bypass valve is normally closedp. 277
Fig. 1 Exhaust gas turbocharger with Wastegatep. 277
Wastegate active, charge pressure control, i.e. bypass valve openp. 277
Fig. 1 Exhaust gas turbocharger with Wastegatep. 277
Wastegate on TCD 2013p. 278
Fig. 2 Exhaust gas turbocharger with Wastegatep. 278
+8.10 Adjust the valve clearancep. 279
8.10 Adjust the valve clearancep. 279
+We recommend to have this work carried out by trained personnel or our after sales service.p. 279
+We recommend to have this work carried out by trained personnel or our after sales service.p. 279
We recommend to have this work carried out by trained personnel or our after sales service.p. 279
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. 279
Fig. 3p. 279
+l Remove the valve coverp. 279
+l Remove the valve coverp. 279
(Fig. 3)p. 279
l Turn the crankshaft with the cranking device until the valves are overlapping.p. 279
+Firing sequence 1-5-3-6-2-4p. 279
Firing sequence 1-5-3-6-2-4p. 279
Overlapping of valves: Exhaust valve not yet closed, intake valve starts to open.p. 279
+Valvesp. 279
Valvesp. 279
+Cylinderp. 279
Cylinderp. 279
+overlappingp. 279
overlappingp. 279
+1p. 279
1p. 279
+5p. 279
5p. 279
+3p. 279
3p. 279
+6p. 279
6p. 279
+2p. 279
2p. 279
+4p. 279
4p. 279
+adjustmentp. 279
adjustmentp. 279
+6p. 279
6p. 279
+2p. 279
2p. 279
+4p. 279
4p. 279
+1p. 279
1p. 279
+5p. 279
5p. 279
+3p. 279
3p. 279
Fig. 4p. 279
+l Loosen the counter nut (1)p. 279
+l Loosen the counter nut (1)p. 279
(Fig. 4)p. 279
l Attach the rotation angle disc (3) and the spanner socket (4) to the valve clearance adjustment screw (2).p. 279
+l Fix the magnet (5) of the rotation angle disc.p. 279
l Fix the magnet (5) of the rotation angle disc.p. 279
+l Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 279
l Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 279
+l Turn the rotation angle disc counterclockwise, until the specified angle is reached.p. 279
l Turn the rotation angle disc counterclockwise, until the specified angle is reached.p. 279
+Intake valvep. 279
Intake valvep. 279
+90°p. 279
+10°p. 279
Exhaust valvep. 279
+150°p. 279
+10°p. 279
+l Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut (1).p. 279
l Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut (1).p. 279
Tightening torque: 20 Nmp. 279
+l Repeat this adjustment procedure an all other cylinders, after cranking the crankshaft accordingly.p. 279
l Repeat this adjustment procedure an all other cylinders, after cranking the crankshaft accordingly.p. 279
l Assemble the cylinder head cover with a new gasket.p. 279
Tightening torque: 13 Nmp. 279
+l After a short test run check the engine for leaks.p. 279
l After a short test run check the engine for leaks.p. 279
+8.11 Checking the engine oil levelp. 280
8.11 Checking the engine oil levelp. 280
+The machine must be in horizontal position.p. 280
+The machine must be in horizontal position.p. 280
The machine must be in horizontal position.p. 280
If the engine is warm, shut it down and check the oil level after five minutes.p. 280
With a cold engine the oil level can be checked immediately.p. 280
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 280
Fig. 5p. 280
+l Open the engine hood.p. 280
l Open the engine hood.p. 280
+l Pull the dipstickp. 280
(Fig. 5)p. 280
l Pull the dipstick back out.p. 280
The oil level must always be between the "MIN"- and "MAX"-marks.p. 280
Fig. 6p. 280
+l If the oil level is too low, top up oil to the "MAX" mark immediately.p. 280
+l If the oil level is too low, top up oil to the "MAX" mark immediately.p. 280
(Fig. 6)p. 280
l If the oil level is above the “MAX” mark, determine the cause and drain off oil.p. 280
+8.12 Change engine oil and oil filter cartridgep. 280
8.12 Change engine oil and oil filter cartridgep. 280
+Danger of scalding!p. 280
+Danger of scalding!p. 280
Danger of scalding!p. 280
When draining off hot oil.p. 280
By hot oil when unscrewing the engine oil filter.p. 280
+Drain the oil only when the engine is warm.p. 280
Drain the oil only when the engine is warm.p. 280
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 280
+Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 280
Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 280
+l Remove the maintenance cover.p. 280
l Remove the maintenance cover.p. 280
Fig. 7p. 280
+l Unscrew the safety cap (2)p. 280
+l Unscrew the safety cap (2)p. 280
(Fig. 7)p. 280
l Unscrew oil drain plug (3) and catch running out oil.p. 280
l Once all oil has run out disconnect the drain hose and screw the protective cap back on.p. 280
Fig. 8p. 281
+l Open the engine hood and unscrew the filter cartridgep. 281
+l Open the engine hood and unscrew the filter cartridgep. 281
(Fig. 8)p. 281
+l Clean the sealing face on the filter carrier from any dirt.p. 281
l Clean the sealing face on the filter carrier from any dirt.p. 281
l Slightly oil the rubber seal on the new filter cartridges.p. 281
+l Screw the new filter on by hand, until the seal contacts, then tighten for half a turn.p. 281
l Screw the new filter on by hand, until the seal contacts, then tighten for half a turn.p. 281
Fig. 9p. 281
+l Fill in new engine oilp. 281
+l Fill in new engine oilp. 281
(Fig. 9)p. 281
+l Tighten the oil filler cap properly.p. 281
l Tighten the oil filler cap properly.p. 281
+l After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 281
l After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 281
l Check filter cartridge and drain plug for leaks.p. 281
+8.13 Checking, cleaning the water separatorp. 281
8.13 Checking, cleaning the water separatorp. 281
+Fire hazard!p. 281
+Fire hazard!p. 281
Fire hazard!p. 281
When working on the fuel system do not use open fire, do not smoke, do not spill any fuel.p. 281
+Health hazard!p. 281
Health hazard!p. 281
Do not inhale any fuel fumes.p. 281
+Catch running out fuel and dispose of environmentally.p. 281
Catch running out fuel and dispose of environmentally.p. 281
+The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the filter bowl initially every day, later as requi…p. 281
The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the filter bowl initially every day, later as requi…p. 281
If a too high quantity is drained off, the filter needs to be bled, see section "Replacing the fuel pre-cleaner cartridge".p. 281
Fig. 10p. 281
+l If the warning light for water in the fuel (a)p. 281
+l If the warning light for water in the fuel (a)p. 281
(Fig. 10)p. 281
l Open the engine hood.p. 281
Fig. 11p. 282
+l Slacken the drain plugp. 282
+l Slacken the drain plugp. 282
(Fig. 11)p. 282
l Turn the plug tightly back in. Check for leaks, if necessary use a new seal ring.p. 282
+Once the water separator is empty the warning light for water in fuel must go out.p. 282
Once the water separator is empty the warning light for water in fuel must go out.p. 282
+8.14 Replacing the fuel pre-filter cartridge, bleeding the fuel systemp. 282
8.14 Replacing the fuel pre-filter cartridge, bleeding the fuel systemp. 282
+Fire hazard!p. 282
+Fire hazard!p. 282
Fire hazard!p. 282
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 282
+Health hazard!p. 282
Health hazard!p. 282
Do not inhale any fuel fumes.p. 282
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 282
Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 282
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 282
Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory.p. 282
+Catch running out fuel and dispose of environmentally.p. 282
Catch running out fuel and dispose of environmentally.p. 282
+Change the fuel pre-filter cartridgep. 282
Change the fuel pre-filter cartridgep. 282
Fig. 12p. 282
+l Tighten the cable on the water separatorp. 282
+l Tighten the cable on the water separatorp. 282
(Fig. 12)p. 282
l (1) Loosen the bleeding screw and drain off fuel from the bleeding screw.p. 282
l (2) Loosen and unscrew the fuel pre-filter cartridge using an appropriate filter wrench.p. 282
l (3) Unscrew the water separator from the filter cartridge.p. 282
l (4) Apply a thin coat of oil to the rubber seal of the water separator.p. 282
l (5) Turn the water separator on by hand, until the seal contacts, then tighten hand-tight.p. 283
l (6) Apply a thin coat of oil to the rubber seal of the filter element (5).p. 283
l (7) Turn the filter cartridge on by hand, until the seal contacts, then tighten hand-tight.p. 283
l Plug the water sensor cable back on.p. 283
+Bleed the fuel systemp. 283
Bleed the fuel systemp. 283
+Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 283
Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 283
Therefore bleed the fuel system after changing the fuel pre-filter or working on the fuel system.p. 283
Fig. 13p. 283
+l Slacken the bleeding screw (1)p. 283
+l Slacken the bleeding screw (1)p. 283
(Fig. 13)p. 283
l Unlock the bayonet lock of the fuel hand pump by pressing it down and turning it anti-clockwise.p. 283
l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles.p. 283
l Then tighten the bleeding screw while pumping.p. 283
Fig. 14p. 283
+l Slacken the bleeding screws (2)p. 283
+l Slacken the bleeding screws (2)p. 283
(Fig. 14)p. 283
+l Operate the fuel hand pump (2)p. 283
(Fig. 13)p. 283
l Then tighten the bleeding screws while pumping.p. 283
l Lock the bayonet lock of the fuel hand pump by pressing it down and turning it clockwise.p. 283
l Start the engine and run it 5 minutes with idle speed.p. 283
+8.15 Replacing the fuel filter cartridgesp. 284
8.15 Replacing the fuel filter cartridgesp. 284
+Fire hazard!p. 284
+Fire hazard!p. 284
Fire hazard!p. 284
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 284
+Health hazard!p. 284
Health hazard!p. 284
Do not inhale any fuel fumes.p. 284
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 284
Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 284
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 284
Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory.p. 284
+Catch running out fuel and dispose of environmentally.p. 284
Catch running out fuel and dispose of environmentally.p. 284
Fig. 15p. 284
+l Loosen both fuel filtersp. 284
+l Loosen both fuel filtersp. 284
(Fig. 15)p. 284
+l Clean the sealing face on the filter carriers from any dirt.p. 284
l Clean the sealing face on the filter carriers from any dirt.p. 284
+The filter cartridge must never be filled beforehand.p. 284
The filter cartridge must never be filled beforehand.p. 284
Fig. 16p. 284
+l Slightly oil the rubber seal on the new filter cartridgep. 284
+l Slightly oil the rubber seal on the new filter cartridgep. 284
(Fig. 16)p. 284
l Turn the new filter cartridge on by hand, until the seal contacts.p. 284
l Then tighten hand-tight.p. 284
l Always bleed the fuel system after changing the fuel pre-filter cartridge (see next chapter).p. 284
l Check for leaks after a short test run.p. 284
+8.16 Check the coolant levelp. 285
8.16 Check the coolant levelp. 285
+Danger of scalding!p. 285
+Danger of scalding!p. 285
Danger of scalding!p. 285
Open the cap on the coolant compensation tank only when the engine is cold.p. 285
+If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 285
If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 285
Do not use radiator sealant to seal leaks.p. 285
For coolant refer to the "table of fuels and lubricants".p. 285
Fig. 17p. 285
+A too low coolant level is indicated by the coolant level warning light (g)p. 285
+A too low coolant level is indicated by the coolant level warning light (g)p. 285
(Fig. 17)p. 285
Fig. 18p. 285
+l Check the coolant levelp. 285
+l Check the coolant levelp. 285
(Fig. 18)p. 285
l The coolant level must reach the MAX-mark, top up if necessary.p. 285
+8.17 Changing the coolantp. 285
8.17 Changing the coolantp. 285
+Danger of scalding!p. 285
+Danger of scalding!p. 285
Danger of scalding!p. 285
Change the coolant only when the engine is cold.p. 285
+Do not start the engine after draining off the coolant.p. 285
Do not start the engine after draining off the coolant.p. 285
In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned. Lubrication oil can dam…p. 285
When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.p. 285
+For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 285
For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 285
Do not mix different coolants and additives, see section "Fuelds and Lubricants – Coolant".p. 285
+Catch coolant and dispose of environmentally.p. 285
Catch coolant and dispose of environmentally.p. 285
+l Open the engine hood.p. 285
l Open the engine hood.p. 285
l Remove the rear maintenance cover.p. 285
Fig. 19p. 285
+l Unscrew the coverp. 285
+l Unscrew the coverp. 285
(Fig. 19)p. 285
Fig. 20p. 286
+l Connect the drain hose to the drain cockp. 286
+l Connect the drain hose to the drain cockp. 286
(Fig. 20)p. 286
l Open the drain coc, let the coolant run out and catch it.p. 286
l Once all coolant has run out close the drain cock, remove the drain hose and screw the plug back on.p. 286
+Thoroughly flush the cooling system if the coolant is contaminated by corrosion residues or other suspended matter.p. 286
Thoroughly flush the cooling system if the coolant is contaminated by corrosion residues or other suspended matter.p. 286
If lubrication oil has entered you must add a cleansing agent in order to remove any residues from the system. Follow the instructions of the manufacturer. If in doubt consult your local service station or the engine manufacturer.p. 286
+l Remove the thermostat.p. 286
l Remove the thermostat.p. 286
l Fill in clean water.p. 286
l Start the diesel engine and run it warm to operating temperature.p. 286
l Allow the engine to cool down to approx. 50 °C.p. 286
l Drain all water off.p. 286
l Repeat the flushing process twice using a cleansing agent with clear water.p. 286
l Screw the plug back in once all coolant has run out.p. 286
l Reinstall the thermostat .p. 286
+The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.p. 286
The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.p. 286
Fig. 21p. 286
+l Fill in coolantp. 286
+l Fill in coolantp. 286
(Fig. 21)p. 286
l Start the diesel engine and run it warm to operating temperature.p. 286
l Check the coolant level again, top up if necessary.p. 286
+8.18 Checking the anti-freeze concentrationp. 287
8.18 Checking the anti-freeze concentrationp. 287
+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. 287
+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. 287
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. 287
+Danger of scalding!p. 287
Danger of scalding!p. 287
Check the anti-freeze concentration only when the engine is cold.p. 287
+l Perform the inspection with conventional test equipment.p. 287
l Perform the inspection with conventional test equipment.p. 287
l The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.p. 287
+Health hazard!p. 287
Health hazard!p. 287
The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.p. 287
+Catch all anti-freeze agent and dispose of environmentally.p. 287
Catch all anti-freeze agent and dispose of environmentally.p. 287
+8.20 Checking ribbed V-belts and compressor V-beltsp. 287
8.19 Checking the thermostat in disassembled statep. 287
+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. 287
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. 287
Fig. 1p. 287
+l Measure and write down the measurement "a" on the thermostatp. 287
+l Measure and write down the measurement "a" on the thermostatp. 287
(Fig. 1)p. 287
+"a" = beginning of stroke at approx. 83 ± 2°C (T1)p. 287
"a" = beginning of stroke at approx. 83 ± 2°C (T1)p. 287
"b" = end of stroke at approx. 95 °C (T2)p. 287
Fig. 2p. 287
+l Warm up the thermostat in a water bathp. 287
+l Warm up the thermostat in a water bathp. 287
(Fig. 2)p. 287
+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. 287
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. 287
The water must thereby be stirred continuously, to ensure even temperature distribution.p. 287
The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.p. 288
Fig. 3p. 288
+l Measure and write down the measurement "b" on the thermostat .p. 288
+l Measure and write down the measurement "b" on the thermostat .p. 288
(Fig. 3)p. 288
l Calculate the stroke.p. 288
Stroke = b – ap. 288
+The stroke at the given temperature (T2) should be min. 8 mm.p. 288
The stroke at the given temperature (T2) should be min. 8 mm.p. 288
+8.20 Checking ribbed V-belts and compressor V-beltsp. 288
+8.20 Checking ribbed V-belts and compressor V-beltsp. 288
Optional equipmentp. 288
+Danger of injury!p. 288
+Danger of injury!p. 288
Danger of injury!p. 288
Perform this work only with the engine shut down.p. 288
+Check condition and tension of ribbed V- belt.p. 288
Check condition and tension of ribbed V- belt.p. 288
Fig. 4p. 288
+l Inspect the entire circumference of the ribbed V-beltp. 288
+l Inspect the entire circumference of the ribbed V-beltp. 288
(Fig. 4)p. 288
Fig. 5p. 288
+l Check the distance between the tongue of the moveable tensioner arm and the stop on the fixed tensioner housing .p. 288
l Check the distance between the tongue of the moveable tensioner arm and the stop on the fixed tensioner housing .p. 288
+l If the distance "a"p. 288
(Fig. 5)p. 288
+Checking the condition and tension of the compressor V-belt*p. 289
Checking the condition and tension of the compressor V-belt*p. 289
Fig. 6p. 289
+l Inspect the entire circumference of the compressor V-beltp. 289
+l Inspect the entire circumference of the compressor V-beltp. 289
(Fig. 6)p. 289
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. 289
+8.21 Replacing ribbed V-belt and idler pulleyp. 289
8.21 Replacing ribbed V-belt and idler pulleyp. 289
+l Remove the compressor V-beltp. 289
+l Remove the compressor V-beltp. 289
+l Remove the compressor V-beltp. 289
Optional equipmentp. 289
Fig. 7p. 289
+l Press idler pulley (1)p. 289
+l Press idler pulley (1)p. 289
(Fig. 7)p. 289
+l Take the ribbed V-belt (2) first off the smallest pulley.p. 289
l Take the ribbed V-belt (2) first off the smallest pulley.p. 289
l Unscrew fastening screws (5) and take off idler pulley.p. 289
l Install a new idler pulley and tighten the fastening screw with 80 Nm (59 ft.lbs)p. 289
l Install the new ribbed V-belt.p. 289
l Counter the idler pulley with a ratchet and remove the locking pin.p. 289
l Check whether the ribbed V-belt is correctly seated in the guides.p. 289
l Install and tighten the compressor V-belt.p. 289
+8.22 Combustion air filter servicep. 290
8.22 Combustion air filter servicep. 290
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 290
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 290
Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 290
Fig. 8p. 290
+Maintenance of the dry air filter is due when air filter control light (k)p. 290
(Fig. 8)p. 290
+Once the air filter warning light lights up, work may be continued until the end of the day.p. 290
Once the air filter warning light lights up, work may be continued until the end of the day.p. 290
Fig. 9p. 290
+l Open the engine hoodp. 290
+l Open the engine hoodp. 290
(Fig. 9)p. 290
+Removing the main filter elementp. 290
Removing the main filter elementp. 290
Fig. 10p. 290
+l Loosen both locking hooksp. 290
+l Loosen both locking hooksp. 290
(Fig. 10)p. 290
Fig. 11p. 290
+l Pull out the main filter elementp. 290
+l Pull out the main filter elementp. 290
(Fig. 11)p. 290
+Cleaning the main filter elementp. 290
Cleaning the main filter elementp. 290
+If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years.p. 290
If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years.p. 290
The number of cleaning intervals of the main filter element can be marked on the safety element with a ball pen or a felt pen.p. 290
Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new filter cartridge.p. 290
Incorrectly handled inserts may become ineffective because of damage (e.g. cracks) and cause damage to the engine.p. 290
Replace the safety cartridge if the main filter element is defective!p. 290
Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.p. 291
Fig. 12p. 291
+l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar)p. 291
+l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar)p. 291
(Fig. 12)p. 291
Fig. 13p. 291
+l Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 291
+l Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 291
(Fig. 13)p. 291
+Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 291
Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 291
+Cleaning the dust bowlp. 291
Cleaning the dust bowlp. 291
Fig. 14p. 291
+l Pull the internal partp. 291
+l Pull the internal partp. 291
(Fig. 14)p. 291
l Reinsert the inner part.p. 291
+When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part.p. 291
When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part.p. 291
+Installing the main filter elementp. 291
Installing the main filter elementp. 291
+l Slide the main filter element carefully into the housing.p. 291
l Slide the main filter element carefully into the housing.p. 291
When closing the housing cover the main filter element is automatically forced in the correct position.p. 291
+Changing the safety filter elementp. 291
Changing the safety filter elementp. 291
+The safety filter element must not be cleaned and should not be used again after it has been removed.p. 291
The safety filter element must not be cleaned and should not be used again after it has been removed.p. 291
Break the seal only to replace the safety filter element.p. 291
The safety filter element must be replaced:p. 291
If the main filter element is defective.p. 291
after five service intervals of the filter cartridge,p. 291
at the latest after 2 years,p. 291
if the warning light comes on again after servicing the main filter cartridge.p. 291
+l Remove the housing cover and pull the main filter element off.p. 291
l Remove the housing cover and pull the main filter element off.p. 291
Fig. 15p. 292
+l Pull the safety elementp. 292
+l Pull the safety elementp. 292
(Fig. 15)p. 292
l Push in a new safety filter element.p. 292
l Reassemble main filter element and cover.p. 292
+Make sure that the cover locks engage correctly.p. 292
Make sure that the cover locks engage correctly.p. 292
+8.23 Replacing the crank case ventilation valvep. 292
8.23 Replacing the crank case ventilation valvep. 292
Fig. 16p. 292
+l Replace the ventilation valvep. 292
+l Replace the ventilation valvep. 292
(Fig. 16)p. 292
+8.24 Checking the fastening of engine / turbocharger / combustion air hosesp. 293
8.24 Checking the fastening of engine / turbocharger / combustion air hosesp. 293
Fig. 17p. 293
+l Check exhaust pipe and lubrication oil line to and from the exhaust turbo chargerp. 293
+l Check exhaust pipe and lubrication oil line to and from the exhaust turbo chargerp. 293
(Fig. 17)p. 293
l Check connecting sockets for tight fit.p. 293
+l Retighten the fastening screws for oil sump and engine mounts.p. 293
l Retighten the fastening screws for oil sump and engine mounts.p. 293
+8.25 Checking the engine mountsp. 293
8.25 Checking the engine mountsp. 293
Fig. 18p. 293
+l Check all fastening screws on the engine mounts for tight fit, tighten if necessaryp. 293
+l Check all fastening screws on the engine mounts for tight fit, tighten if necessaryp. 293
(Fig. 18)p. 293
l Check condition of engine mounts, replace if necessary.p. 293
8.26 Special tools, Deutz engine (TCD 2013 2V)p. 294
+9 Air conditioning systemp. 313
+9 Air conditioning systemp. 313
9.1 Physical basicsp. 314
+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. 314
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. 314
The four well known physical conditions of water apply also for the refrigerant in the air conditioning system.p. 314
1. gaseous (invisible)p. 314
2. vaporousp. 314
3. liquidp. 314
4. solidp. 314
Fig. 1p. 314
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. 314
+A – heat absorptionp. 314
A – heat absorptionp. 314
B- Heat dissipationp. 314
Fig. 2p. 314
+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. 314
Pressure and boiling pointp. 315
The boiling point is the temperature at which fluid changes to gaseous state.p. 315
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. 315
When looking at water, the following values do apply:p. 315
+l Atmospheric pressure, boiling point 100°Cp. 315
l Atmospheric pressure, boiling point 100°Cp. 315
l Overpressure 0.4 bar, boiling point 126°Cp. 315
l Vacuum -0.6 bar, boiling point 71°Cp. 315
For an optimal exchange of heat, liquid refrigerants must have a low boiling point, so that they can absorb and dissipate heat quickly.p. 315
Fig. 3 Steam pressure curvep. 315
Steam pressure curve for refrigerant R134ap. 315
The steam pressure curve is a means for explaining the operation principle of an air conditioning system.p. 315
A- liquidp. 315
B- gaseousp. 315
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. 315
For better understanding one must also be aware of the following:p. 315
1. A gas heats up when being compressed (e.g. air pump, turbo charger, …).p. 315
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. 315
3. Condensing gas dissipates a lot of heat energy.p. 315
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. 315
+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. 315
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. 315
Fig. 4 Pressure – Temperature Diagramp. 315
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. 315
The characters A, B, C, D stand for:p. 315
A – compressionp. 315
B- condensationp. 315
C- relaxationp. 315
D- evaporation.p. 315
+Excerpt from the wet steam tablep. 316
+Excerpt from the wet steam tablep. 316
This table is used for the determination of evaporation and condensation temperature.p. 316
+Saturation temperaturep. 316
Saturation temperaturep. 316
+Overpressure (pressure gauge reading Pe in bar)p. 316
Overpressure (pressure gauge reading Pe in bar)p. 316
+Absolute pressure (pamb = 1 bar P in bar)p. 316
Absolute pressure (pamb = 1 bar P in bar)p. 316
+-20p. 316
-20p. 316
+0,33p. 316
0,33p. 316
+1,33p. 316
1,33p. 316
+-10p. 316
-10p. 316
+1,01p. 316
1,01p. 316
+2,01p. 316
2,01p. 316
+0p. 316
0p. 316
+1,93p. 316
1,93p. 316
+2,93p. 316
2,93p. 316
+10p. 316
10p. 316
+3,15p. 316
3,15p. 316
+4,15p. 316
4,15p. 316
+20p. 316
20p. 316
+4,72p. 316
4,72p. 316
+5,72p. 316
5,72p. 316
+9.6 Description of componentsp. 317
9.2 Refrigerant R134ap. 317
+Generalp. 317
Generalp. 317
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. 317
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. 317
Physical data of the refrigerant R134ap. 317
Chemical formula:p. 317
CH2F-CF3 or CF3-CH2Fp. 317
Chemical designation:p. 317
Tetrafluoroethanep. 317
Boiling point at 1 bar:p. 317
– 26.5 °Cp. 317
Solidification point:p. 317
-101.6 °Cp. 317
Critical temperature:p. 317
100,6 °Cp. 317
Critical pressure:p. 317
40.56 bar (absolute)p. 317
Critical point:p. 317
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. 317
Characteristics of the refrigerant R134a:p. 317
Refrigerant R134a is currently available under the following trade marks. H-FKW 134a SUVA 134a KLEA 134ap. 317
Colour:p. 317
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. 317
Steam pressure:p. 317
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. 317
Physical properties of R134a:p. 317
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. 317
Behaviour with metals:p. 317
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. 317
Critical temperature / critical pressure:p. 317
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. 317
Water content:p. 317
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. 317
Inflammability:p. 318
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. 318
Filling factor:p. 318
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. 318
+Environmental aspectsp. 318
Environmental aspectsp. 318
The contribution of R134a to the greenhouse effect is by factor 10 smaller than the contribution of R12.p. 318
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. 318
+9.6 Description of componentsp. 318
9.3 Compressor oil / refrigeration oilp. 318
+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. 318
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. 318
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. 318
Compressor oil (the oil quantity should be 10 % of the refrigerant weight) mixes with the refrigerant and circulates permanently through the system.p. 318
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. 318
Properties of compressor oil / refrigeration oil:p. 318
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. 318
+9.6 Description of componentsp. 319
9.4 Working principle of the air conditioning systemp. 319
+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. 319
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. 319
Fig. 1 Principle sketch of an air conditioning systemp. 319
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. 319
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. 319
In the dryer / liquid container (3) the refrigerant is then collected and freed of moisture and contaminants.p. 319
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. 319
+9.6 Description of componentsp. 319
+9.5 Monitoring devicesp. 319
+Pressure switchp. 319
Pressure switchp. 319
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. 319
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. 319
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. 319
+Thermostatp. 319
Thermostatp. 319
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. 319
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. 319
+Monitoring chainp. 320
Monitoring chainp. 320
Fig. 2 Monitoring chain consisting of:p. 320
+l 1 Switchp. 320
l 1 Switchp. 320
l 2 Fusep. 320
l 3 Thermostatp. 320
l 4 Low pressure switch contactp. 320
l 5 High pressure switch contactp. 320
l 6 Relayp. 320
l 7 Connection for magnetic clutchp. 320
l 8 Pressure switchp. 320
+9.6 Description of componentsp. 320
9.6 Description of componentsp. 320
+Compressorp. 320
Compressorp. 320
Fig. 3 Refrigerant compressorp. 320
+The compressor 1p. 320
(Fig. 3)p. 320
+Compressor datap. 320
Compressor datap. 320
Displacement: 155 cm²p. 320
Weight: 6.9 kgp. 320
max. rpm: 6000p. 320
Sense of rotation: clockwisep. 320
Refrigerant: R134ap. 320
Oil quantity (scope of delivery): 207 grp. 320
Oil: PAG SP-20 (H14-003-404)p. 320
The service valves are installed directly on the compressor. These are used to e.g. evacuate and fill the system.p. 320
+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. 320
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. 320
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. 320
The actual quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 320
+Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 320
Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 320
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. 321
+Reason of oil lossp. 321
Reason of oil lossp. 321
+Amount of oil lostp. 321
Amount of oil lostp. 321
+Loss when emptyingp. 321
Loss when emptyingp. 321
+approx. 15 grp. 321
approx. 15 grp. 321
+Defective A/C hosep. 321
Defective A/C hosep. 321
+approx. 30 grp. 321
approx. 30 grp. 321
+Replacement of condenserp. 321
Replacement of condenserp. 321
+approx. 15 grp. 321
approx. 15 grp. 321
+Replacement of evaporatorp. 321
Replacement of evaporatorp. 321
+approx. 30 grp. 321
approx. 30 grp. 321
+Replacement of liquid containerp. 321
Replacement of liquid containerp. 321
+approx. 30 grp. 321
approx. 30 grp. 321
+Replacement of expansion valvep. 321
Replacement of expansion valvep. 321
+approx. 15 grp. 321
approx. 15 grp. 321
+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. 321
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. 321
The quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 321
The compressor oil quantity must be 10% of the refrigerant quantity in the complete system.p. 321
With a refrigerant filling of 1100 gr. the system requires a compressor oil / refrigerant oil filling of 110 gr.p. 321
Procedure:p. 321
Drain and measure the compressor oil from the old compressor.p. 321
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. 321
+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. 321
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. 321
Condenserp. 321
Fig. 4p. 321
The condenser is located under the engine hood, in front of the radiator. It emits heat energy from the system into the surrounding air and liquefies the gaseous refrigerant.p. 321
+The fins must be free of dirt and damage.p. 321
The fins must be free of dirt and damage.p. 321
+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. 321
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. 321
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. 322
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. 322
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. 322
+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. 322
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. 322
+The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 322
The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 322
This requires emptying the air conditioning system!p. 322
Installation position:p. 322
The arrow marks on the filter/dryer must point in flow direction, i.e. towards the expansion valve.p. 322
Filter/dryer cannot be treated for further use!p. 322
Pressure relief valvep. 322
Fig. 6p. 322
The fluid container is equipped with a safety valve.p. 322
Response pressure 32 +/- 4 barp. 322
Tightening torque 10 – 15 Nmp. 322
Inspection glassp. 322
Fig. 7p. 322
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. 322
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. 322
+Air in the system is characterized by high pressures and temperatures.p. 323
Air in the system is characterized by high pressures and temperatures.p. 323
On R134a refrigeration systems 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 changes its colou…p. 323
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. 323
+In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 323
In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 323
Pressure switchp. 323
Fig. 8p. 323
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. 323
Working pressure:p. 323
Low pressure off: 1,5 ±0,5 barp. 323
Low pressure on: 3.5 barp. 323
Overpressure off: 25,0 ±1,5 barp. 323
Overpressure on: 18,0 ±1,5 barp. 323
Expansion valvep. 324
Fig. 9p. 324
The expansion valve is mounted inside the HKL-module in the cabin. 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 th…p. 324
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. 324
+In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 324
In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 324
Evaporatorp. 324
Fig. 10p. 324
The evaporator is mounted inside the HKL-module in the cabin. It consists of a heat exchanger (inside air – refrigerant), with refrigerant flowing to a pipe system with cooling flanges.p. 324
As with the condenser, correct operation of all fans and cleanliness of the fins must be assured.p. 324
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. 324
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. 324
+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. 324
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. 324
Thermostatp. 325
Thermostat with fixed settingp. 325
Fig. 11p. 325
The feeler of a defroster thermostat 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.p. 325
With fixed temperature controls the control switches the compressor off at about +1 °C and back on again at about +2.5°C to +5.5 °C.p. 325
Adjustable thermostatp. 325
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. 325
Fig. 12 adjustable temperature controllerp. 325
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 325
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 325
Pipes and hosesp. 325
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. 325
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. 325
Recommended tightening torques for O-ring sealed fittingsp. 325
+Threadp. 325
Threadp. 325
+Spanner widthp. 325
Spanner widthp. 325
+Torquep. 325
Torquep. 325
+5/8“p. 325
5/8“p. 325
+17 or 19p. 325
17 or 19p. 325
+13,6 – 20,3 Nmp. 325
13,6 – 20,3 Nmp. 325
+3/4“p. 325
3/4“p. 325
+32,5 – 39,3 Nmp. 325
32,5 – 39,3 Nmp. 325
+7/8“p. 325
7/8“p. 325
+27p. 325
27p. 325
+35,3 – 42,0 Nmp. 325
35,3 – 42,0 Nmp. 325
+1 1/16“p. 325
1 1/16“p. 325
+32p. 325
32p. 325
+40,7 – 47,5 Nmp. 325
40,7 – 47,5 Nmp. 325
+M30X2p. 325
M30X2p. 325
+36p. 325
36p. 325
+105,0 – 115,0 Nmp. 325
105,0 – 115,0 Nmp. 325
+M36X2p. 325
M36X2p. 325
+41p. 325
41p. 325
+165,0 – 175,0 Nmp. 325
165,0 – 175,0 Nmp. 325
Bending radii for air conditioning hosesp. 325
+Hose typep. 325
Hose typep. 325
+Nominal widthp. 325
Nominal widthp. 325
+Bending radiusp. 325
Bending radiusp. 325
+GH 134p. 325
GH 134p. 325
+NW8p. 325
NW8p. 325
+min. 50 mmp. 325
min. 50 mmp. 325
+GH 134p. 325
GH 134p. 325
+NW10p. 325
NW10p. 325
+min. 65 mmp. 325
min. 65 mmp. 325
+GH 134p. 325
GH 134p. 325
+NW12p. 325
NW12p. 325
+min. 75 mmp. 325
min. 75 mmp. 325
+GH 134p. 325
GH 134p. 325
+NW16p. 325
NW16p. 325
+min. 100 mmp. 325
min. 100 mmp. 325
+GH 494p. 325
GH 494p. 325
+NW20p. 325
NW20p. 325
+min. 160 mmp. 325
min. 160 mmp. 325
+GH 494p. 325
GH 494p. 325
+NW25p. 325
NW25p. 325
+min. 194 mmp. 325
min. 194 mmp. 325
+GH 494p. 325
GH 494p. 325
+NW32p. 325
NW32p. 325
+min. 225 mmp. 325
min. 225 mmp. 325
+9.10 Service the air conditioningp. 326
9.7 Measuring the compressor oil levelp. 326
+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. 326
+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. 326
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. 326
+l Run the compressor for 10 minutes at engine idle speed.p. 326
l Run the compressor for 10 minutes at engine idle speed.p. 326
l remove the refrigerant from the air conditioning system.p. 326
Fig. 1p. 326
+l Turn the compressor, as shown inp. 326
+l Turn the compressor, as shown inp. 326
(Fig. 1)p. 326
l Remove the oil plug.p. 326
+The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 326
The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 326
+l Close the oil plug again.p. 326
l Close the oil plug again.p. 326
+The contact area must be clean and should be free of damage.p. 326
The contact area must be clean and should be free of damage.p. 326
Tightening torque 15 to 25 Nmp. 326
+l Refill the air conditioning system.p. 326
l Refill the air conditioning system.p. 326
+9.10 Service the air conditioningp. 326
9.8 Checking the magnetic clutchp. 326
+l Measure the voltage.p. 326
+l Measure the voltage.p. 326
l Measure the voltage.p. 326
+Nominal value = vehicle voltagep. 326
Nominal value = vehicle voltagep. 326
+l Check the magnetic coil locking ring for secure fit.p. 326
l Check the magnetic coil locking ring for secure fit.p. 326
l Check the current consumption.p. 326
Fig. 1p. 326
+at 12 Volt vehicle voltage approx. 3.5 Amp.p. 326
at 12 Volt vehicle voltage approx. 3.5 Amp.p. 326
at 24 Volt vehicle voltage approx. 1.75 Amp.p. 326
Overcurrent indicates a short circuit inside the magnetic coil.p. 326
No current indicates an interrupted electric circuit.p. 326
Fig. 2 Measuring the air gapp. 326
+l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 326
l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 326
+The gap should be 0.4 to 0.8 mm.p. 327
The gap should be 0.4 to 0.8 mm.p. 327
+l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 327
l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 327
+In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 327
In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 327
+Cross-section of magnetic clutchp. 327
Cross-section of magnetic clutchp. 327
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. 327
Fig. 3 Cross-section of magnetic clutchp. 327
+9.10 Service the air conditioningp. 327
9.9 Inspection and maintenance workp. 327
+l Visual inspection of the complete system for damage.p. 327
+l Visual inspection of the complete system for damage.p. 327
l Visual inspection of the complete system for damage.p. 327
l Check the compressor mounting bracket on the vehicle engine for tight fit and damage.p. 327
l Check the condition, alignment and tightness of the V-belt.p. 327
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. 327
l Check the routing of hoses and hoses on the attachment box or in the cabin.p. 327
l Check all hose and screw fittings for leaks.p. 327
l Check the fastening of the condenser unit.p. 327
l Clean the condenser fins, replace the condenser block if damaged fins are found.p. 327
l Check the fastening of the evaporator unit.p. 327
l Check the function of evaporator and condenser fans.p. 327
l Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays.p. 327
l Switch on the cooling system and check the refrigerant level.p. 327
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. 327
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. 327
+l Measuring the pressure in the refrigerant circuitp. 327
l Measuring the pressure in the refrigerant circuitp. 327
+9.10 Service the air conditioningp. 328
+9.10 Service the air conditioningp. 328
Optional equipmentp. 328
+Danger of accident!p. 328
+Danger of accident!p. 328
Danger of accident!p. 328
Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.p. 328
+Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system.p. 328
Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system.p. 328
During cleaning work do not damage the cooling fins and realign bent fins.p. 328
+Clean the condenserp. 328
Clean the condenserp. 328
+l Open the engine hood.p. 328
l Open the engine hood.p. 328
Fig. 4p. 328
+l Clean the condenser fins on front and back with compressed air or cold waterp. 328
+l Clean the condenser fins on front and back with compressed air or cold waterp. 328
(Fig. 4)p. 328
+Checking the refrigerant levelp. 328
Checking the refrigerant levelp. 328
+l Start the engine.p. 328
l Start the engine.p. 328
Fig. 5p. 328
+l Switch the rotary switch for the cabin fan (1)p. 328
+l Switch the rotary switch for the cabin fan (1)p. 328
(Fig. 5)p. 328
+l Select a cooling temperature by turning the air conditioning switch (2) accordingly.p. 328
l Select a cooling temperature by turning the air conditioning switch (2) accordingly.p. 328
+l Open the air outlet nozzles.p. 328
l Open the air outlet nozzles.p. 328
l Check, whether the out flowing air is noticeably cooler.p. 328
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 328
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 328
Fig. 6p. 328
+l Check whether the white floatp. 328
+l Check whether the white floatp. 328
(Fig. 6)p. 328
+The refrigerant level is correct.p. 328
The refrigerant level is correct.p. 328
Fig. 7p. 329
+l If the white floatp. 329
+l If the white floatp. 329
(Fig. 7)p. 329
+The refrigerant level is not correct.p. 329
The refrigerant level is not correct.p. 329
+l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 329
l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 329
+Checking the moisture level of the drying agentp. 329
Checking the moisture level of the drying agentp. 329
Fig. 8p. 329
+l Check the moisture indication pearlp. 329
+l Check the moisture indication pearlp. 329
(Fig. 8)p. 329
+orangep. 329
orangep. 329
Drying agent o.k.p. 329
colourlessp. 329
Moisture level of drying agent too highp. 329
+l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 329
l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 329
+Have the drier/collector unit replaced by the service department every year before the operating season.p. 329
Have the drier/collector unit replaced by the service department every year before the operating season.p. 329
+Checking the condition of the drier/collector unitp. 329
Checking the condition of the drier/collector unitp. 329
+Danger of injury!p. 329
Danger of injury!p. 329
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist.p. 329
In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation.p. 329
In connection with this inspection the drier/collector unit must be visually examined twice every year.p. 329
During these inspections special attention must be paid to corrosion and mechanical damage.p. 329
If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect operators and third parties against any danger arising from the handling and operation of pressure reservoirs.p. 329
Fig. 9p. 329
+l Check the drier/collector unitp. 329
+l Check the drier/collector unitp. 329
(Fig. 9)p. 329
+9.11 Checking ribbed V-belts and compressor V-beltsp. 330
+9.11 Checking ribbed V-belts and compressor V-beltsp. 330
Optional equipmentp. 330
+Danger of injury!p. 330
+Danger of injury!p. 330
Danger of injury!p. 330
Perform this work only with the engine shut down.p. 330
+Check condition and tension of ribbed V- belt.p. 330
Check condition and tension of ribbed V- belt.p. 330
Fig. 10p. 330
+l Inspect the entire circumference of the ribbed V-beltp. 330
+l Inspect the entire circumference of the ribbed V-beltp. 330
(Fig. 10)p. 330
Fig. 11p. 330
+l Check the distance between the tongue of the moveable tensioner arm and the stop on the fixed tensioner housing .p. 330
l Check the distance between the tongue of the moveable tensioner arm and the stop on the fixed tensioner housing .p. 330
+l If the distance "a"p. 330
(Fig. 11)p. 330
+Checking the condition and tension of the compressor V-belt*p. 330
Checking the condition and tension of the compressor V-belt*p. 330
Fig. 12p. 330
+l Inspect the entire circumference of the compressor V-beltp. 330
+l Inspect the entire circumference of the compressor V-beltp. 330
(Fig. 12)p. 330
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. 330
+9.12 Replacing ribbed V-belt and idler pulleyp. 331
9.12 Replacing ribbed V-belt and idler pulleyp. 331
+l Remove the compressor V-beltp. 331
+l Remove the compressor V-beltp. 331
+l Remove the compressor V-beltp. 331
Optional equipmentp. 331
Fig. 13p. 331
+l Press idler pulley (1)p. 331
+l Press idler pulley (1)p. 331
(Fig. 13)p. 331
+l Take the ribbed V-belt (2) first off the smallest pulley.p. 331
l Take the ribbed V-belt (2) first off the smallest pulley.p. 331
l Unscrew fastening screws (5) and take off idler pulley.p. 331
l Install a new idler pulley and tighten the fastening screw with 80 Nm (59 ft.lbs)p. 331
l Install the new ribbed V-belt.p. 331
l Counter the idler pulley with a ratchet and remove the locking pin.p. 331
l Check whether the ribbed V-belt is correctly seated in the guides.p. 331
l Install and tighten the compressor V-belt.p. 331
9.13 Drying and evacuationp. 331
+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. 331
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. 331
Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage.p. 331
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. 331
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. 331
It is common practice to evacuate the refrigeration system to a final vacuum of 1 Torr, i.e. 1.33 mbar.p. 331
Function drying:p. 331
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. 331
9.14 Emptying in case of repairp. 332
+For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 332
For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 332
Especially with expensive refrigerants and larger amounts of oil it may be necessary to keep the refrigerant for later use.p. 332
For later use these refrigerants must be drawn out with suitable equipment and intermediately stored in collecting containers.p. 332
+Contaminated refrigerant must be disposed of environmentallyp. 332
Contaminated refrigerant must be disposed of environmentallyp. 332
Releasing refrigerant into the atmosphere is prohibited (see restrictive injunction concerning CFC, day of enforcement 01. 08. 1991, § 8)p. 332
+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. 332
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. 332
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. 332
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. 332
9.15 Leak testp. 332
+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. 332
+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. 332
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. 332
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. 332
A leak test is required if a pressure drop is noticed.p. 332
The leak test must be repeated after filling the air conditioning system with refrigerant.p. 332
Leak test with electronic leak testerp. 332
Fig. 1 Electronic leak testerp. 332
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. 332
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. 332
+Leak test with soap bubblesp. 332
Leak test with soap bubblesp. 332
Fig. 2 Soap bubble testp. 332
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. 332
9.16 Filling instructionsp. 333
+Filling instructionsp. 333
+Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 333
Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 333
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. 333
Liquid refrigerant is only used to pre-fill the pressure side of the evacuated refrigeration system (protective filling).p. 333
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. 333
+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. 333
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. 333
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. 333
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. 333
+White frost on the suction line is no measure for assessing the filling.p. 333
White frost on the suction line is no measure for assessing the filling.p. 333
Fig. 1p. 334
+1 High pressure – gaseousp. 334
+1 High pressure – gaseousp. 334
1 High pressure – gaseousp. 334
2 High pressure – liquidp. 334
3 Low pressure – gaseousp. 334
4 Compressorp. 334
5 Compressor pressure switch (not used)p. 334
6 not usedp. 334
7 Evaporatorp. 334
8 Expansion valvep. 334
9 Inspection glassp. 334
10 Filter dryerp. 334
11 Fluid containerp. 334
12 Condenserp. 334
13 Manual shut-off valve (not used)p. 334
14 Pressure switch with high and low pressure contactsp. 334
15 Defroster thermostatp. 334
16 Vacuum meterp. 334
17 Low pressure gaugep. 334
18 High pressure gaugep. 334
19 Pressure reducing valvep. 335
20 Vacuum pumpp. 335
21 Nitrogen bottlep. 335
22 Refrigerant bottlep. 335
23 Pressure gauge barp. 335
+Filling instructionsp. 335
Filling instructionsp. 335
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 335
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 335
1 Connect the service adapter with the blue hand wheel in the suction side.p. 335
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. 335
3 Connect the blue suction hose below the blue hand wheel on the pressure gauge bar to the blue service adapter.p. 335
4 Connect the red pressure hose below the red hand wheel on the pressure gauge bar to the red service adapter.p. 335
5 Connect the yellow hose below the yellow hand wheel on the manometer bar to the 2-stage vacuum pump.p. 335
6 Connect the last hose below the black hand wheel on the nitrogen bottle via the pressure reducing valve.p. 335
7 Check on the pressure gauge bar that all hand wheels are closed.p. 335
8 Turn the hand wheels on both service adapter clockwise. This opens the valves (right hand stop).p. 335
9 Open the valve on the nitrogen bottle (only via pressure reducer); pressure approx. 20 bar.p. 335
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. 335
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. 335
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. 335
13 Then connect the hose to the refrigerant bottle.p. 335
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. 335
15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the pressure gauge bar.p. 335
16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained.p. 335
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. 335
18 Close the red hand wheel.p. 335
19 Perform a leak test with the electronic leak detector.p. 335
20 Start the engine and switch on the system.p. 335
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. 335
22 Close the blue hand wheel on the pressure gauge bar.p. 335
23 Preparing the test run: -Close windows and doors -Fan on full speed stage -Mount measuring feelers to air discharge and air intake.p. 335
24 Run the system for approx. 20 minutes with medium engine speed.p. 335
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. 335
26 Switch off system and engine and check for leaks again.p. 335
27 Turn out (left hand stop) and remove the hand wheels on both service adapters.p. 335
28 Fit all valves with dust caps.p. 335
29 Perform a leak test.p. 335
30 Mark the system with the corresponding type plates and information decals, such as type of oil and refrigerant.p. 335
9.17 Trouble shooting in refrigerant circuit, basic principlesp. 336
+Basic principlesp. 336
Basic principlesp. 336
+Requirementsp. 336
Requirementsp. 336
For trouble shooting two requirements must be fulfilled:p. 336
+l Expert knowledgep. 336
l Expert knowledgep. 336
l technical equipmentp. 336
+Technical equipmentp. 336
Technical equipmentp. 336
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. 336
The following tools and auxiliary materials should be available for trouble shooting:p. 336
+l Service stationp. 336
l Service stationp. 336
l Pressure gaugep. 336
l Thermometerp. 336
l dry nitrogenp. 336
l Refrigerant bottle for new refrigerantp. 336
l Container for old oilp. 336
l Vacuum pumpp. 336
l Hosesp. 336
l Scalesp. 336
l Suction stationp. 336
l Leak detectorp. 336
The measuring equipment must be checked at regular intervals. Calibration can only be made by an approved testing authority.p. 336
+Pressure gaugep. 336
Pressure gaugep. 336
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. 336
+Pp. 336
absp. 336
ambp. 336
ep. 336
+Pp. 336
absp. 336
+Pp. 336
ambp. 336
+Pp. 336
ep. 336
Fig. 2 Pressure gaugep. 336
Example:p. 336
+A totally empty air conditioning system holds an atmospheric pressure of approx. Pp. 336
ampp. 336
+Filling the system with refrigerant causes an excess pressure of Pp. 336
ep. 336
+Pp. 336
absp. 336
ambp. 336
ep. 336
+Evacuating the system down to Pp. 336
ep. 336
+Pp. 336
absp. 336
ambp. 336
ep. 336
+Pressure gauge with saturation temperature scalep. 337
Pressure gauge with saturation temperature scalep. 337
Fig. 3 Absolute pressure gaugep. 337
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. 337
If the refrigerant is fluid, the temperature is below the saturation temperature.p. 337
If the refrigerant is gaseous, the temperature is above the saturation temperature.p. 337
Pressure gauges must indicate 0 bar when not connected to the system.p. 337
Low pressure gauges have a blue, high pressure gauges a red border.p. 337
+Thermometerp. 337
Thermometerp. 337
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. 337
+Overheatingp. 337
Overheatingp. 337
+Common overheating valuesp. 337
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. 337
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. 337
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. 337
+Common overheating valuesp. 337
Common overheating valuesp. 337
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. 337
+Overheating is calculated as follows:p. 337
Overheating is calculated as follows:p. 337
+D tp. 337
Dp. 337
o2hp. 337
o2hp. 337
op. 337
+D tp. 337
Dp. 337
o2hp. 337
+tp. 337
o2hp. 337
+tp. 337
op. 337
+„p. 337
hp. 337
+Supercoolingp. 337
Supercoolingp. 337
+Common supercooling valuesp. 337
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. 337
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. 337
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. 337
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. 337
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. 338
+Common supercooling valuesp. 338
Common supercooling valuesp. 338
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. 338
+Supercooling is calculated as follows:p. 338
Supercooling is calculated as follows:p. 338
+D tp. 338
Dp. 338
c2up. 338
cp. 338
c2up. 338
+D tp. 338
Dp. 338
c2up. 338
+tp. 338
c2up. 338
+tp. 338
cp. 338
+„p. 338
up. 338
Fig. 1 Refrigerant circuit with t, h- diagramp. 339
9 Pressure switch with high and low pressure contactsp. 340
10 Dryerp. 340
11 Fluid containerp. 340
12 Hot airp. 340
13 Compressorp. 340
14 Condenserp. 340
15 Cooling airp. 340
16 Pressure gauge, low pressurep. 340
9.19 Trouble shooting procedurep. 341
+Procedurep. 341
Procedurep. 341
+Knowledgep. 341
Knowledgep. 341
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. 341
+Visual inspectionp. 341
Visual inspectionp. 341
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. 341
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. 341
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. 341
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. 341
Unusually cold pressure lines indicate "wet" intake of the compressor.p. 341
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. 341
Water in the system can simply be detected through the inspection glass with moisture indicator.p. 341
+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. 341
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. 341
+Test prerequisitesp. 341
Test prerequisitesp. 341
+l Cooler and condenser are clean, clean if necessary.p. 341
l Cooler and condenser are clean, clean if necessary.p. 341
l The ribbed belt for compressor and generator is correctly tightened.p. 341
l All air ducts, covers and seals are OK and correctly fitted. Flaps reach their end positions.p. 341
l The engine has operating temperature.p. 341
l Evaporator and heating (with highest fresh air fan speed) do not draw leak air.p. 341
l The fresh air fan runs when the engine is running and the air conditioning system is set to max. cooling power.p. 341
l Ambient temperature above 15 °C.p. 341
l The thermostat is correctly installed and the switching temperatures are correct.p. 341
+Example: Measurement of overheatingp. 342
Measuring points and measurementsp. 342
Fig. 2 Flow diagram with measuring pointsp. 342
+l C, condenser measuring pointsp. 342
l C, condenser measuring pointsp. 342
l E, expansion valve measuring pointsp. 342
l O, evaporator measuring pointsp. 342
l V, compressor measuring pointsp. 342
The flow diagram contains "Minimum Requirements" which must be fulfilled to be able to check the system or perform trouble shooting.p. 342
+Example: Measurement of overheatingp. 342
Example: Measurement of overheatingp. 342
+l a) Which measuring equipment is required?p. 342
l a) Which measuring equipment is required?p. 342
l b) Where to measure with which size?p. 342
+l c) A pressure gauge connected to the evaporator indicates "Pp. 342
eo2p. 342
op. 342
+l d) How high is the evaporator temperature "tp. 342
op. 342
+l e) A thermal sensor attached to the evaporator outlet measures the temperature "tp. 342
o2hp. 342
Dp. 342
o2hp. 342
l f) Evaluation of the measured overheating.p. 342
+Solution:p. 343
Solution:p. 343
+l a) Pressure gauge, thermometer, steam tablep. 343
l a) Pressure gauge, thermometer, steam tablep. 343
+l b) Evaporation pressure "Pp. 343
eo2p. 343
o2hp. 343
+l c) Pp. 343
op. 343
eo2p. 343
ambp. 343
+l d) "Pp. 343
cp. 343
op. 343
+l e)p. 343
Dp. 343
o2hp. 343
o2hp. 343
op. 343
l f) The determined overheating is within the usual range of 4 – 12 Kelvin.p. 343
+Example: Measuring supercoolingp. 343
Example: Measuring supercoolingp. 343
+l a) Which measuring equipment is required?p. 343
l a) Which measuring equipment is required?p. 343
l b) Where to measure with which size?p. 343
+l c) A pressure gauge connected to the condenser indicates "Pp. 343
ec2p. 343
cp. 343
+l d) How high is the condensing temperature "tp. 343
cp. 343
+l e) A thermal sensor attached to the condenser outlet measures the temperature "tp. 343
c2up. 343
Dp. 343
c2up. 343
l f) Evaluation of the measured supercooling.p. 343
+Solution:p. 343
Solution:p. 343
+l a) Pressure gauge, thermometer, steam tablep. 343
l a) Pressure gauge, thermometer, steam tablep. 343
+l b) Condensing pressure "Pp. 343
ec2p. 343
c2up. 343
+l c) Pp. 343
cp. 343
ec2p. 343
ambp. 343
+l d) "Pp. 343
cp. 343
cp. 343
+l e)p. 343
Dp. 343
c2up. 343
cp. 343
c2up. 343
l f) The determined overheating is within the usual range of approx. "0" Zero Kelvin.p. 343
+Typical faults and possible causesp. 343
Typical faults and possible causesp. 343
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. 343
The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds).p. 343
Suction pressure (low pressure gauge)p. 343
+Ambient temperature in °Cp. 343
Ambient temperature in °Cp. 343
+Excess pressure in barp. 343
Excess pressure in barp. 343
+25p. 343
25p. 343
+approx. 2,0p. 343
approx. 2,0p. 343
+30p. 343
30p. 343
+approx. 2,5p. 343
approx. 2,5p. 343
+35p. 343
35p. 343
+approx. 3p. 343
approx. 3p. 343
High pressure (high pressure gauge)p. 343
+Ambient temperature in °Cp. 343
Ambient temperature in °Cp. 343
+Excess pressure in barp. 343
Excess pressure in barp. 343
+25p. 343
25p. 343
+approx. 8,0p. 343
approx. 8,0p. 343
+35p. 343
35p. 343
+approx. 13p. 343
approx. 13p. 343
+40p. 343
40p. 343
+approx. 16p. 343
approx. 16p. 343
+45p. 343
45p. 343
+approx. 18p. 343
approx. 18p. 343
+Noise in systemp. 344
Values effecting the operating pressuresp. 344
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. 344
+Measuring valuep. 344
Measuring valuep. 344
+Suction pressurep. 344
Suction pressurep. 344
+High pressurep. 344
High pressurep. 344
+increasesp. 344
increasesp. 344
+dropsp. 344
dropsp. 344
+increasesp. 344
increasesp. 344
+dropsp. 344
dropsp. 344
+Compressor speedp. 344
Compressor speedp. 344
+increasesp. 344
increasesp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+dropsp. 344
dropsp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+Vehicle interior temperaturep. 344
Vehicle interior temperaturep. 344
+increasesp. 344
increasesp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+dropsp. 344
dropsp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+Ambient temperaturep. 344
Ambient temperaturep. 344
+increasesp. 344
increasesp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+dropsp. 344
dropsp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+Humidityp. 344
Humidityp. 344
+increasesp. 344
increasesp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+dropsp. 344
dropsp. 344
+Xp. 344
Xp. 344
+Xp. 344
Xp. 344
+Noise in systemp. 345
Suction pressure too low (1), high pressure too low to normal (2)p. 345
Fig. 3p. 345
+Causep. 345
Causep. 345
+Possible effectp. 345
Possible effectp. 345
+Remedyp. 345
Remedyp. 345
+Lack of refrigerantp. 345
Lack of refrigerantp. 345
+no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 345
no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 345
+Check for leaks, refillp. 345
Check for leaks, refillp. 345
+Evaporator fins or air filter soiledp. 345
Evaporator fins or air filter soiledp. 345
+Cooling power too lowp. 345
Cooling power too lowp. 345
+cleanp. 345
cleanp. 345
+Evaporator fan failedp. 345
Evaporator fan failedp. 345
+Low pressure shut offp. 345
Low pressure shut offp. 345
+Repair the fanp. 345
Repair the fanp. 345
+Expansion valve defectivep. 345
Expansion valve defectivep. 345
+Suction pressure gauge shows vacuum, because the valve has closedp. 345
Suction pressure gauge shows vacuum, because the valve has closedp. 345
+Replace the valvep. 345
Replace the valvep. 345
+Screen or nozzle in expansion valve cloggedp. 345
Screen or nozzle in expansion valve cloggedp. 345
+high overheatingp. 345
high overheatingp. 345
+cleanp. 345
cleanp. 345
+Filter dryer cloggedp. 345
Filter dryer cloggedp. 345
+Bubbles in inspection glass, high overheating, filter dryer coldp. 345
Bubbles in inspection glass, high overheating, filter dryer coldp. 345
Suction pressure normal (1), high pressure too high (2)p. 346
Fig. 4p. 346
+Causep. 346
Causep. 346
+Possible effectp. 346
Possible effectp. 346
+Remedyp. 346
Remedyp. 346
+Condenser dirtyp. 346
Condenser dirtyp. 346
+high hot gas temperature, low cooling powerp. 346
high hot gas temperature, low cooling powerp. 346
+cleanp. 346
cleanp. 346
+Condenser fan failedp. 346
Condenser fan failedp. 346
+high hot gas temperature, high pressure shut downp. 346
high hot gas temperature, high pressure shut downp. 346
+repairp. 346
repairp. 346
+overfilledp. 346
overfilledp. 346
+high hot gas temperature, low supercooling, low cooling powerp. 346
high hot gas temperature, low supercooling, low cooling powerp. 346
+Correct the filling capacityp. 346
Correct the filling capacityp. 346
+Leak gas (air)p. 346
Leak gas (air)p. 346
+high hot gas temperature, low measured supercooling, low cooling powerp. 346
high hot gas temperature, low measured supercooling, low cooling powerp. 346
+renew fillingp. 346
renew fillingp. 346
+Restriction between compressor and condenserp. 346
Restriction between compressor and condenserp. 346
+high hot gas temperature, low cooling powerp. 346
high hot gas temperature, low cooling powerp. 346
+Check lines and valvesp. 346
Check lines and valvesp. 346
+Noise in systemp. 347
Suction pressure too high (1), high pressure too low to normal (2)p. 347
Fig. 5p. 347
+Causep. 347
Causep. 347
+Possible effectp. 347
Possible effectp. 347
+Remedyp. 347
Remedyp. 347
+Compressor defectivep. 347
Compressor defectivep. 347
+Cooling power too lowp. 347
Cooling power too lowp. 347
+Replace the compressorp. 347
Replace the compressorp. 347
+Noise in systemp. 348
Suction pressure too high (1), high pressure too high (2)p. 348
Fig. 6p. 348
+Causep. 348
Causep. 348
+Possible effectp. 348
Possible effectp. 348
+Remedyp. 348
Remedyp. 348
+Expansion valve defectivep. 348
Expansion valve defectivep. 348
+overheating too low, wet operation of compressorp. 348
overheating too low, wet operation of compressorp. 348
+Replace the valvep. 348
Replace the valvep. 348
+Noise in systemp. 349
Other faultsp. 349
+Symptomp. 349
Symptomp. 349
+Causep. 349
Causep. 349
+Possible effectp. 349
Possible effectp. 349
+Remedyp. 349
Remedyp. 349
+Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 349
Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 349
+Lack of refrigeration oilp. 349
Lack of refrigeration oilp. 349
+increased compressor wearp. 349
increased compressor wearp. 349
+Refill refrigeration oilp. 349
Refill refrigeration oilp. 349
+Compressor does not startp. 349
Compressor does not startp. 349
+Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 349
Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 349
+System stoppedp. 349
System stoppedp. 349
+Check the control units, check cause for switching and rectifyp. 349
Check the control units, check cause for switching and rectifyp. 349
+Compressor switches continuouslyp. 349
Compressor switches continuouslyp. 349
+Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 349
Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 349
+Cycling of compressor, increased wear, too low cooling powerp. 349
Cycling of compressor, increased wear, too low cooling powerp. 349
+Check the control units, check cause for switching and rectifyp. 349
Check the control units, check cause for switching and rectifyp. 349
+Excessive overheatingp. 349
Excessive overheatingp. 349
+Expansion valve deadjusted or screen blocked, lack of refrigerantp. 349
Expansion valve deadjusted or screen blocked, lack of refrigerantp. 349
+low cooling power, hot gas temperatures too highp. 349
low cooling power, hot gas temperatures too highp. 349
+Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 349
Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 349
+Hoarfrost on inlet side of evaporatorp. 349
Hoarfrost on inlet side of evaporatorp. 349
+incorrectly working expansion valve, lack of refrigerantp. 349
incorrectly working expansion valve, lack of refrigerantp. 349
+too low infeed of refrigerant into the evaporatorp. 349
too low infeed of refrigerant into the evaporatorp. 349
+Check the expansion valve, check the refrigerant fillingp. 349
Check the expansion valve, check the refrigerant fillingp. 349
+Evaporator fully covered with hoarfrostp. 349
Evaporator fully covered with hoarfrostp. 349
+Load problem, too low air flow volumep. 349
Load problem, too low air flow volumep. 349
+low cooling power of systemp. 349
low cooling power of systemp. 349
+Clean the evaporator, check the evaporator fanp. 349
Clean the evaporator, check the evaporator fanp. 349
+Fluid line is warm and shows condensationp. 349
Fluid line is warm and shows condensationp. 349
+Pressure drop in fluid line, filter dryer cloggedp. 349
Pressure drop in fluid line, filter dryer cloggedp. 349
+low cooling powerp. 349
low cooling powerp. 349
+Eliminate the pressure drop, replace the filter dryerp. 349
Eliminate the pressure drop, replace the filter dryerp. 349
+Exceptionally cold pressure linesp. 349
Exceptionally cold pressure linesp. 349
+"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 349
"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 349
+low cooling power, excessive wear of compressorp. 349
low cooling power, excessive wear of compressorp. 349
+Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 349
Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 349
+Noise in systemp. 349
Noise in systemp. 349
+Faultsp. 349
Faultsp. 349
+Possible causep. 349
Possible causep. 349
+Remedyp. 349
Remedyp. 349
+V-belt loose or excessively wornp. 349
V-belt loose or excessively wornp. 349
+V-belt slips and generates noisep. 349
V-belt slips and generates noisep. 349
+Retention or renew the V-beltp. 349
Retention or renew the V-beltp. 349
+Magnetic clutch loudp. 349
Magnetic clutch loudp. 349
+Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 349
Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 349
+Repair or replace the magnetic clutchp. 349
Repair or replace the magnetic clutchp. 349
+Refrigerant compressor is loudp. 349
Refrigerant compressor is loudp. 349
+Mounting bracket is loose, internal parts worn, low oil level in compressorp. 349
Mounting bracket is loose, internal parts worn, low oil level in compressorp. 349
+Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 349
Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 349
+Fan is loud, fan motor excessively wornp. 349
Fan is loud, fan motor excessively wornp. 349
+Replace the fan motorp. 349
Replace the fan motorp. 349
+Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 349
Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 349
+V-belt pulley and bearing wornp. 349
V-belt pulley and bearing wornp. 349
+Replace the bearing, check V-belt pulley for wearp. 349
Replace the bearing, check V-belt pulley for wearp. 349
+Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 349
Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 349
+System overfilledp. 349
System overfilledp. 349
+Draw out refrigerantp. 349
Draw out refrigerantp. 349
+Expansion valve loudp. 349
Expansion valve loudp. 349
+excessive moisture in systemp. 349
excessive moisture in systemp. 349
+Replace the dryerp. 349
Replace the dryerp. 349
+Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 349
Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 349
+refrigerant level in system too lowp. 349
refrigerant level in system too lowp. 349
+Perform a leak test, fill up the systemp. 349
Perform a leak test, fill up the systemp. 349
+Inspection glassp. 350
Inspection glassp. 350
+Faultsp. 350
Faultsp. 350
+Possible causep. 350
Possible causep. 350
+Remedyp. 350
Remedyp. 350
+Steam bubbles in inspection glassp. 350
Steam bubbles in inspection glassp. 350
+No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 350
No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 350
+Fill up the system, replace the filter dryer, perform a leak testp. 350
Fill up the system, replace the filter dryer, perform a leak testp. 350
+Discolouration of inspection glass (black from inside)p. 350
Discolouration of inspection glass (black from inside)p. 350
+Lubricant destroyed by excessive operating temperaturesp. 350
Lubricant destroyed by excessive operating temperaturesp. 350
+Replace the refrigeration oil, examine the temperature increasep. 350
Replace the refrigeration oil, examine the temperature increasep. 350
+Moisture indicator changes to pinkp. 350
Moisture indicator changes to pinkp. 350
+Moisture level of drying agent too highp. 350
Moisture level of drying agent too highp. 350
+Replace the filter dryerp. 350
Replace the filter dryerp. 350
+Ball floats at bottomp. 350
Ball floats at bottomp. 350
+lack of refrigerantp. 350
lack of refrigerantp. 350
+Fill the systemp. 350
Fill the systemp. 350
+Monitoring devicesp. 350
Monitoring devicesp. 350
+Faultsp. 350
Faultsp. 350
+Possible causep. 350
Possible causep. 350
+Remedyp. 350
Remedyp. 350
+The high pressure contact has switched off the magnetic clutchp. 350
The high pressure contact has switched off the magnetic clutchp. 350
System pressure exceeded, condenser excessively soiled, condenser fan defective, expansion valve defectivep. 350
+Clean the condenser, replace the expansion valve, check the condenser fanp. 350
Clean the condenser, replace the expansion valve, check the condenser fanp. 350
+The low pressure contact has switched off the magnetic clutchp. 350
The low pressure contact has switched off the magnetic clutchp. 350
+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. 350
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. 350
+Clean the evaporator, replace the expansion valve, check the evaporator fanp. 350
Clean the evaporator, replace the expansion valve, check the evaporator fanp. 350
+The thermostat has switched off the magnetic clutchp. 350
The thermostat has switched off the magnetic clutchp. 350
+Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 350
Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 350
+Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 350
Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 350
Steam table for R134a
+Temperaturep. 351
Temperaturep. 351
+Pressurep. 351
Pressurep. 351
+Densityp. 351
Densityp. 351
+spec. volumep. 351
spec. volumep. 351
+spec. enthalpyp. 351
spec. enthalpyp. 351
+Evaporation heatp. 351
Evaporation heatp. 351
+of the fluidp. 351
of the fluidp. 351
+of the steamp. 351
of the steamp. 351
+of the fluidp. 351
of the fluidp. 351
+of the steamp. 351
of the steamp. 351
+of the fluidp. 351
of the fluidp. 351
+of the steamp. 351
of the steamp. 351
Module A108p. 356
+10 Central lubrication systemp. 357
10 Central lubrication systemp. 357
+Control light for central lubrication systemp. 358
10.1 System layoutp. 358
+The sanitary landfill compactors are equipped with an automatically working central lubrication system.p. 358
The sanitary landfill compactors are equipped with an automatically working central lubrication system.p. 358
Fig. 1 Lubrication system RB machinep. 358
Fig. 2 Lubrication system RS machinep. 358
+1 Ignition switchp. 358
1 Ignition switchp. 358
2 Fuse F16p. 358
3 Push button with control lightp. 358
4 Lubrication pump with integrated controlp. 358
5 Main distributorp. 358
6 Main distributor in rear framep. 358
7 Piston detector, monitors and ends duty cyclep. 358
8 Sub-distributor in front framep. 358
+Control light for central lubrication systemp. 359
10.2 Technical descriptionp. 359
+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. 359
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. 359
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. 359
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. 359
+Control light for central lubrication systemp. 359
Control light for central lubrication systemp. 359
+The control light (b)p. 359
(Fig. 3)p. 359
Faults are displayed by flashing sequences of different lengths.p. 359
Fig. 3 Monitoring boardp. 359
+b yellowp. 359
+b yellowp. 359
bp. 359
lights during the lubrication process and flashes in case of functional disturbances.p. 359
+The control light indicates the same operating states as the function displayp. 359
+The control light indicates the same operating states as the function displayp. 359
(Fig. 4)p. 359
Fig. 4 Control boardp. 359
+10.5 Progressive distributorp. 360
Function controlp. 360
Fig. 5 Push buttonp. 360
+To check the function of the system you can perform a test run. For this purpose press the push buttonp. 360
(Fig. 5)p. 360
+Start an additional lubrication cycle.p. 360
Start an additional lubrication cycle.p. 360
Press the push button longer than 2 seconds (> 2 s).p. 360
Short pressing of button acknowledges the fault signal, i.e the flashing control lamp changes to a permanent light.p. 360
+Acknowledging a faultp. 360
Acknowledging a faultp. 360
Press the push button for short moment (< 1 s).p. 360
+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. 360
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. 360
Fig. 6 Operating statesp. 360
+Ap. 360
Ap. 360
Fault indicatorp. 360
Bp. 360
Function display or acknowledged faultp. 360
+in case of a faultp. 360
in case of a faultp. 360
Switch the pump on again by pressing the button (> 2 s).p. 360
+The fault can also be acknowledge or reset by triggering an additional lubrication cycle by pressing push button 4p. 360
+The fault can also be acknowledge or reset by triggering an additional lubrication cycle by pressing push button 4p. 360
(Fig. 7)p. 360
Fig. 7 Control boardp. 360
+10.5 Progressive distributorp. 361
10.3 Controlp. 361
+Control boardp. 361
Control boardp. 361
The control board is integrated in the pump housing.p. 361
Fig. 8 Control board installed in the housingp. 361
Fig. 9 Control boardp. 361
+Voltage supplyp. 361
+Intermittent flashing signalp. 361
(Fig. 10)p. 361
Fig. 10 Jumper B/D plugged onp. 361
+Voltage supplyp. 361
+Voltage supplyp. 361
(Fig. 11)p. 361
Fig. 11 Jumper 15/30 plugged onp. 361
With jumper 39/15 plugged on the connections 15 and 30 are bridged within the control board.p. 361
Function displayp. 362
Fig. 12 Function display on circuit boardp. 362
+The function display indicates the same operating states as the control light in the LCD group display.p. 362
The function display indicates the same operating states as the control light in the LCD group display.p. 362
+l The control boardp. 362
+l The control boardp. 362
(Fig. 12)p. 362
Fig. 13 Time diagramp. 362
+tBp. 362
tBp. 362
+Operating hoursp. 362
Operating hoursp. 362
+tPp. 362
tPp. 362
+individual pause timesp. 362
individual pause timesp. 362
+Tp. 362
Tp. 362
+Lubrication cyclep. 362
Lubrication cyclep. 362
+T1p. 362
T1p. 362
+saved pause timesp. 362
saved pause timesp. 362
+T2p. 362
T2p. 362
+Duty timesp. 362
Duty timesp. 362
+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. 362
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. 362
l During the duty time the pump element delivers lubricant through the progressive distributors to the lubrication points.p. 362
+Pause time Pp. 362
(Fig. 14)p. 362
Fig. 14 Sequence of a lubrication cyclep. 362
+Ap. 362
Ap. 362
+Monitoring of motor and control lightp. 362
Monitoring of motor and control lightp. 362
+Bp. 362
Bp. 362
+Sequence of timep. 362
Sequence of timep. 362
+Cp. 362
Cp. 362
+Sequence of monitoring timep. 362
Sequence of monitoring timep. 362
+Ip. 362
Ip. 362
+Duty cyclep. 362
Duty cyclep. 362
+Pp. 362
Pp. 362
+Pausep. 362
Pausep. 362
+The pause time Pp. 362
(Fig. 14)p. 362
+l determines the frequency of lubrication cycles within the time of usep. 362
l determines the frequency of lubrication cycles within the time of usep. 362
l is started and stopped with the ignition switchp. 362
l can be changedp. 362
+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. 362
(Fig. 19)p. 362
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. 362
+Duty cycle Ip. 363
(Fig. 15)p. 363
Fig. 15 Sequence of a lubrication cyclep. 363
+Ap. 363
Ap. 363
+Monitoring of motor and control lightp. 363
Monitoring of motor and control lightp. 363
+Bp. 363
Bp. 363
+Sequence of timep. 363
Sequence of timep. 363
+Cp. 363
Cp. 363
+Sequence of monitoring timep. 363
Sequence of monitoring timep. 363
+Ip. 363
Ip. 363
+Duty cyclep. 363
Duty cyclep. 363
+Pp. 363
Pp. 363
+Pausep. 363
Pausep. 363
+The duty cycle Ap. 363
(Fig. 15)p. 363
(Fig. 16)p. 363
Fig. 16 Piston detector, B52p. 363
If the duty time is interrupted by switching of the ignition switch, it will be eresrated from the beginning when switched on again.p. 363
+Monitoring time Cp. 363
(Fig. 17)p. 363
Fig. 17 Sequence of a lubrication cyclep. 363
+Ap. 363
Ap. 363
+Monitoring of motor and control lightp. 363
Monitoring of motor and control lightp. 363
+Bp. 363
Bp. 363
+Sequence of timep. 363
Sequence of timep. 363
+Cp. 363
Cp. 363
+Sequence of monitoring timep. 363
Sequence of monitoring timep. 363
+Ip. 363
Ip. 363
+Duty cyclep. 363
Duty cyclep. 363
+Pp. 363
Pp. 363
+Pausep. 363
Pausep. 363
+A fixed monitoring time of max. 5 or 30 minutes (depending on jumper setting) runs parallel to the duty timep. 363
(Fig. 18)p. 363
Fig. 18 Jumper for monitoring rangesp. 363
1 – Jumper for monitoring time, 5 minutes (5min) or 30 minutes (30min).p. 363
2 – Jumper for 1st lubrication circuit (1 O) or for 2nd lubrication circuit (2 O).p. 363
+The monitoring time normally ends with the end of the duty time.p. 363
The monitoring time normally ends with the end of the duty time.p. 363
+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. 363
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. 363
+The indicator lamp will flash with the corresponding frequency and the pump will stop.p. 364
The indicator lamp will flash with the corresponding frequency and the pump will stop.p. 364
+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. 364
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. 364
l If two monitored lubrication circuits are available, the jumper must be replugged for two lubrication circuits (2 O).p. 364
Time settingp. 364
Fig. 19 Setting the pause timep. 364
+l Open the cover.p. 364
l Open the cover.p. 364
+The pause time can be set in 15 stages by the blue rotary switch.p. 364
The pause time can be set in 15 stages by the blue rotary switch.p. 364
+Set the pause time to position (1).p. 364
Set the pause time to position (1).p. 364
+The time ranges (hours or minutes) can be changed by replugging the jumper on the control board.p. 364
The time ranges (hours or minutes) can be changed by replugging the jumper on the control board.p. 364
Replugging the jumper requires removal of the circuit board.p. 364
+Plug the jumper for the time range hours (1 – 15h, right).p. 364
Plug the jumper for the time range hours (1 – 15h, right).p. 364
+After setting the pause time close the cover again.p. 364
After setting the pause time close the cover again.p. 364
+10.5 Progressive distributorp. 365
10.4 Lubrication processp. 365
+Main and sub-distributorp. 365
Main and sub-distributorp. 365
+Lubrication pointsp. 365
Lubrication pointsp. 365
The sub-distributor in the rear frame supplies the following points in the rear frame with grease:p. 365
+l the rocker bearings (4 pieces) on both steering cylindersp. 365
l the rocker bearings (4 pieces) on both steering cylindersp. 365
l top and bottom bearings on the articulated jointp. 365
The sub-distributor in the front frame supplies the following points in the rear frame with grease:p. 365
+l the live ring bearing in the oscillating jointp. 365
l the live ring bearing in the oscillating jointp. 365
l all bucket bearingsp. 365
l the upper rocker bearing on the bucket cylinderp. 365
+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. 365
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. 365
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. 365
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. 365
+The fundamental internal structure of the progressive distributor ensures self-monitoring of the working cycle in the distributor.p. 365
The fundamental internal structure of the progressive distributor ensures self-monitoring of the working cycle in the distributor.p. 365
The cross-linking of this system enables monitoring of the complete system.p. 365
Due to the use of the piston detector functional faults are immediately detected and indicated by a flashing sequence of the control light.p. 365
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. 365
+10.5 Progressive distributorp. 365
10.5 Progressive distributorp. 365
+Componentsp. 365
Componentsp. 365
Fig. 20p. 365
+1 Inlet fittingp. 365
1 Inlet fittingp. 365
2 Delivery bore from pistonp. 365
3 Fitting, assembledp. 365
4 Plug, pistonp. 365
5 Check valve, completep. 365
6 Clamping ring (brass)p. 365
7 Valve bodyp. 365
8 Cutting ringp. 365
9 Spigot nutp. 365
10 Connecting channelp. 365
11 Copper seal ringp. 365
12 Plugp. 365
+Features of a progressive distributorp. 365
Features of a progressive distributorp. 365
The expression “Progressive” hints to a speciality that occurs during the lubricant supply inside the distributor, such asp. 365
+l successive movement of the individual pistons in the distributor caused by the supplied pressurized lubricant.p. 365
l successive movement of the individual pistons in the distributor caused by the supplied pressurized lubricant.p. 365
l The pistons move in a preset sequence and in constantly repeated cycles.p. 365
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. 365
l The pistons work in dependence on each other.p. 365
None of the connected lubrication points will be missed out.p. 365
Progressive distributors of type SSV are piston distributors.p. 365
+l They control the distribution of the lubricant (progressively) to the connected lubrication points.p. 365
l They control the distribution of the lubricant (progressively) to the connected lubrication points.p. 365
+l Per outlet and piston stroke a quantity of 0.2 cmp. 365
3p. 365
l By closing single outlets it is possible to deliver the double or multiple amounts of lubricant.p. 366
l This distributor provides the possibility to connect several lubrication points to one central lubrication point.p. 366
Description of functionp. 366
The following five illustrations show how the individual outlets are supplied with the proper amount of lubricant.p. 366
+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. 366
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. 366
Phase 1p. 366
Fig. 21 Phase 1p. 366
+The lubricant enters from above (vertical arrow) into the lubricant distributor and flows to the right end of piston Ap. 366
(Fig. 21)p. 366
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. 366
Phase 2p. 366
Fig. 22 Phase 2p. 366
+When piston Ap. 366
(Fig. 22)p. 366
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. 366
Phase 3p. 366
Fig. 23 Phase 3p. 366
+When piston Bp. 366
(Fig. 23)p. 366
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. 366
Phase 4p. 367
Fig. 24 Phase 4p. 367
+The connecting passage at the right hand end of piston Dp. 367
(Fig. 24)p. 367
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. 367
Phase 5p. 367
Fig. 25 Phase 5p. 367
+In phase 4 piston Dp. 367
(Fig. 25)p. 367
The flowing lubricant (vertical arrow) pushes piston A to the right (upper horizontal arrow) and conveys the confined lubricant to outlet 1.p. 367
During the continuing delivery sequence the pistons B – D move from left to right, one after the other.p. 367
Thus one complete revolution has come to an end and a new cycle can start.p. 367
If the flow of lubricant is interrupted the piston will stop. In this case no lubricant is conveyed to the lubrication points.p. 367
When lubricant flows through the distributor again, the cycle starts exactly at the point where it was interrupted.p. 367
+10.7 Checking the central lubrication systemp. 368
10.6 Lubrication oil pumpp. 368
+During the lubrication cycle the pump delivers lubricant to the connected lubrication points via several distributors.p. 368
During the lubrication cycle the pump delivers lubricant to the connected lubrication points via several distributors.p. 368
+Despite an existing fault monitoring feature the visual inspections and function checks of the lubrication system must be performed at regular intervals.p. 368
Despite an existing fault monitoring feature the visual inspections and function checks of the lubrication system must be performed at regular intervals.p. 368
+Componentsp. 368
Componentsp. 368
Fig. 26 Pump components:p. 368
+1 Tankp. 368
1 Tankp. 368
2 Pump elementp. 368
3 Pressure relief valvep. 368
4 Filling nipple, for emergency lubricationp. 368
5 Connection plug 2A1 (only for industrial applications), on BOMAG machines with fixed cablep. 368
6 Filling nipple, pumpp. 368
7 Control boardp. 368
8 Connection plug 1A1 (only for industrial applications)p. 368
9 Return flow connection, not usedp. 368
The pump is a compact multiple-line pump and consists of:p. 368
+l Container with agitator wingp. 368
l Container with agitator wingp. 368
l housing with built-in motorp. 368
l Control unitp. 368
l Pump element with pressure relief valvep. 368
l Filling facilityp. 368
+Hydraulic diagramp. 368
Hydraulic diagramp. 368
Fig. 27 Hydraulic diagram of pumpp. 368
+1 Container with agitator wingp. 368
1 Container with agitator wingp. 368
2 Pumpp. 368
3 Check valve, spring loadedp. 368
4 Pressure relief valvep. 368
+Rp. 368
Rp. 368
Return linep. 368
Pp. 368
Pressure linep. 368
+(3)p. 368
(Fig. 27)p. 368
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. 368
+(4)p. 368
(Fig. 27)p. 368
(Fig. 28)p. 368
The pressure relief valve limits the pressure in the system to the adjusted value.p. 368
+The valve opens at a pressure ofp. 368
305 barp. 368
Lubricant escaping from the pressure relief valve indicates a fault in the system.p. 368
Fig. 28 Pressure relief valvep. 369
Checking the pressure relief valvep. 369
Fig. 29 Checking the pressure relief valvep. 369
+3p. 369
3p. 369
+Pressure relief valvep. 369
Pressure relief valvep. 369
+Ap. 369
Ap. 369
+Hose, at least 1 m longp. 369
Hose, at least 1 m longp. 369
+Bp. 369
Bp. 369
+T-piecep. 369
T-piecep. 369
+Cp. 369
Cp. 369
+Pressure gauge (0-600 bar / 0-8708 psi)p. 369
Pressure gauge (0-600 bar / 0-8708 psi)p. 369
+Dp. 369
Dp. 369
+Relieve cockp. 369
Relieve cockp. 369
+l Connect the pressure gauge Cp. 369
+l Connect the pressure gauge Cp. 369
(Fig. 29)p. 369
+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. 369
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. 369
+l Start an additional lubrication cycle.p. 369
l Start an additional lubrication cycle.p. 369
Pump elementp. 369
Fig. 30 Pump elementp. 369
+1 Pistonp. 369
1 Pistonp. 369
2 Resetting springp. 369
3 Check valvep. 369
+The electric motor drives the eccentric 1p. 369
(Fig. 31)p. 369
+During operation the piston 2p. 369
(Fig. 30)p. 369
Fig. 31 Pump element drawing in greasep. 369
+1 Eccentricp. 369
1 Eccentricp. 369
2 Pistonp. 369
3 Springp. 369
4 Check valvep. 369
Fig. 32 Pump element pumpingp. 369
+1 Eccentricp. 369
1 Eccentricp. 369
2 Pistonp. 369
3 Springp. 369
4 Check valvep. 369
+10.7 Checking the central lubrication systemp. 370
+10.7 Checking the central lubrication systemp. 370
Optional equipmentp. 370
+The following lubrication points are effectively and reliably supplied with lubricant by the central lubrication system.p. 370
The following lubrication points are effectively and reliably supplied with lubricant by the central lubrication system.p. 370
+l 2 x dozer blade fastening,p. 370
l 2 x dozer blade fastening,p. 370
l 1 x dozer blade cylinder eye, top,p. 370
l 4 x steering cylinder eye,p. 370
l 2 x articulated joint,p. 370
l 4 x live ring of articulated jointp. 370
A differentiation is made between the time cycles for pause and duty.p. 370
Pause: No lubrication over a period of 60 minutes.p. 370
Duty cycle: Factory set.p. 370
+Checkp. 370
Checkp. 370
Fig. 33p. 370
+l Switch on the ignition.p. 370
l Switch on the ignition.p. 370
+l Actuate push buttonp. 370
(Fig. 33)p. 370
Fig. 34p. 370
+l The agitator in the transparent container (1)p. 370
+l The agitator in the transparent container (1)p. 370
(Fig. 34)p. 370
+Use the push button only to check the system.p. 370
Use the push button only to check the system.p. 370
+Failure of a lubrication pointp. 370
Failure of a lubrication pointp. 370
(e.g. a clogged lubrication point)p. 370
+l Grease emerging from opening (3)p. 370
+l Grease emerging from opening (3)p. 370
(Fig. 34)p. 370
l Identify and rectify the cause.p. 370
+Filling through the grease nipplep. 370
Filling through the grease nipplep. 370
+Ensure strict cleanliness, as otherwise the distributors may seize.p. 370
Ensure strict cleanliness, as otherwise the distributors may seize.p. 370
Do not fill the grease container by removing the cover.p. 370
Fill the grease container if it is only 1/4 filled.p. 370
+l Clean the grease nipple.p. 370
l Clean the grease nipple.p. 370
+l Fill the grease container through the grease nipple (2)p. 370
(Fig. 34)p. 370
For quality and quantity of grease refer to the table of fuels, lubricants and filling capacities.p. 370
+l Switch on the ignition, actuate the push buttonp. 370
+l Switch on the ignition, actuate the push buttonp. 370
(Fig. 33)p. 370
+Filling with the hand pumpp. 370
Filling with the hand pumpp. 370
+Ensure strict cleanliness, as otherwise the distributors may seize.p. 370
Ensure strict cleanliness, as otherwise the distributors may seize.p. 370
For quality and quantity of grease refer to the table of fuels, lubricants and filling capacities.p. 370
Fig. 35p. 370
+l Remove both lids from the cartridge (1)p. 370
+l Remove both lids from the cartridge (1)p. 370
(Fig. 35)p. 370
l Unscrew the connecting fitting from the hand pump (2).p. 370
l Pull the actuator rod completely out.p. 370
l Slide the cartridge into the hand pump with the triangle mark to the front.p. 371
l Check whether the seal ring has been inserted into the connecting fitting.p. 371
l Screw the connecting fitting onto the hand pump.p. 371
Fig. 36p. 371
+l Clean the area around the locking cap on the central lubrication system.p. 371
l Clean the area around the locking cap on the central lubrication system.p. 371
+l Unscrew the locking cap from the central lubrication system and the locking plug from the hand pumpp. 371
(Fig. 36)p. 371
l Screw the hand pump onto the socket on the central lubrication system.p. 371
l Push the grease into the transparent container by operating the actuating rod.p. 371
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. 371
+After filling screw locking cap and locking plug back on.p. 371
After filling screw locking cap and locking plug back on.p. 371
10.8 Faults and causesp. 371
+Indication of faultsp. 371
Indication of faultsp. 371
Fig. 37 Flashing frequencies in case of faultsp. 371
+Ap. 371
+Ap. 371
Ap. 371
+Motor defectivep. 371
Motor defectivep. 371
+Faultsp. 371
Faultsp. 371
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. 371
+l A= 1 second ”ON” – 1 second ”OFF”p. 371
l A= 1 second ”ON” – 1 second ”OFF”p. 371
+Bp. 371
+Bp. 371
Bp. 371
+Fault in lubrication circuit 1p. 371
Fault in lubrication circuit 1p. 371
e.g.:p. 371
+l blocked lubrication point(s)p. 371
l blocked lubrication point(s)p. 371
l blocked distributorp. 371
l main hose to distributor with piston detector interruptedp. 371
l air in system.p. 371
The above faults mean that the piston in the monitored distributor cannot move any more.p. 371
The control lamp shows the following flashing sequence:p. 371
+l 0.5 seconds ”ON” – 1 second ”OFF”p. 371
l 0.5 seconds ”ON” – 1 second ”OFF”p. 371
+Cp. 371
+Cp. 371
Cp. 371
+Fault in lubrication circuit 2 (not applicable)p. 371
Fault in lubrication circuit 2p. 371
+Dp. 371
+Dp. 371
Dp. 371
+Fault in lubrication circuits 1 and 2 (not applicable)p. 371
Fault in lubrication circuits 1 and 2p. 371
+Ep. 372
+Ep. 372
Ep. 372
+Empty signal: Container emptyp. 372
Empty signal:p. 372
The control lamp shows the following flashing sequence:p. 372
+l 0.5 seconds ”ON” – 0.5 seconds ”OFF”p. 372
l 0.5 seconds ”ON” – 0.5 seconds ”OFF”p. 372
+After 6 motor revolutions the empty signal will be converted to a flashing signal with the above mentioned frequency.p. 372
After 6 motor revolutions the empty signal will be converted to a flashing signal with the above mentioned frequency.p. 372
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. 372
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. 372
+l This is followed by a fault signalp. 372
l This is followed by a fault signalp. 372
l The contact lamp flashesp. 372
l The pump does no longer start automatically.p. 372
+Fp. 372
+Fp. 372
Fp. 372
+Acknowledged fault (permanent light)p. 372
Acknowledged faultp. 372
Short pressing of button (< 1 second) acknowledges the fault signal, i.e the flashing of the control lamp changes to a permanent light.p. 372
+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. 372
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. 372
Rectify the fault and release additional lubricationp. 372
+l In the event of a fault check the central lubrication pump and the connected system for faults.p. 372
l In the event of a fault check the central lubrication pump and the connected system for faults.p. 372
Rectify the cause of the fault.p. 372
+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. 372
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. 372
+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. 372
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. 372
10.9 Fault – Cause – Remedyp. 373
+Faultp. 373
Faultp. 373
+Causep. 373
Causep. 373
+Remedyp. 373
Remedyp. 373
+Pump does not workp. 373
Pump does not workp. 373
+Electric line interruptedp. 373
Electric line interruptedp. 373
+Replace the electric linep. 373
Replace the electric linep. 373
+Pump defectivep. 373
Pump defectivep. 373
+Replace the pumpp. 373
Replace the pumpp. 373
+Pump works, but does not deliverp. 373
Pump works, but does not deliverp. 373
+Air cushion in pumping pistonp. 373
Air cushion in pumping pistonp. 373
+Vent the pumpp. 373
Vent the pumpp. 373
+Min. filling level fallen short ofp. 373
Min. filling level fallen short ofp. 373
+Fill up the provision containerp. 373
Fill up the provision containerp. 373
+Pump element defectivep. 373
Pump element defectivep. 373
+Replace the pump elementp. 373
Replace the pump elementp. 373
+No grease collar at the lubrication pointsp. 373
No grease collar at the lubrication pointsp. 373
+Pump does not workp. 373
Pump does not workp. 373
+See "Pump does not work"p. 373
See "Pump does not work"p. 373
+Pause time too long or lubrication period too shortp. 373
Pause time too long or lubrication period too shortp. 373
+Reduce pause time or extend lubrication timep. 373
Reduce pause time or extend lubrication timep. 373
+System blockedp. 373
System blockedp. 373
+See "Grease emerging from pressure relief valve"p. 373
See "Grease emerging from pressure relief valve"p. 373
+No grease collars at various lubrication pointsp. 373
No grease collars at various lubrication pointsp. 373
+Supply line to secondary distributor burst or leakingp. 373
Supply line to secondary distributor burst or leakingp. 373
+Replace the linep. 373
Replace the linep. 373
+Screw fittings leakingp. 373
Screw fittings leakingp. 373
+Retighten or replace screw fittingp. 373
Retighten or replace screw fittingp. 373
+No grease collar on one lubrication pointp. 373
No grease collar on one lubrication pointp. 373
+Corresponding grease line burst or leakingp. 373
Corresponding grease line burst or leakingp. 373
+Replace the linep. 373
Replace the linep. 373
+Screw fitting leakingp. 373
Screw fitting leakingp. 373
+Retighten or replace screw fittingp. 373
Retighten or replace screw fittingp. 373
+Pump speed too lowp. 373
Pump speed too lowp. 373
+High system pressure or low ambient temperaturep. 373
High system pressure or low ambient temperaturep. 373
+Check system / bearing pointp. 373
Check system / bearing pointp. 373
No damage (perform 1 or 2 intermediate lubrication cycles)p. 373
+Grease emerging from pressure relief valvep. 373
Grease emerging from pressure relief valvep. 373
+System pressure too highp. 373
System pressure too highp. 373
+Check systemp. 373
Check systemp. 373
+Progressive distributor blockedp. 373
Progressive distributor blockedp. 373
+Replace the distributorp. 373
Replace the distributorp. 373
+System blockedp. 373
System blockedp. 373
+Repair blocked / seized bearing pointsp. 373
Repair blocked / seized bearing pointsp. 373
+Cause for a blockage in the systemp. 373
Cause for a blockage in the systemp. 373
+l A crushed or blocked lubricant linep. 373
l A crushed or blocked lubricant linep. 373
l A bearing overfilled with lubricant or blockedp. 373
l An unsuitable lubricant for central lubrication systemsp. 373
l A blocked distributor outletp. 373
l A blocked distributorp. 373
Indication of a blockagep. 373
+l Grease emerging from pressure relief valvep. 373
l Grease emerging from pressure relief valvep. 373
Identify the location of the blockagep. 374
+All repair work must be carried out with utmost cleanliness.p. 374
All repair work must be carried out with utmost cleanliness.p. 374
Fig. 38p. 374
+l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 374
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 374
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. 374
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication point.p. 374
Fig. 39 KIT to check central lubrication systemsp. 374
10.10 Failure of central lubrication system (grease emerges from relief valve)p. 375
+11 Hydraulicsp. 377
11 Hydraulicsp. 377
+Variable displacement pumps, A4VG 85 to 110 DAp. 378
11.1 Hydraulic circuitp. 378
+Open circuitp. 378
Open circuitp. 378
Fig. 1 Open circuitp. 378
+Open in this case means that the suction line of ap. 378
pumpp. 378
(Fig. 1)p. 378
+In an open circuit the hydraulic fluid is fed to thep. 378
consumerp. 378
+Closed circuitp. 379
Closed circuitp. 379
Fig. 2 Closed circuitp. 379
+One talks about a closed hydraulic system, when the hydraulic oil flows from thep. 379
consumerp. 379
(Fig. 2)p. 379
pumpp. 379
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment on the consumer).p. 379
+The high pressure side is protected byp. 379
pressure relief valvesp. 379
+Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by ap. 379
charge pumpp. 379
check valvep. 379
charge pressure relief valvep. 379
pumpp. 379
+Variable displacement pumps, A4VG 85 to 110 DAp. 380
Travel pump A4VG110 DAp. 380
+Variable displacement pumps, A4VG 85 to 110 DAp. 380
Variable displacement pumps, A4VG 85 to 110 DAp. 380
+DA – Automatic control, speed dependentp. 380
DA – Automatic control, speed dependentp. 380
The A4VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits.p. 380
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow. It has been designed for mobile applications, e.g. in construction equipment.p. 380
Fig. 3 A4VG, series 40p. 380
+1p. 380
1p. 380
+Drive shaftp. 380
Drive shaftp. 380
+7p. 380
7p. 380
+Suction portp. 380
Suction portp. 380
+2p. 380
2p. 380
+Retracting platep. 380
Retracting platep. 380
+8p. 380
8p. 380
+Cylinderp. 380
Cylinderp. 380
+3p. 380
3p. 380
+Control pistonp. 380
Control pistonp. 380
+9p. 380
9p. 380
+Pistonp. 380
Pistonp. 380
+4p. 380
4p. 380
+Control unitp. 380
Control unitp. 380
+10p. 380
10p. 380
+Slipper padp. 380
Slipper padp. 380
+5p. 380
5p. 380
+Valve platep. 380
Valve platep. 380
+11p. 380
11p. 380
+Swashing cradlep. 380
Swashing cradlep. 380
+6p. 380
6p. 380
+Auxiliary pumpp. 380
Auxiliary pumpp. 380
+The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 380
The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 380
+Hydraulic diagramp. 380
Hydraulic diagramp. 380
+DA-control valve with fixed setting (control start set in factory)p. 380
DA-control valve with fixed setting (control start set in factory)p. 380
Fig. 4 Hydraulic diagramp. 381
Fig. 5 Connection overviewp. 381
+Ap. 382
Ap. 382
+Work connectionp. 382
Work connectionp. 382
+Rp. 382
Rp. 382
+Ventilationp. 382
Ventilationp. 382
+Bp. 382
Bp. 382
+Work connectionp. 382
Work connectionp. 382
+Sp. 382
Sp. 382
+Suctionp. 382
Suctionp. 382
+Gp. 382
Gp. 382
+Pressure port for charge circuitp. 382
Pressure port for charge circuitp. 382
+T1p. 382
+Tp. 382
1p. 382
+Tankp. 382
Tankp. 382
+Fap. 382
+Fp. 382
ap. 382
+Charge pressure inletp. 382
Charge pressure inletp. 382
+T2p. 382
+Tp. 382
2p. 382
+Tankp. 382
Tankp. 382
+Fep. 382
+Fp. 382
ep. 382
+Charge pressure outletp. 382
Charge pressure outletp. 382
+X1 X2p. 382
+Xp. 382
1p. 382
2p. 382
+Port for control pressures, pressure in front of nozzlep. 382
Port for control pressures, pressure in front of nozzlep. 382
Control pressure inlet, constant throttle optionp. 382
+Closed loop controlp. 382
Closed loop controlp. 382
Fig. 6p. 382
Depending on the drive speed the DA-control valve generates a control pressure, which is then applied to the control cylinder of the pump via a 4/3-way valve, which infinitely alters the position of the swash plate, i.e. the displacement. The 4/3-way…p. 382
High pressure relief valves (HP-valves) with integrated boost check valvesp. 383
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side. Th…p. 383
Fig. 7 HP – valvesp. 383
HP-valves are always adjusted 10% higher than the pressure override.p. 383
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and fl…p. 383
+Bypass controlp. 383
Bypass controlp. 383
Fig. 8 Bypass functionp. 383
In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves integrated in the variable displacement pump have a so-called bypass function. This means that by turning the screw the valve insert is r…p. 383
Activate the bypass functionp. 384
+l Shut down the engine.p. 384
l Shut down the engine.p. 384
+l Back out the shuttle valve (1)p. 384
(Fig. 8)p. 384
Towing finishedp. 384
After towing turn the shuttle valve back again. This resets the high pressure valves to their original setting.p. 384
Tightening torque 50 Nmp. 384
+Charge pressure relief valvep. 384
Charge pressure relief valvep. 384
Fig. 9 Charge pressure relief valvep. 384
The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the pre-adjusted value.p. 384
+Pressure override valvep. 384
Pressure override valvep. 384
Fig. 10 Pressure override valvep. 384
The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation, which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent, that the adjusted pressure is j…p. 384
+DA-control valvep. 384
DA-control valvep. 384
The DA-control valve enables the pump swashing angle to follow the engine speed.p. 384
Fig. 11 DA-control valvep. 385
+Thep. 385
speed dependent drive regulationp. 385
+l Kicking down the throttle pedal increases the engine speed.p. 385
l Kicking down the throttle pedal increases the engine speed.p. 385
l An increase in engine speed also causes an increase in pump speed. Since the charge pump is an integral part of the drive pump, its flow volume will also increase.p. 385
l The higher the flow volume through the DA-control valve, the further the pump will swash away from neutral and thus deliver a correspondingly higher flow volume. The travel speed increases because of the higher engine speed and the larger swashing …p. 385
+Auxiliary pumpp. 385
Auxiliary pumpp. 385
The auxiliary pump permanently delivers a sufficient amount of fluid (charging volume) from a small tank through a check valve into the low pressure side of the closed circuit, in order to replace internal leakages in variable displacement pump and c…p. 385
+Variable displacement pumps, A4VG 85 to 110 HTp. 386
Travel pump A4VG110 HTp. 386
+Variable displacement pumps, A4VG 85 to 110 HTp. 386
Variable displacement pumps, A4VG 85 to 110 HTp. 386
+HT – Control hydraulic, direct controlledp. 386
HT – Control hydraulic, direct controlledp. 386
The A4VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits.p. 386
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow. It has been designed for mobile applications, e.g. in construction equipment.p. 386
Fig. 12 A4VG, series 40p. 386
+1p. 386
1p. 386
+Drive shaftp. 386
Drive shaftp. 386
+7p. 386
7p. 386
+Suction portp. 386
Suction portp. 386
+2p. 386
2p. 386
+Retracting platep. 386
Retracting platep. 386
+8p. 386
8p. 386
+Cylinderp. 386
Cylinderp. 386
+3p. 386
3p. 386
+Control pistonp. 386
Control pistonp. 386
+9p. 386
9p. 386
+Pistonp. 386
Pistonp. 386
+4p. 386
4p. 386
+not usedp. 386
not usedp. 386
+10p. 386
10p. 386
+Slipper padp. 386
Slipper padp. 386
+5p. 386
5p. 386
+Valve platep. 386
Valve platep. 386
+11p. 386
11p. 386
+Swashing cradlep. 386
Swashing cradlep. 386
+6p. 386
6p. 386
+Auxiliary pumpp. 386
Auxiliary pumpp. 386
+The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 386
The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 386
+Hydraulic diagramp. 387
Hydraulic diagramp. 387
Fig. 13 Hydraulic diagramp. 387
Fig. 14 Connection overviewp. 387
+Ap. 388
Ap. 388
+Work connectionp. 388
Work connectionp. 388
+Rp. 388
Rp. 388
+Ventilationp. 388
Ventilationp. 388
+Bp. 388
Bp. 388
+Work connectionp. 388
Work connectionp. 388
+Sp. 388
Sp. 388
+Suctionp. 388
Suctionp. 388
+Gp. 388
Gp. 388
+Pressure port for charge circuitp. 388
Pressure port for charge circuitp. 388
+T1p. 388
+Tp. 388
1p. 388
+Tankp. 388
Tankp. 388
+Fap. 388
+Fp. 388
ap. 388
+Charge pressure inletp. 388
Charge pressure inletp. 388
+T2p. 388
+Tp. 388
2p. 388
+Tankp. 388
Tankp. 388
+Fep. 388
+Fp. 388
ep. 388
+Charge pressure outletp. 388
Charge pressure outletp. 388
+X1 X2p. 388
+Xp. 388
1p. 388
2p. 388
+Port for control pressures, pressure in front of nozzlep. 388
Port for control pressures, pressure in front of nozzlep. 388
Control pressure inlet, constant throttle optionp. 388
+YHTp. 388
+Yp. 388
HTp. 388
+Control pressure outletp. 388
Control pressure outletp. 388
+Closed loop controlp. 388
Closed loop controlp. 388
Fig. 15p. 388
+With the direct controlled control (HT) the displacement of the pump is influenced by a hydraulic control pressure, which acts directly on the control piston via Xp. 388
1p. 388
2p. 388
The flow direction depends on the pressure applied to the control pressure port.p. 388
The displacement of the pump is infinitely adjustable and proportional to the applied control pressure, but is influenced by the system pressure and the pump speed.p. 388
High pressure relief valves (HP-valves) with integrated boost check valvesp. 389
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side. Th…p. 389
Fig. 16 HP – valvesp. 389
HP-valves are always adjusted 10% higher than the pressure override.p. 389
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and fl…p. 389
+Bypass controlp. 389
Bypass controlp. 389
Fig. 17 Bypass functionp. 389
In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves integrated in the variable displacement pump have a so-called bypass function. This means that by turning the screw the valve insert is r…p. 389
Activate the bypass functionp. 389
+l Shut down the engine.p. 389
l Shut down the engine.p. 389
+l Back out the shuttle valve (1)p. 389
(Fig. 8)p. 389
Towing finishedp. 390
After towing turn the shuttle valve back again. This resets the high pressure valves to their original setting.p. 390
Tightening torque 50 Nmp. 390
+Charge pressure relief valvep. 390
Charge pressure relief valvep. 390
Fig. 18 Charge pressure relief valvep. 390
The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the pre-adjusted value.p. 390
+Pressure override valvep. 390
Pressure override valvep. 390
Fig. 19 Pressure override valvep. 390
The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation, which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent, that the adjusted pressure is j…p. 390
+Auxiliary pumpp. 390
Auxiliary pumpp. 390
The auxiliary pump permanently delivers a sufficient amount of fluid (charging volume) from a small tank through a check valve into the low pressure side of the closed circuit, in order to replace internal leakages in variable displacement pump and c…p. 390
+Swash plate principlep. 391
Axial piston swash plate principle.p. 391
+Swash plate principlep. 391
Swash plate principlep. 391
Fig. 20p. 391
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive shaft. The pistons are thereby supported by the swash plate.p. 391
+Description of functionp. 391
Description of functionp. 391
Fig. 21p. 391
+1p. 391
1p. 391
+Drive shaftp. 391
Drive shaftp. 391
+8p. 391
8p. 391
+Through drivep. 391
Through drivep. 391
+2p. 391
2p. 391
+Pistonp. 391
Pistonp. 391
+9p. 391
9p. 391
+Valve platep. 391
Valve platep. 391
+3p. 391
3p. 391
+Piston areap. 391
Piston areap. 391
+10p. 391
10p. 391
+Top dead centre TDCp. 391
Top dead centre TDCp. 391
+4p. 391
4p. 391
+Piston strokep. 391
Piston strokep. 391
+11p. 391
11p. 391
+Bottom dead centre BTCp. 391
Bottom dead centre BTCp. 391
+5p. 391
5p. 391
+Slipping discp. 391
Slipping discp. 391
+12p. 391
12p. 391
+Control slots in suction side of swash plate (for sense of rotation shown)p. 391
Control slots in suction side of swash plate (for sense of rotation shown)p. 391
+6p. 391
6p. 391
+Adjusting anglep. 391
Adjusting anglep. 391
+13p. 391
13p. 391
+Control slot on pressure sidep. 391
Control slot on pressure sidep. 391
+7p. 391
7p. 391
+Cylinderp. 391
Cylinderp. 391
Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the swashing cradle an…p. 392
11.5 Troubleshooting axial piston pumpsp. 393
+The following table should be of help when performing troubleshooting This table is by no means complete.p. 393
The following table should be of help when performing troubleshooting This table is by no means complete.p. 393
In practice you may encounter problems that have not been listed here.p. 393
+Procedurep. 393
Procedurep. 393
+l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 393
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 393
l Get an overview over the function of the product in connection with the overall system.p. 393
l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred.p. 393
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver.p. 393
Try to detect changes to the overall system, the product is installed in:p. 393
+l Have conditions or area of application of the product been changed?p. 393
l Have conditions or area of application of the product been changed?p. 393
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or to the product? If yes: What kind?p. 393
l Has the product or the machine been operated as intended?p. 393
l How does the fault occur?p. 393
+Faultp. 393
Faultp. 393
+Possible causep. 393
Possible causep. 393
+Remedyp. 393
Remedyp. 393
+Unusual noisesp. 393
Unusual noisesp. 393
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 393
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 393
+Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 393
Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 393
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 393
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 393
+Remove foreign bodies from inside the suction line.p. 393
Remove foreign bodies from inside the suction line.p. 393
+Inappropriate fastening of the axial piston unit.p. 393
Inappropriate fastening of the axial piston unit.p. 393
+Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 393
Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 393
+Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 393
Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 393
+Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 393
Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 393
+Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 393
Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 393
+Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 393
Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 393
+Mechanical damage to the axial piston unit.p. 393
Mechanical damage to the axial piston unit.p. 393
+Replace the axial piston unit, consult the service department.p. 393
Replace the axial piston unit, consult the service department.p. 393
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 394
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 394
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 394
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 394
+Remove foreign bodies from inside the suction line.p. 394
Remove foreign bodies from inside the suction line.p. 394
+Pressure fluid not within the optimal viscosity range.p. 394
Pressure fluid not within the optimal viscosity range.p. 394
+Use appropriate pressure fluid.p. 394
Use appropriate pressure fluid.p. 394
+External control and setting facilities defective.p. 394
External control and setting facilities defective.p. 394
+Check the external control.p. 394
Check the external control.p. 394
+Pilot or control pressure too low.p. 394
Pilot or control pressure too low.p. 394
+Check pilot and control pressure, consult the service department.p. 394
Check pilot and control pressure, consult the service department.p. 394
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 394
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 394
+Consult the service department.p. 394
Consult the service department.p. 394
+Wear of the axial piston unit.p. 394
Wear of the axial piston unit.p. 394
+Replace the axial piston unit.p. 394
Replace the axial piston unit.p. 394
+Mechanical damage to the axial piston unit.p. 394
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 395
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 395
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 395
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 395
+Remove foreign bodies from inside the suction line.p. 395
Remove foreign bodies from inside the suction line.p. 395
+Pressure fluid not within the optimal viscosity range.p. 395
Pressure fluid not within the optimal viscosity range.p. 395
+Use appropriate pressure fluid.p. 395
Use appropriate pressure fluid.p. 395
+External control and setting facilities defective.p. 395
External control and setting facilities defective.p. 395
+Check the external control.p. 395
Check the external control.p. 395
+Pilot or control pressure too low.p. 395
Pilot or control pressure too low.p. 395
+Check pilot and control pressure.p. 395
Check pilot and control pressure.p. 395
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 395
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 395
+Consult the service department.p. 395
Consult the service department.p. 395
+Wear of the axial piston unit.p. 395
Wear of the axial piston unit.p. 395
+Replace the axial piston unit.p. 395
Replace the axial piston unit.p. 395
+Mechanical damage to the axial piston unit.p. 395
Mechanical damage to the axial piston unit.p. 395
+Replace the axial piston unit.p. 395
Replace the axial piston unit.p. 395
+Drive unit defective (e.g. hydraulic motor or cylinder).p. 395
Drive unit defective (e.g. hydraulic motor or cylinder).p. 395
+Check the drive unit, replace if necessary.p. 395
Check the drive unit, replace if necessary.p. 395
+Fluctuations in pressure/volumetric flowp. 395
Fluctuations in pressure/volumetric flowp. 395
+Axial piston unit not or insufficiently purged.p. 395
Axial piston unit not or insufficiently purged.p. 395
+Completely purge the axial piston unit.p. 395
Completely purge the axial piston unit.p. 395
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 395
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 395
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 395
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 395
+Remove foreign bodies from inside the suction line.p. 395
Remove foreign bodies from inside the suction line.p. 395
+Pressure fluid too hot.p. 395
Pressure fluid too hot.p. 395
+Excessive input temperature on axial piston unit.p. 395
Excessive input temperature on axial piston unit.p. 395
+Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 395
Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 395
+Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 395
Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 395
+Consult the service department.p. 395
Consult the service department.p. 395
+Malfunction of the flushing valve (not for nominal size 18).p. 395
Malfunction of the flushing valve (not for nominal size 18).p. 395
+Consult the service department.p. 395
Consult the service department.p. 395
+Wear of the axial piston unit.p. 395
Wear of the axial piston unit.p. 395
+Replace the axial piston unit.p. 395
Replace the axial piston unit.p. 395
+Description of functionp. 396
11.6 Travel circuitp. 396
+1p. 397
1p. 397
+Travel pump for travel drive, frontp. 397
Travel pump for travel drive, frontp. 397
+6.2p. 397
6.2p. 397
+Travel motor with gearbox, rear rightp. 397
Travel motor with gearbox, rear rightp. 397
+2p. 397
2p. 397
+Travel pump for travel drive, rearp. 397
Travel pump for travel drive, rearp. 397
+6.3p. 397
6.3p. 397
+Travel motor with travel gear, front leftp. 397
Travel motor with travel gear, front leftp. 397
+3p. 397
3p. 397
+working pumpp. 397
working pumpp. 397
+6.4p. 397
6.4p. 397
+Travel motor with travel gear, front rightp. 397
Travel motor with travel gear, front rightp. 397
+4p. 397
4p. 397
+Charge pump on auxiliary drive of enginep. 397
Charge pump on auxiliary drive of enginep. 397
+7p. 397
7p. 397
+Flushing valvep. 397
Flushing valvep. 397
+5p. 397
5p. 397
+Traction module, flow dividerp. 397
Traction module, flow dividerp. 397
+8p. 397
8p. 397
+Brake releasing valvep. 397
Brake releasing valvep. 397
+5.1p. 397
5.1p. 397
+Flow divider, front travel systemp. 397
Flow divider, front travel systemp. 397
+9p. 397
9p. 397
+Brake valve (Y04) and travel speed range selector valve (Y03)p. 397
Brake valve (Y04) and travel speed range selector valve (Y03)p. 397
+5.2p. 397
5.2p. 397
+Flow divider, rear travel systemp. 397
Flow divider, rear travel systemp. 397
+10p. 397
10p. 397
+Check valvesp. 397
Check valvesp. 397
+6p. 397
6p. 397
+travel motorsp. 397
travel motorsp. 397
+11p. 397
11p. 397
+Filterp. 397
Filterp. 397
+6.1p. 397
6.1p. 397
+Travel motor with travel gear, rear leftp. 397
Travel motor with travel gear, rear leftp. 397
Fig. 22 Schematic travel system, hydraulicsp. 397
+Travel systemp. 397
Travel systemp. 397
+The travel system of the refuse compactor works withp. 397
+The travel system of the refuse compactor works withp. 397
two closed hydraulic circuitsp. 397
+The travel system is designed in such a way, that one pump each is serving the front and rear drive train. Whereby the control (forward – neutral – reverse) takes place on the front pump, the flange mounted second pump follows the first pump because …p. 397
connected contro, linesp. 397
(Fig. 23)p. 397
Each of the travel gears is driven by a variable displacement axial piston bent axle motor from Bosch-Rexroth A6VM HA2T.p. 397
Fig. 23 Control line connectionp. 398
+Thep. 398
control line connectionp. 398
+Control chamber connections Xp. 398
+Control chamber connections Xp. 398
1p. 398
1p. 398
2p. 398
2p. 398
+Control line connections Pp. 398
+Control line connections Pp. 398
Sp. 398
S2p. 398
STp. 398
Sp. 398
+Thep. 398
+Thep. 398
speed dependent drive regulation (DA)p. 398
(Fig. 24)p. 398
Fig. 24 Schematic, travel circuit electricsp. 399
+l Kicking down the throttle pedal (S119) increases the engine speed.p. 399
l Kicking down the throttle pedal (S119) increases the engine speed.p. 399
l An increase in engine speed also causes an increase in pump speed. Since the charge pump is an integral part of the drive pump, its flow volume will also increase.p. 399
l The higher the flow volume through the DA-control valve, the further the pump will swash away from neutral and thus deliver a correspondingly higher flow volume. The travel speed increases because of the higher engine speed and the larger swashing …p. 399
+Charge circuitp. 400
Charge circuitp. 400
Fig. 25 Charge oil supply, high pressure test portsp. 400
+The earth and refuse compactors are equipped withp. 400
three charge pumpsp. 400
+Thep. 400
pilot oilp. 400
internal charge pumpsp. 400
(Fig. 25)p. 400
The third pump (gear pump) is mounted to the auxiliary drive of the engine and is primarily responsible for feeding the flow dividers.p. 400
+Allp. 400
three charge circuitsp. 400
(Fig. 26)p. 400
+Thep. 400
filtersp. 400
by-pass valvesp. 400
Dp. 400
+Thep. 400
differential pressure switchesp. 400
Dp. 400
Fig. 26 Schematic of charge circuitp. 401
+The charge oil flow is additionally needed forp. 401
releasing the multi-disc brakesp. 401
integrated multi-disc brakesp. 401
Fig. 27 Brake valve in rear framep. 402
+Return flow filter blockp. 402
Return flow filter blockp. 402
+Allp. 402
leakages and flushing quantitiesp. 402
central return flow filter blockp. 402
(Fig. 28)p. 402
The return flow filter block contains two 80 µ filters, one magnetic sensor (B19), one pressure switch (B25), one temperature control valve, one pressure relief valve, one test port and eight magnetic plugs.p. 402
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. 402
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. 402
In addition to this the dirt sensor (B19) reports any metallic contamination in the oil via a visual indicator in the cabin.p. 402
Fig. 28 Schematic of leak oil linesp. 403
+Traction modulep. 404
Traction modulep. 404
The traction module is a flow divider (volumetric flow divider) to control the synchronism and freewheeling of hydraulic motors.p. 404
Fig. 29 Flow divider and flushing valve frontp. 404
+Ap. 404
flushing valvep. 404
At a pressure differential of 3 – 5 bar in the work system lines A and B the flushing valve is opened by high pressure. The charge pressure valve is set to a pressure of 16 bar and has the function of securing the minimum charge pressure. Flushing ta…p. 404
+Travel motors HA – Automatic displacement control, high pressure dependentp. 404
Travel motors HA – Automatic displacement control, high pressure dependentp. 404
Each wheel of the refuse compactor is driven by an axial piston bent-axle motor with variable displacement from Bosch-Rexroth A6VM 107 HA2T, which is installed in a travel gear. These motors are designed with two different displacements and can there…p. 404
In combination with DA-pumps the high pressure dependent control HA is of relevance for the variable displacement motor.p. 404
With the automatic displacement control, high pressure dependent, the adjustment of the displacement is accomplished automatically in dependence on the operating pressure.p. 404
+The motors can be hydraulically overridden through port (X) and changed from minimum displacement Vp. 404
gminp. 404
gmaxp. 404
gminp. 404
maxp. 404
Fig. 30p. 405
1. travel speed rangep. 405
+Through the solenoid valve (Y03) the charge pressure is applied to the motor via port (X) and the motor will immediately change to Vp. 405
gmaxp. 405
2. travel speed rangep. 405
+The motors are not switched and remain in Vp. 405
gminp. 405
gmaxp. 405
+The pressure range and the speed with which the motors swash from Vp. 405
gminp. 405
gmaxp. 405
Control start and control endp. 405
+l Control start at Vp. 405
+l Control start at Vp. 405
g minp. 405
+l Control end at Vp. 405
g maxp. 405
Fig. 31 Travel speed range selectorp. 406
The hose connections (G) between the motors are necessary for synchronous running of all motors.p. 406
+Description of functionp. 406
Description of functionp. 406
+The travel motors A6VM and A6VE just differ by a different housing.p. 406
The travel motors A6VM and A6VE just differ by a different housing.p. 406
The A6VM/VE is a variable displacement axial piston motor with a tapered axial piston drive in swash plate design for hydrostatic drives in open and closed hydraulic circuits. Due to this bent axle design the torque is generated directly on the drive…p. 406
+The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 406
The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 406
Fig. 32p. 407
+1p. 407
1p. 407
+Drive shaftp. 407
Drive shaftp. 407
+6p. 407
6p. 407
+Cylinderp. 407
Cylinderp. 407
+2p. 407
2p. 407
+Control pistonp. 407
Control pistonp. 407
+7p. 407
7p. 407
+Pistonp. 407
Pistonp. 407
+3p. 407
3p. 407
+Control pistonp. 407
Control pistonp. 407
+8p. 407
8p. 407
+Setscrew for control startp. 407
Setscrew for control startp. 407
+4p. 407
4p. 407
+Connecting platep. 407
Connecting platep. 407
+9p. 407
9p. 407
+Setscrew, Vg minp. 407
Setscrew, Vg minp. 407
+5p. 407
5p. 407
+Valve platep. 407
Valve platep. 407
In variable displacement axial piston in bent axle design the pistons (7) are arranged in an inclined position to the drive shaft (1). The pistons perform an axial movement, which is then converted to a rotary movement by the piston joint on the driv…p. 407
+Motor functionp. 407
Motor functionp. 407
A variable displacement axial piston motor converts the hydrostatic energy into mechanical energy. Pressure fluid is fed through the connecting plate (4) and the valve plate (5) into the cylinder bores. The pistons (7) inside the cylinder bores perfo…p. 407
+Sensorsp. 407
Sensorsp. 407
The A6VM/VE…U version has been designed with a gearing on the drive. An attached rotary speed sensor enables the detection signals proportional to the motor speed.p. 407
Fig. 33p. 408
The DSM sensor is fastened to the specially intended connection with a fastening screwp. 408
+Controlp. 408
Controlp. 408
In a variable displacement axial piston motor the angle of the bent axle can be infinitely adjusted within certain limits. The change in swashing angle of the bent axle causes a difference in stroke length and thus a change in displacement. The swash…p. 408
+The following table should be of help when performing troubleshooting This table is by no means complete.p. 409
The following table should be of help when performing troubleshooting This table is by no means complete.p. 409
In practice you may encounter problems that have not been listed here.p. 409
+Procedurep. 409
Procedurep. 409
+l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 409
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 409
l Get an overview over the function of the product in connection with the overall system.p. 409
l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred.p. 409
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver.p. 409
Try to detect changes to the overall system, the product is installed in:p. 409
+l Have conditions or area of application of the product been changed?p. 409
l Have conditions or area of application of the product been changed?p. 409
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or to the product? If yes: What kind?p. 409
l Has the product or the machine been operated as intended?p. 409
l How does the fault occur?p. 409
+Faultp. 409
Faultp. 409
+Possible causep. 409
Possible causep. 409
+Remedyp. 409
Remedyp. 409
+Unusual noisesp. 409
Unusual noisesp. 409
+Inappropriate fastening of the axial piston unitp. 409
Inappropriate fastening of the axial piston unitp. 409
+Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques!p. 409
Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques!p. 409
+Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 409
Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 409
+Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 409
Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 409
+Mechanical damage to the axial piston unit.p. 409
Mechanical damage to the axial piston unit.p. 409
+Replace the axial piston unitp. 409
Replace the axial piston unitp. 409
+Fluctuations in pressure/volumetric flowp. 409
Fluctuations in pressure/volumetric flowp. 409
+Axial piston unit not or insufficiently purged.p. 409
Axial piston unit not or insufficiently purged.p. 409
+Completely purge the axial piston unit.p. 409
Completely purge the axial piston unit.p. 409
+Operation data are not reached.p. 410
Operation data are not reached.p. 410
+Insufficient flow from hydraulic pumpp. 410
Insufficient flow from hydraulic pumpp. 410
+Check the function of the hydraulic pumpp. 410
Check the function of the hydraulic pumpp. 410
+Minimum displacement incorrectly setp. 410
Minimum displacement incorrectly setp. 410
+Consult the service department.p. 410
Consult the service department.p. 410
+External control and setting facilities defective.p. 410
External control and setting facilities defective.p. 410
+Check the external control.p. 410
Check the external control.p. 410
+Control pressure too lowp. 410
Control pressure too lowp. 410
+Check control pressure, consult the service department.p. 410
Check control pressure, consult the service department.p. 410
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 410
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 410
+Consult the service department.p. 410
Consult the service department.p. 410
+Pressure fluid not within the optimal viscosity range.p. 410
Pressure fluid not within the optimal viscosity range.p. 410
+Use appropriate pressure fluid.p. 410
Use appropriate pressure fluid.p. 410
+Wear of the axial piston unitp. 410
Wear of the axial piston unitp. 410
+Replace the axial piston unitp. 410
Replace the axial piston unitp. 410
+Mechanical damage to the axial piston unit.p. 410
Mechanical damage to the axial piston unit.p. 410
+Replace the axial piston unitp. 410
Replace the axial piston unitp. 410
+Pressure fluid too hot.p. 410
Pressure fluid too hot.p. 410
+Excessive input temperature on axial piston unit.p. 410
Excessive input temperature on axial piston unit.p. 410
+Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 410
Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 410
+Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 410
Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 410
+Consult the service department.p. 410
Consult the service department.p. 410
+Failure of the flushing valvep. 410
Failure of the flushing valvep. 410
+Consult the service department.p. 410
Consult the service department.p. 410
+Wear of the axial piston unitp. 410
Wear of the axial piston unitp. 410
+Replace the axial piston unitp. 410
Replace the axial piston unitp. 410
+11.9 Check the hydraulic oil levelp. 411
11.8 Steering and working hydraulicsp. 411
Fig. 1 Page 7 from the hydraulic diagramp. 411
The steering and working hydraulics of the new earth and refuse compactor are fully hydraulic. The system is controlled via hydraulic joysticks, which are arranged directly at the operator's place (driver's seat).p. 411
+Steeringp. 412
Steeringp. 412
+The steering system is completely hydraulic, i.e the steering pump delivers hydraulic fluid through the steering valves (steering joystick) to the steering cylinders.p. 412
The steering system is completely hydraulic, i.e the steering pump delivers hydraulic fluid through the steering valves (steering joystick) to the steering cylinders.p. 412
Fig. 1 Excerpt from the wiring diagramp. 412
03 Steering and work system pumpp. 412
15 Steering joystickp. 412
17 Steering and work system valvep. 412
+Steering and working pump, A10VO85DFR1p. 412
Steering and working pump, A10VO85DFR1p. 412
The pump is a swash plate operated axial piston pump with variable displacement.p. 412
Fig. 2 Steering and working pump in machinep. 413
+1 Steering and working pumpp. 413
1 Steering and working pumpp. 413
2 Pressure test port, M22p. 413
3 Pressure test port flow control valve (stand-by) 20-25 barp. 413
+11.9 Check the hydraulic oil levelp. 414
Axial piston pumps, A10VO/VSO 18 to 100 DFR1p. 414
+This document is valid for pump typesp. 414
+This document is valid for pump typesp. 414
VOp. 414
VSOp. 414
The pump delivers oil only to one direction, i.e. the swash plate moves out of neutral position only to one direction. It is therefore particularly suitable for the use in open hydraulic circuits.p. 414
+The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 414
The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 414
Fig. 3p. 414
+DFR1, pressure-flow controllerp. 414
DFR1, pressure-flow controllerp. 414
Pressure control valvep. 414
The pressure control valve keeps the pressure in an hydraulic system at a constant level within the control range of the pump. This way the pump will only deliver as much hydraulic fluid as can be absorbed by the hydraulic consumers. The pressure can…p. 414
DFR1 – pressure and flow controllerp. 414
In addition to the function of a pressure controller an orifice records the differential pressure before and after the orifice, which then controls the flow rate of the pump. The pump delivers the pressure fluid quantity actually required by the cons…p. 414
The pressure controller is superimposed.p. 414
Fig. 4 Sectional drawingp. 415
Fig. 5 Hydraulic diagramp. 415
+Bp. 415
Bp. 415
+Working linep. 415
Working linep. 415
+Sp. 415
Sp. 415
+Suctionp. 415
Suctionp. 415
+L / L1p. 415
L / L1p. 415
+Leak oilp. 415
Leak oilp. 415
+Xp. 415
Xp. 415
+Pilot pressurep. 415
Pilot pressurep. 415
+Working principlep. 416
Working principlep. 416
Fig. 6p. 416
+l When thep. 416
+l When thep. 416
+engine is not running (1)p. 416
(Fig. 6)p. 416
+l When starting the engine pressure will build up at the pump outletp. 416
(no consumer active (2)p. 416
flow controllerp. 416
Fig. 7p. 416
+l If the system pressure increases because of active consumers (3)p. 416
+l If the system pressure increases because of active consumers (3)p. 416
(Fig. 7)p. 416
l If the pressure drops below the adjusted value (4), the spring in the pressure control valve will be able to close the pressure control valve again, the pump can return to a higher displacement.p. 416
+11.9 Check the hydraulic oil levelp. 417
Steering and working valve for RB-typesp. 417
Fig. 8 RB-valvep. 417
+Pressure test portsp. 418
Steering and working valve for RS-typesp. 418
Fig. 9 RS-valvep. 418
+Pressure test portsp. 419
Steering and working valve for EB-typesp. 419
Fig. 10 EB-valvep. 419
+Pressure test portsp. 420
Control via joystickp. 420
Fig. 11 Steering joystick and work system joystickp. 420
+Pressure test portsp. 421
Pressure test portsp. 421
Fig. 12 Test ports under driver's standp. 421
Fig. 13 Steering and work system valve in frame at frontp. 422
Steering and work system valve in frame at front under the flapp. 423
Fig. 14 Front framep. 423
+11.9 Check the hydraulic oil levelp. 424
11.9 Check the hydraulic oil levelp. 424
Fig. 15p. 424
+l Check the oil level in the inspection glassp. 424
+l Check the oil level in the inspection glassp. 424
(Fig. 15)p. 424
+Check the oil level with the dozer blade lowered.p. 424
Check the oil level with the dozer blade lowered.p. 424
At a room temperature of approx. 20 °C the oil level should reach approx. 1/2 way up the inspection glass.p. 424
+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. 424
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. 424
+l If necessary fill in hydraulic oil through the filler neck.p. 424
l If necessary fill in hydraulic oil through the filler neck.p. 424
For quality and quantity of oil refer to the "table of fuels, lubricants and filling capacities".p. 424
+11.10 Change the hydraulic oil fine filterp. 424
11.10 Change the hydraulic oil fine filterp. 424
+Danger of scalding!p. 424
+Danger of scalding!p. 424
Danger of scalding!p. 424
Danger of scalding by hot oil when unscrewing the fine filter.p. 424
+Do not let old oil seep into the ground, but dispose off environmentally.p. 424
Do not let old oil seep into the ground, but dispose off environmentally.p. 424
+If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run.p. 424
If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run.p. 424
+Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.p. 424
Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.p. 424
+Changing the hydraulic oil fine filter (right side of engine)p. 424
Changing the hydraulic oil fine filter (right side of engine)p. 424
Fig. 16p. 424
+l Remove the locking wire, if present.p. 424
l Remove the locking wire, if present.p. 424
+l Unscrew spigot nut 1p. 424
(Fig. 16)p. 424
l Remove filter bowl (2) with filter element.p. 424
Fig. 17p. 425
+Catch running out oil.p. 425
Catch running out oil.p. 425
+l Do not use the oil in the filter bowl again.p. 425
l Do not use the oil in the filter bowl again.p. 425
+l Take out the old filter element (3)p. 425
(Fig. 17)p. 425
l Clean the thread on the filter bowl.p. 425
l Assemble the filter bowls with a new filter elements, check the condition of the seal rings (4).p. 425
+Changing the hydraulic oil fine filter (left side of engine)p. 425
Changing the hydraulic oil fine filter (left side of engine)p. 425
Fig. 18p. 425
+l Remove the locking wire, if present.p. 425
l Remove the locking wire, if present.p. 425
+l Unscrew spigot nut 1p. 425
(Fig. 18)p. 425
l Remove filter bowl (2) with filter element.p. 425
Fig. 19p. 425
+Catch running out oil.p. 425
Catch running out oil.p. 425
+l Do not use the oil in the filter bowl again.p. 425
l Do not use the oil in the filter bowl again.p. 425
+l Take out the old filter element (3)p. 425
(Fig. 19)p. 425
l Clean the thread on the filter bowl.p. 425
l Assemble the filter bowls with a new filter elements, check the condition of the seal rings (4).p. 425
+l Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system.p. 425
l Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system.p. 425
l Check for leaks after a short test run.p. 425
+11.11 Changing hydraulic oil and breather filterp. 426
11.11 Changing hydraulic oil and breather filterp. 426
+See also notes on the hydraulic system.p. 426
See also notes on the hydraulic system.p. 426
+l Perform the oil change when the hydraulic oil is warm.p. 426
l Perform the oil change when the hydraulic oil is warm.p. 426
l Clean the area round hydraulic oil tank, filler opening and breather filter.p. 426
l Do not run the pumps without oil.p. 426
l Do not use any detergents to clean the system.p. 426
l Use only lint-free cleaning cloths.p. 426
+Replace the hydraulic oil filter element with every hydraulic oil change.p. 426
Replace the hydraulic oil filter element with every hydraulic oil change.p. 426
+Generally replace the hydraulic oil filter after the test run.p. 426
Generally replace the hydraulic oil filter after the test run.p. 426
+l Run the diesel engine for max. 3 minutes at low speed.p. 426
l Run the diesel engine for max. 3 minutes at low speed.p. 426
l The system must be bled again after the filter change.p. 426
+Do not start the engine after draining the hydraulic oil.p. 426
Do not start the engine after draining the hydraulic oil.p. 426
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. 426
+Catch old oil and dispose of environmentally.p. 426
Catch old oil and dispose of environmentally.p. 426
+l Remove the rear cover.p. 426
l Remove the rear cover.p. 426
Fig. 20p. 426
+l Unscrew the breather filterp. 426
+l Unscrew the breather filterp. 426
(Fig. 20)p. 426
+Do not remove the filter element from the cover of the compensation tank.p. 426
Do not remove the filter element from the cover of the compensation tank.p. 426
Fig. 21p. 426
+Danger of scalding!p. 426
Danger of scalding!p. 426
Danger of scalding when draining off hot hydraulic oil!p. 426
+l Unscrew plug (1)p. 426
+l Unscrew plug (1)p. 426
(Fig. 21)p. 426
l Guide the drain hose into a vessel of appropriate size.p. 426
l Open drain cock (2) and let the old oil run out.p. 426
l Once all old oil has run out close the drain cock, remove the drain hose and screw the plug back on.p. 426
+Cleaning the hydraulic oil tankp. 426
Cleaning the hydraulic oil tankp. 426
+If the hydraulic oil tank needs to be cleaned from inside the following work must be performed:p. 426
If the hydraulic oil tank needs to be cleaned from inside the following work must be performed:p. 426
Fig. 22p. 427
+l Unscrew the hexagon screws and take off the coverp. 427
+l Unscrew the hexagon screws and take off the coverp. 427
(Fig. 22)p. 427
l Wipe the inside of the hydraulic tank clean with the lint-free cloth.p. 427
+Do not use any detergents. This will contaminate the hydraulic oil!p. 427
Do not use any detergents. This will contaminate the hydraulic oil!p. 427
+l Insert a new seal and reinstall the cover.p. 427
l Insert a new seal and reinstall the cover.p. 427
+Fill in hydraulic oil.p. 427
Fill in hydraulic oil.p. 427
Fig. 23p. 427
+We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydr…p. 427
We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydr…p. 427
+l Fill in new hydraulic oil through the screenp. 427
+l Fill in new hydraulic oil through the screenp. 427
(Fig. 23)p. 427
For quality and quantity of oil refer to the table of fuels and lubricants.p. 427
Fig. 24p. 427
+l Check the oil level in the inspection glassp. 427
+l Check the oil level in the inspection glassp. 427
(Fig. 24)p. 427
+Check the oil level with the dozer blade lowered.p. 427
Check the oil level with the dozer blade lowered.p. 427
At a room temperature of approx. 20 °C the oil level should reach approx. 1/2 way up the inspection glass.p. 427
+l Screw the new breather filter on .p. 427
l Screw the new breather filter on .p. 427
l Perform a test run and check the system for leaks.p. 427
l Assemble the service door.p. 427
+Bleeding the hydraulic systemp. 427
Bleeding the hydraulic systemp. 427
+l Run the diesel engine for max. 3 minutes at low speed.p. 427
l Run the diesel engine for max. 3 minutes at low speed.p. 427
l Run the machine until operating temperature is achieved, then shut the engine.p. 427
+Catch running out oil and dispose of environmentally.p. 427
Catch running out oil and dispose of environmentally.p. 427
+12 Oscillating articulated jointp. 429
+12 Oscillating articulated jointp. 429
Repair overviewp. 430
+4 Live ring bearingp. 431
+4 Live ring bearingp. 431
4 Live ring bearingp. 431
5 not usedp. 431
6 Hexagon screw M16X120p. 431
7 Taper roller bearingp. 431
8 Dirt scraperp. 432
9 Hexagon screw M12X60p. 432
10 Hexagon screw M20X20p. 432
11 Roll pinp. 432
12 Snap ringp. 432
13 Boltp. 432
14 Sleevep. 432
15 Coverp. 432
16 Flanged coverp. 432
17 Washerp. 432
18 Consolep. 432
19 Seal ringp. 432
20 Central blockp. 432
21 Flapp. 432
22 Socket head cap screw M6X16p. 432
23 not usedp. 432
24 not usedp. 432
25 not usedp. 432
26 Hexagon screw M20X140p. 432
27 Tensioning washerp. 432
12.2 Repairing the articulated jointp. 433
+Disassembling the articulated jointp. 433
Disassembling the articulated jointp. 433
+Fig. 1p. 433
Fig. 1p. 433
+1. Unscrew hexagon screws 1p. 433
+1. Unscrew hexagon screws 1p. 433
(Fig. 1)p. 433
+Fig. 2p. 433
Fig. 2p. 433
+2. Lift off the live ring bearingp. 433
+2. Lift off the live ring bearingp. 433
(Fig. 2)p. 433
+Fig. 3p. 433
Fig. 3p. 433
+Perform the work steps shown inp. 433
+Perform the work steps shown inp. 433
(Fig. 3)p. 433
(Fig. 4)p. 433
+3. Unscrew the hexagon screwsp. 433
+3. Unscrew the hexagon screwsp. 433
(Fig. 3)p. 433
+Fig. 4p. 434
Fig. 4p. 434
+4. take off cover 1p. 434
+4. take off cover 1p. 434
(Fig. 4)p. 434
+Fig. 5p. 434
Fig. 5p. 434
+5. Attach lifting tackle (belts) to the central block.p. 434
5. Attach lifting tackle (belts) to the central block.p. 434
+Perform the following work stepsp. 434
+Perform the following work stepsp. 434
(Fig. 5)p. 434
(Fig. 6)p. 434
+6. Knock out bolt (1) towards the inside using a suitable drift punch.p. 434
6. Knock out bolt (1) towards the inside using a suitable drift punch.p. 434
+Fig. 6p. 434
Fig. 6p. 434
+7. Knock the sleeves (1) carefully out towards the outside using a suitable drift punch or flat chisel.p. 434
7. Knock the sleeves (1) carefully out towards the outside using a suitable drift punch or flat chisel.p. 434
+Fig. 7p. 434
Fig. 7p. 434
+8. Lift the central block out of the consolep. 434
+8. Lift the central block out of the consolep. 434
(Fig. 7)p. 434
+Fig. 8p. 435
Fig. 8p. 435
+Perform the work steps shown inp. 435
+Perform the work steps shown inp. 435
(Fig. 8)p. 435
(Fig. 9)p. 435
(Fig. 10)p. 435
+9. Unscrew the hexagon screwsp. 435
+9. Unscrew the hexagon screwsp. 435
(Fig. 8)p. 435
+Fig. 9p. 435
Fig. 9p. 435
+10. Take off both flange covers 1p. 435
+10. Take off both flange covers 1p. 435
(Fig. 9)p. 435
+11. Remove the dirt scraper (2).p. 435
11. Remove the dirt scraper (2).p. 435
+Fig. 10p. 435
Fig. 10p. 435
+12. Take out the outer circlips 1p. 435
+12. Take out the outer circlips 1p. 435
(Fig. 10)p. 435
+13. Use a suitable drift punch to knock out the taper roller bearings towards the outside.p. 435
13. Use a suitable drift punch to knock out the taper roller bearings towards the outside.p. 435
+14. Take out the inner circlips (3).p. 435
14. Take out the inner circlips (3).p. 435
+15. Remove the dirt scraper (4).p. 435
15. Remove the dirt scraper (4).p. 435
Assembling the articulated jointp. 436
+Fig. 1p. 436
Fig. 1p. 436
+Perform the work steps shown inp. 436
+Perform the work steps shown inp. 436
(Fig. 1)p. 436
(Fig. 7)p. 436
+1. Assemble the new dirt scrapers (1) with grease.p. 436
1. Assemble the new dirt scrapers (1) with grease.p. 436
+Observe the installation direction.p. 436
Observe the installation direction.p. 436
+Fig. 2p. 436
Fig. 2p. 436
+2. Click the inner circlipsp. 436
+2. Click the inner circlipsp. 436
(Fig. 2)p. 436
+Fig. 3p. 436
Fig. 3p. 436
+3. Slightly oil the taper roller bearings and press them into the central blockp. 436
+3. Slightly oil the taper roller bearings and press them into the central blockp. 436
(Fig. 3)p. 436
+Fig. 4p. 436
Fig. 4p. 436
+4. Click the outer circlipsp. 436
+4. Click the outer circlipsp. 436
(Fig. 4)p. 436
+Fig. 5p. 437
Fig. 5p. 437
+5. Assemble the new dirt scrapers with greasep. 437
+5. Assemble the new dirt scrapers with greasep. 437
(Fig. 5)p. 437
+Observe the installation direction.p. 437
Observe the installation direction.p. 437
+Fig. 6p. 437
Fig. 6p. 437
+6. Fasten both flange covers with hexagon screws.p. 437
6. Fasten both flange covers with hexagon screws.p. 437
+Fig. 7p. 437
Fig. 7p. 437
+7. Attach lifting tackle (belts) to the central block.p. 437
7. Attach lifting tackle (belts) to the central block.p. 437
+8. Insert the central block into the consolep. 437
+8. Insert the central block into the consolep. 437
(Fig. 7)p. 437
+Fig. 8p. 437
Fig. 8p. 437
+Perform the work steps shown inp. 437
+Perform the work steps shown inp. 437
(Fig. 8)p. 437
(Fig. 10)p. 437
Make sure that the oil bores of the bolt face in direction of travel.p. 437
+9. Slightly oil the bolt and press it carefully into the joint against the end stop.p. 437
9. Slightly oil the bolt and press it carefully into the joint against the end stop.p. 437
+Fig. 9p. 438
Fig. 9p. 438
+10. Slightly oil the sleeves and drive them in with a plastic hammerp. 438
+10. Slightly oil the sleeves and drive them in with a plastic hammerp. 438
(Fig. 9)p. 438
+Observe the installation direction.p. 438
Observe the installation direction.p. 438
Assemble the bushings with the grooves facing towards the inside.p. 438
+11. Turn the hexagin screws (1) with seal rings into the joint bolts.p. 438
11. Turn the hexagin screws (1) with seal rings into the joint bolts.p. 438
+Fig. 10p. 438
Fig. 10p. 438
+12. Fasten the disc with hexagon screwsp. 438
+12. Fasten the disc with hexagon screwsp. 438
(Fig. 10)p. 438
+Observe the roll pin (arrow).p. 438
Observe the roll pin (arrow).p. 438
+Fig. 11p. 438
Fig. 11p. 438
+13. Fasten the disc with hexagon screwsp. 438
+13. Fasten the disc with hexagon screwsp. 438
(Fig. 11)p. 438
+Install the 5 inner screws (1) first.p. 438
Install the 5 inner screws (1) first.p. 438
Then rotate the cover with the connected joint bolt to align the 6 outer bores.p. 438
+Fig. 12p. 438
Fig. 12p. 438
+14. Attach the live ring bearingp. 438
+14. Attach the live ring bearingp. 438
(Fig. 12)p. 438
+Fig. 13p. 439
Fig. 13p. 439
+15. Fasten the live ring bearing on the central block with screws and washers.p. 439
15. Fasten the live ring bearing on the central block with screws and washers.p. 439
+13 Compactor wheels and dozer bladep. 441
13 Compactor wheels and dozer bladep. 441
+13.1 Replacing the wheel capsp. 442
13.1 Replacing the wheel capsp. 442
+Danger of accident!p. 442
+Danger of accident!p. 442
Danger of accident!p. 442
Perform all work only with the engine shut down and after actuating the emergency stop switch.p. 442
Wear goggles and proper working gloves during all work.p. 442
+This work shall only be performed by qualified specialists.p. 442
This work shall only be performed by qualified specialists.p. 442
The caps should be replaced at the latest when the front faces collapse.p. 442
Use only new roll pins, as otherwise caps and pad feet may be damaged.p. 442
+Required tools/materials:p. 442
Required tools/materials:p. 442
l Hydraulic hammer with gun handle, tool adapter 22×82 mm (approx. 12 kg)p. 442
l Power station with sufficient pressure (max pressure min. 125 bar)p. 442
l Mandrel to drive out, BOMAG PN 570 036 37ap. 442
l Mandrel to drive in, BOMAG PN 570 036 36p. 442
l new pad foot capsp. 442
l new roll pinsp. 442
l copper pastep. 442
+If the roll pins are completely filled with hardened material, driving out the pins may be obstructed. In this case the inside area of the roll pin must be cleaned out with an 10 mm impact drill with an effective drilling length of 100 – 120 mm.p. 442
If the roll pins are completely filled with hardened material, driving out the pins may be obstructed. In this case the inside area of the roll pin must be cleaned out with an 10 mm impact drill with an effective drilling length of 100 – 120 mm.p. 442
Fig. 14p. 442
+l Drive out the roll pins with hydraulic hammerp. 442
+l Drive out the roll pins with hydraulic hammerp. 442
(Fig. 14)p. 442
Fig. 15p. 442
+l Take off the pad foot cap and clean the base thoroughlyp. 442
+l Take off the pad foot cap and clean the base thoroughlyp. 442
(Fig. 15)p. 442
Fig. 16p. 442
+l Attach the new pad foot cap.p. 442
l Attach the new pad foot cap.p. 442
+l Grease the large roll pin (1)p. 442
(Fig. 16)p. 442
l Grease the smaller roll pin (2) with copper paste and attach it with the groove pointing down., drive it in with the mandrel.p. 442
+13.2 Adjust scrapers and edge cutterp. 443
13.2 Adjust scrapers and edge cutterp. 443
+Scrapersp. 443
Scrapersp. 443
Fig. 17p. 443
+l Check the condition of all scrapers 1p. 443
+l Check the condition of all scrapers 1p. 443
(Fig. 17)p. 443
l Check the gap between scrapers and compactor wheels, adjust the gap of the inner scrapers to 0 mm.p. 443
l Adjust the gaps of all other scrapers to 5 mm.p. 443
+l For adjustment slacken screws 2p. 443
(Fig. 17)p. 443
l Retighten the slackened screws.p. 443
l Tightening torque 502 Nm.p. 443
+The tightening torques apply only for screws covered with OKS 240 (copper paste).p. 443
The tightening torques apply only for screws covered with OKS 240 (copper paste).p. 443
+Edge cutterp. 443
Edge cutterp. 443
Fig. 18p. 443
+l Check the condition of all edge cutters 1p. 443
+l Check the condition of all edge cutters 1p. 443
(Fig. 18)p. 443
l Check the gap (2) between edge cutters and compactor wheels.p. 443
l At the closest point (2) there must be metal to metal contact between the edge cutters and the shell surfaces of the compactor wheels.p. 443
l For adjustment slacken the screws (3) and adjust the edge cutters.p. 443
+For manufacturing reasons the shell of the compactor wheels may not be absolutely round.p. 443
For manufacturing reasons the shell of the compactor wheels may not be absolutely round.p. 443
At the widest points the edge cutters may therefore have a few millimetres distance to the shell surface.p. 443
+l Retighten the slackened screws.p. 443
l Retighten the slackened screws.p. 443
+Remove refuse residues, cables, ropes, wires etc. to prevent premature wear of the wheel shell edge.p. 443
Remove refuse residues, cables, ropes, wires etc. to prevent premature wear of the wheel shell edge.p. 443
+13.3 Checking the cutting plates, replacing the cutting plates if necessaryp. 444
13.3 Checking the cutting plates, replacing the cutting plates if necessaryp. 444
Fig. 19p. 444
+l Check the condition of the cutting plates 1p. 444
+l Check the condition of the cutting plates 1p. 444
(Fig. 19)p. 444
l Lift the dozer blade/bucket up and support it safely.p. 444
+Danger of accident!p. 444
Danger of accident!p. 444
Do not work on the lifted and unsupported dozer blade/bucket.p. 444
+l To change the plate unscrew the hexagon nuts (2). Take the washer (3) off, cut it of with a torch, if required.p. 444
l To change the plate unscrew the hexagon nuts (2). Take the washer (3) off, cut it of with a torch, if required.p. 444
l Knock the hexagon screws (4) and take the old cutting plate off.p. 444
l Before assembling the new cutting plate check the contact face on the dozer blade, rework it if necessary.p. 444
l Attach the cutting plate, insert the counter-sunk screws and observe the locating recess, install the washer and fasten the assembly.p. 444
+14 Suppliers documentationp. 445
14 Suppliers documentationp. 445
14.1 Steering and working pumpp. 447
14.2 Wheel drivep. 477
14.3 Travel motorp. 531
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. 532
+15 Circuit diagramsp. 585
15 Circuit diagramsp. 585
S/N Wiring diagram 930 107 70p. 586
S/N Wiring diagram 930 107 70p. 587
+S/N Wiring diagram 930 107 70p. 589
15.1 Hydraulic diagram 930,108 40p. 589
S/N Wiring diagram 930 107 70p. 590
S/N Wiring diagram 930 107 70p. 591
S/N Wiring diagram 930 107 70p. 602
+S/N Wiring diagram 930 107 70p. 603
15.2 Wiring diagram 930,107 70p. 603
S/N Wiring diagram 930 107 70p. 604
+S/N Wiring diagram 930 107 70p. 604
S/N Wiring diagram 930 107 70p. 604
+S/N 101 930 001 001p. 604
Ûp. 604
+S/N 101 930 011 001p. 604
Ûp. 604
+S/N 101 930 021 001p. 604
Ûp. 604
+S/N 101 930 031 001p. 604
Ûp. 604
S/N Wiring diagram 5p. 605
+S/N Wiring diagram 5p. 639
15.3 Wiring diagram 5p. 639
S/N Wiring diagram 5p. 640
+S/N Wiring diagram 5p. 640
S/N Wiring diagram 5p. 640
+S/N 101 930 001 008p. 640
Ûp. 640
+S/N 101 930 011 009p. 640
Ûp. 640
+S/N 101 930 021 010p. 640
Ûp. 640
+S/N 101 930 031 008p. 640
Ûp. 640
+S/N 101 930 041 001p. 640
Ûp. 640
+S/N 101 930 051 001p. 640
Ûp. 640
S/N Wiring diagram 75p. 641
S/N Wiring diagram 75p. 680
+S/N Wiring diagram 75p. 681
15.4 Wiring diagram 75p. 681
S/N Wiring diagram 75p. 682
+S/N Wiring diagram 75p. 682
S/N Wiring diagram 75p. 682
+S/N 101 930 041 002p. 682
Ûp. 682
+S/N 101 930 051 002p. 682
Ûp. 682
S/N Wiring diagram 95p. 683
+S/N Wiring diagram 95p. 727
15.5 Wiring diagram 95p. 727
S/N Wiring diagram 95p. 728
+S/N Wiring diagram 95p. 728
S/N Wiring diagram 95p. 728
+S/N 101 930 001 012p. 728
Ûp. 728
+S/N 101 930 011 011p. 728
Ûp. 728
+S/N 101 930 021 013p. 728
Ûp. 728
+S/N 101 930 031 010p. 728
Ûp. 728
+S/N 101 930 041 004p. 728
Ûp. 728
+S/N 101 930 051 005p. 728
Ûp. 728
+S/N 101 930 061 001p. 728
Ûp. 728
+S/N 101 930 071 001p. 728
Ûp. 728
What This Manual Enables You to Do
With this BOMAG BC462 RB BC472 RB RS BC462 EB Compactor Service Manual on hand, you can confidently tackle engine repairs including valve clearance adjustment, fuel system service, coolant system maintenance and turbocharger checks. The electrical diagnostics section lets you read fault codes through the EMR3 system, interpret flashing codes and use SERDIA or CAN-bus diagnostics to pinpoint faults. Hydraulic repairs are covered from the travel pumps and motors through to the steering and working hydraulics, with troubleshooting tables for axial piston pumps and motors. The manual also covers air conditioning service, central lubrication system maintenance, articulated joint repair and compactor wheel maintenance including scraper adjustment and cutting plate replacement.
Correct procedures and specifications matter on machines of this size and complexity. The BOMAG BC 462 RB, BC 472 RB, BC 472 RS and BC 462 EB are used in demanding landfill and earthworks applications where reliability is critical. Using the wrong torque value on a hydraulic fitting, misdiagnosing an engine fault or skipping a maintenance interval can lead to expensive downtime. This manual provides the factory procedures and technical data to help you get it right the first time.
Instant PDF Delivery
The BOMAG BC462 RB BC472 RB RS BC462 EB Compactor Service Manual is delivered as an instant PDF download after payment. There is no shipping, no waiting for a physical book and no risk of a damaged or missing copy. You can access the manual on any device — laptop, tablet or smartphone — and print the pages you need for the workshop. Whether you are a BOMAG dealer technician, an independent heavy equipment mechanic or a fleet owner maintaining your own compactors, this PDF service manual gives you the complete workshop reference in a practical, searchable format.
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