BOMAG BF 300 C Road Finisher Service Training Manual – Complete Workshop PDF
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Full BOMAG BF 300 C road finisher service training manual, document 008 922 07, February 2013. Covers engine, travel drive, screed, hydraulics, electrics, input codes and circuit diagrams across 1050 pages.
BOMAG BF 300 C Road Finisher Service Training Manual
This BOMAG BF 300 C Road Finisher Service Training Manual is the complete service training documentation for the BF 300 C tracked road finisher and its S340 variants. Published under document number 008 922 07 in February 2013, it covers every major system on the machine: the Kubota V3307 T diesel engine, the hydrostatic travel drive, the material hopper and scraper belts, the augers, the vibrating screed, the electrics and E-Plan wiring diagrams, the hydraulic circuits, and the central lubrication system. The manual runs to 1050 pages and is written for the technician working on the machine rather than for a general audience.
File Details
Manual type: Service Training Manual
Brand: BOMAG
Model: BF 300 C / S340
Language: English
Page count: 1050
File format: PDF
Document number: 008 922 07
Edition / date: February 2013
IMAGES PREVIEW
Chapters Covered
General – introduction, safety regulations, general repair instructions, tightening torques
Technical data – engine, travel pumps, travel motors, travel gear, service pump, tamper, vibration, auger, scraper belt, cleaning kit, noise and vibration values
Maintenance – general notes, fuels and lubricants, running-in instructions, maintenance table
Electrics – ECOMODE, glow plugs, speed sensors, oil pressure switch, coolant temperature switch, air filter vacuum switch, coolant float switch, charge control light, water separator, level sensor in diesel tank, fuses and fuse assignment, component overview, wiring looms, control elements, monitoring modules, functional block diagrams, voltage supply checks, diagnostics concept
Input codes – display functions and operation, automatic calibration of travel system currents, teaching the E-throttle function, teaching the L.C.S. function, resetting to factory settings, showing stored faults, deleting the fault log, driving against the closed brake, adapting the engine speed, speed range change when cornering, deactivating and activating the speed sensors
Replacement of components – procedures after replacing the ESX control, travel pumps and E-throttle actuator
Engine – features, cooling system, thermostat, coolant level and change, engine oil and filter, fuel system and filter, water separator, generator V-belt, air filter, engine mounts, valve clearance, engine problems
Material hopper – material flow, scraper belts, augers
Tests and adjustments – special tools, checking and adjusting vibration, tamping, scraper belts, augers, main screed, screed levelling, hopper wings, mobile screed
Central lubrication system – filling the lubricant container, electric pump, integrated electronic control, progressive distributor, fault finding, repair of a blocked distributor
Circuit diagrams – hydraulic diagram, electric circuit diagrams
For a technician working on a BF 300 C, this manual does more than list specifications. It explains the design and function of each assembly, gives the settings and tightening torques needed to work on it, and supplies the diagnostic codes and test procedures that let you confirm a repair is correct. The E-Plan section alone is worth the file: it shows how to read the wiring diagrams, trace a circuit through the terminal designations, and locate a fault without guesswork. The hydraulic chapter breaks the machine into its individual circuits, travel, vibration and tamping, scraper belt, auger and cylinder functions, so you can isolate a problem to one pump, one valve block or one motor before you start pulling lines.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BF 300 C Road Finisher Service Training Manual – Complete Workshop PDF” are as follows:
+BF 300_Cp. 1
+BF 300_Cp. 1
BF 300_Cp. 1
+S/N 821 837 57 1001 ….p. 1
S/N 821 837 57 1001 ….p. 1
S/N 821 837 69 1001 ….p. 1
S/N 821 837 82 1001 ….p. 1
S/N 821 891 03 1001 ….p. 1
S/N 821 891 04 1001 ….p. 1
Road Finisherp. 1
+1 Generalp. 7
1 Generalp. 7
+1.1 Introductionp. 8
+1.1 Introductionp. 8
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 Service informationp. 8
4 Fundamental electricsp. 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
+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. 1 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
+Batteryp. 12
Batteryp. 12
+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. 12
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. 12
l Work only well ventilated rooms (formation of oxyhydrogen gas).p. 12
l Do not lean over the battery while it is under load, being charged or tested (danger of explosion).p. 12
l Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the batteryp. 12
l Use battery chargers etc. only in strict compliance with the operating instructions.p. 12
l After an accident with acid flush the skin with a sufficient amount of water and seek medical advice.p. 12
l Do not allow children access to batteries.p. 12
l When mixing battery fluid always pour acid into water, never vice-versa.p. 12
+Special safety regulationsp. 12
Special safety regulationsp. 12
+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. 12
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. 12
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. 12
l Unauthorized changes to the machine are prohibited for safety reasons.p. 12
l Do not perform any cleaning work while the engine is running.p. 12
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. 12
l If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!).p. 12
l Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous!p. 12
l Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.p. 12
l Always ensure an adequate supply of fresh air when refuelling in closed rooms.p. 12
l Dispose of used filters in accordance with applicable environmental regulations.p. 12
l When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations.p. 12
l Do not heat up oils higher than 160 °C because they may ignite.p. 12
l Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations.p. 12
l Dispose of old batteries according to applicable environmental regulations.p. 12
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. 12
l Do not exceed the max. permissible tire pressure.p. 12
+The values specified in the table apply for screws:p. 13
General repair instructionsp. 13
+Generalp. 13
Generalp. 13
+l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 13
l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 13
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. 13
+The values specified in the table apply for screws:p. 13
Electricsp. 13
+Generalp. 13
Generalp. 13
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. 13
Diagnostics according to planp. 13
Well structured trouble shooting procedures can save time and money.p. 13
Random tests have revealed that purely electronic components or control units only very rarely are the actual cause of failures:p. 13
+l In approx. 10 % of the examined cases the problems were caused by control units.p. 13
l In approx. 10 % of the examined cases the problems were caused by control units.p. 13
l In approx. 15 % sensors and actuators were the cause of the problems.p. 13
By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.).p. 13
General:p. 13
+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. 13
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. 13
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. 13
l Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately.p. 13
l Do not disconnect or connect battery or generator while the engine is running.p. 13
l Do not operate the main battery switch under load.p. 13
l Do not use jump leads after the battery has been removed.p. 13
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. 13
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. 13
l Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!p. 13
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. 14
l Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions.p. 14
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. 14
+Electrics and weldingp. 14
Electrics and weldingp. 14
+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. 14
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. 14
+l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 14
l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 14
l Isolate the generator and all control units from the electric circuit.p. 14
l Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.p. 14
l When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings.p. 14
+The values specified in the table apply for screws:p. 14
Batteryp. 14
Rules for the handling of batteriesp. 14
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. 14
Fasten the terminal clamps with a little force as possible.p. 14
Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related development of heat.p. 14
Make sure the battery is properly fastened in the vehicle.p. 14
+The values specified in the table apply for screws:p. 15
Generatorp. 15
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. 15
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. 15
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. 15
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. 15
Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle.p. 15
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. 15
+The values specified in the table apply for screws:p. 15
Starter motorp. 15
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. 15
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. 15
Starter motors must not be cleaned with high pressure steam cleaning equipment.p. 15
The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection).p. 15
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. 15
Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.p. 15
+The values specified in the table apply for screws:p. 16
Hydraulic systemp. 16
+Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 16
Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 16
+Please notep. 16
Please notep. 16
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 16
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 16
+l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 16
l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 16
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 16
l During repair work keep all openings closed with clean plastic plugs and caps.p. 16
l Never run pumps, motors and engines without oil or hydraulic oil.p. 16
l When cleaning hydraulic components take care not to damage any fine machine surfaces.p. 16
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. 16
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. 16
l Avoid the formation of rust on fine machined caused by hand sweat.p. 16
l Use new O-rings or seal rings for reassembly.p. 16
l Use only hydraulic oil as sliding agent when reassembling. Do not use any grease!p. 16
l Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.p. 16
l Check the hydraulic oil level before and after the work.p. 16
l Fill in only clean oil as specified in the maintenance instructions.p. 16
l Check the hydraulic system for leaks, if necessary find and rectify the cause.p. 16
l Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions.p. 16
l After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system.p. 16
l Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).p. 16
l After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.p. 16
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. 16
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. 16
+Before commissioningp. 16
Before commissioningp. 16
+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. 16
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. 16
l After changing a component flush the hydraulic system as described in the flushing instructions.p. 16
+Taking into operationp. 16
Taking into operationp. 16
+l Bleed the hydraulic circuits.p. 16
l Bleed the hydraulic circuits.p. 16
l Start up the hydraulic system without load.p. 16
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. 16
+After taking into operationp. 16
After taking into operationp. 16
+l Check fittings and flanges for leaks.p. 16
l Check fittings and flanges for leaks.p. 16
l After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary.p. 16
l Do not adjust pressure relief valves and control valves to values above their specified values.p. 16
+The values specified in the table apply for screws:p. 17
Fuel hosesp. 17
Fig. 1p. 17
+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. 17
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. 17
+The values specified in the table apply for screws:p. 17
Gaskets and mating surfacesp. 17
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 17
+l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 17
l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 17
l Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 17
l Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 17
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. 17
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. 17
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. 17
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. 17
Assembly of radial sealsp. 17
Fig. 2p. 17
+l Lubricate the sealing lips (2)p. 17
+l Lubricate the sealing lips (2)p. 17
(Fig. 2)p. 17
l Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 17
+If possible, use an assembly sleeve (1p. 17
+If possible, use an assembly sleeve (1p. 17
(Fig. 2)p. 17
to protect the lip from being damaged by sharp edges, threads or splines.p. 17
+l Lubricate the outer rim (arrow 3p. 18
+l Lubricate the outer rim (arrow 3p. 18
(Fig. 2)p. 18
Fig. 3p. 18
+l Press or knock the seal into the housing, until it is flush with the housing surface.p. 18
l Press or knock the seal into the housing, until it is flush with the housing surface.p. 18
+If possible, use a "bell" (1p. 18
+If possible, use a "bell" (1p. 18
(Fig. 3)p. 18
that the seal will not skew.p. 18
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. 18
+The values specified in the table apply for screws:p. 18
Feather keys and keywaysp. 18
+Feather keys may only be reused if they are free of damage.p. 18
Feather keys may only be reused if they are free of damage.p. 18
Fig. 4p. 18
+l Clean and thoroughly examine the feather key.p. 18
l Clean and thoroughly examine the feather key.p. 18
l Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 18
+The values specified in the table apply for screws:p. 19
Ball and roller bearingsp. 19
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 19
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 19
Fig. 5p. 19
+l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 19
l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 19
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. 19
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. 19
l Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 19
l Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 19
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. 19
l Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 19
l Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 19
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. 19
Fig. 6p. 19
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 19
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 19
(Fig. 6)p. 19
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 19
+The values specified in the table apply for screws:p. 20
Screws and nutsp. 20
Tightening torquep. 20
+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. 20
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. 20
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. 20
Self-locking nuts must generally be replaced after disassembly.p. 20
The use of screws with too high strength can cause damage!p. 20
+l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 20
l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 20
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. 20
+l Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 20
The same applies for self-locking nuts.p. 20
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. 20
Strength classes, metric screwsp. 20
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. 20
Fig. 7 Identification of screwsp. 20
Example: A screw is identified with 12.9.p. 20
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 20
2p. 20
+l The nominal tensile strength is 12 X 100 N/mmp. 20
+l The nominal tensile strength is 12 X 100 N/mmp. 20
2p. 20
2p. 20
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 20
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 20
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 20
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 20
+l The lower tensile strength is 9/10 X 1200 N/mmp. 20
+l The lower tensile strength is 9/10 X 1200 N/mmp. 20
2p. 20
2p. 20
+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. 20
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. 20
Strength classes of metric nutsp. 21
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. 21
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 21
Fig. 8 Identification of nutsp. 21
+In a connection with a screw, these nuts 1p. 21
(Fig. 8)p. 21
Nut height above 0.8 d (d = nominal dimension).p. 21
+Strength class of nutp. 21
Strength class of nutp. 21
+Strength class of associated screwp. 21
Strength class of associated screwp. 21
+4p. 21
4p. 21
+3.6, 4.6, 4.8p. 21
3.6, 4.6, 4.8p. 21
+5p. 21
5p. 21
+3.6, 4.6, 4.8p. 21
3.6, 4.6, 4.8p. 21
5.6, 5.8p. 21
+6p. 21
6p. 21
+6.8p. 21
6.8p. 21
+8p. 21
8p. 21
+8.8p. 21
8.8p. 21
+9p. 21
9p. 21
+9.8p. 21
9.8p. 21
+10p. 21
10p. 21
+10.8p. 21
10.8p. 21
+12p. 21
12p. 21
+12.8p. 21
12.8p. 21
Nuts for screw joints with limited load factor (04, 05)p. 21
+The preceding "0" indicates that, due to their low height, nuts 2p. 21
(Fig. 8)p. 21
Nut height below 0,8 d (d = nominal dimension).p. 21
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 21
+This standard contains strength classes (hardness classes) for nuts 3p. 21
(Fig. 8)p. 21
Nut height below 0,5 d (d = nominal dimension).p. 21
Identification in clock systemp. 21
Fig. 9 Identification of nuts in clock systemp. 21
+For small nutsp. 21
(Fig. 9)p. 21
+l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 21
l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 21
l The strength class is identified by a dash (b).p. 21
Identification of UNF-threadsp. 22
Fig. 10p. 22
Screwsp. 22
+The screw head is marked with a stamped in, round cavity 3p. 22
(Fig. 10)p. 22
Nutsp. 22
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 22
Studs and brake rodsp. 22
At the outmost end a short end of the component is reduced to its core diameter (1).p. 22
Cotter pinsp. 22
Fig. 11p. 22
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 22
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 22
+The values specified in the table apply for screws:p. 23
Tightening torquesp. 23
+The values specified in the table apply for screws:p. 23
The values specified in the table apply for screws:p. 23
+l black oiledp. 23
l black oiledp. 23
l with surface protection A4Cp. 23
l with surface protection DACROMETp. 23
+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. 23
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. 23
+Tightening torques for screws with metric unified threadp. 23
+Tightening torques for screws with metric unified threadp. 23
+Tightening torques for screws with metric unified threadp. 23
+Coefficient of friction m tot. = 0,14p. 23
mp. 23
+Screw dimensionp. 23
Screw dimensionp. 23
+Tightening torques Nmp. 23
Tightening torques Nmp. 23
+8.8p. 23
8.8p. 23
+10.9p. 23
10.9p. 23
+12.9p. 23
12.9p. 23
+M4p. 23
M4p. 23
+3p. 23
3p. 23
+5p. 23
5p. 23
+5p. 23
5p. 23
+M5p. 23
M5p. 23
+6p. 23
6p. 23
+9p. 23
9p. 23
+10p. 23
10p. 23
+M6p. 23
M6p. 23
+10p. 23
10p. 23
+15p. 23
15p. 23
+18p. 23
18p. 23
+M8p. 23
M8p. 23
+25p. 23
25p. 23
+35p. 23
35p. 23
+45p. 23
45p. 23
+M10p. 23
M10p. 23
+50p. 23
50p. 23
+75p. 23
75p. 23
+83p. 23
83p. 23
+M12p. 23
M12p. 23
+88p. 23
88p. 23
+123p. 23
123p. 23
+147p. 23
147p. 23
+M14p. 23
M14p. 23
+137p. 23
137p. 23
+196p. 23
196p. 23
+235p. 23
235p. 23
+M16p. 23
M16p. 23
+211p. 23
211p. 23
+300p. 23
300p. 23
+358p. 23
358p. 23
+M18p. 23
M18p. 23
+290p. 23
290p. 23
+412p. 23
412p. 23
+490p. 23
490p. 23
+M20p. 23
M20p. 23
+412p. 23
412p. 23
+578p. 23
578p. 23
+696p. 23
696p. 23
+M22p. 23
M22p. 23
+560p. 23
560p. 23
+785p. 23
785p. 23
+942p. 23
942p. 23
+M24p. 23
M24p. 23
+711p. 23
711p. 23
+1000p. 23
1000p. 23
+1200p. 23
1200p. 23
+M27p. 23
M27p. 23
+1050p. 23
1050p. 23
+1480p. 23
1480p. 23
+1774p. 23
1774p. 23
+M30p. 23
M30p. 23
+1420p. 23
1420p. 23
+2010p. 23
2010p. 23
+2400p. 23
2400p. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Coefficient of friction m tot. = 0,14p. 23
mp. 23
+Screw dimensionp. 23
Screw dimensionp. 23
+Tightening torques Nmp. 23
Tightening torques Nmp. 23
+8.8p. 23
8.8p. 23
+10.9p. 23
10.9p. 23
+12.9p. 23
12.9p. 23
+M8 x 1p. 23
M8 x 1p. 23
+26p. 23
26p. 23
+37p. 23
37p. 23
+48p. 23
48p. 23
+M10 x 1.25p. 23
M10 x 1.25p. 23
+52p. 23
52p. 23
+76p. 23
76p. 23
+88p. 23
88p. 23
+M12 x 1,25p. 23
M12 x 1,25p. 23
+98p. 23
98p. 23
+137p. 23
137p. 23
+126p. 23
126p. 23
+M12 x 1.5p. 23
M12 x 1.5p. 23
+93p. 23
93p. 23
+127p. 23
127p. 23
+152p. 23
152p. 23
+M14 x 1.5p. 23
M14 x 1.5p. 23
+152p. 23
152p. 23
+216p. 23
216p. 23
+255p. 23
255p. 23
+M16 x 1.5p. 23
M16 x 1.5p. 23
+225p. 23
225p. 23
+318p. 23
318p. 23
+383p. 23
383p. 23
+M18 x 1.5p. 23
M18 x 1.5p. 23
+324p. 23
324p. 23
+466p. 23
466p. 23
+554p. 23
554p. 23
+M20 x 1.5p. 23
M20 x 1.5p. 23
+461p. 23
461p. 23
+628p. 23
628p. 23
+775p. 23
775p. 23
+M22 x 1.5p. 23
M22 x 1.5p. 23
+618p. 23
618p. 23
+863p. 23
863p. 23
+1058p. 23
1058p. 23
+M24 x 2p. 23
M24 x 2p. 23
+780p. 23
780p. 23
+1098p. 23
1098p. 23
+1294p. 23
1294p. 23
+M27 x2p. 23
M27 x2p. 23
+1147p. 23
1147p. 23
+1578p. 23
1578p. 23
+1920p. 23
1920p. 23
+M30 x 2p. 23
M30 x 2p. 23
+1568p. 23
1568p. 23
+2254p. 23
2254p. 23
+2695p. 23
2695p. 23
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 24
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 24
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 24
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. 24
+Screw dimensionp. 24
Screw dimensionp. 24
+Tightening torques Nmp. 24
Tightening torques Nmp. 24
+8.8p. 24
8.8p. 24
+10.9p. 24
10.9p. 24
+12.9p. 24
12.9p. 24
+M16p. 24
M16p. 24
+169p. 24
169p. 24
+240p. 24
240p. 24
+287p. 24
287p. 24
+M16 x 1.5p. 24
M16 x 1.5p. 24
+180p. 24
180p. 24
+255p. 24
255p. 24
+307p. 24
307p. 24
+M18p. 24
M18p. 24
+232p. 24
232p. 24
+330p. 24
330p. 24
+392p. 24
392p. 24
+M18 x 1.5p. 24
M18 x 1.5p. 24
+260p. 24
260p. 24
+373p. 24
373p. 24
+444p. 24
444p. 24
+M20p. 24
M20p. 24
+330p. 24
330p. 24
+463p. 24
463p. 24
+557p. 24
557p. 24
+M20 x 1.5p. 24
M20 x 1.5p. 24
+369p. 24
369p. 24
+502p. 24
502p. 24
+620p. 24
620p. 24
+M22p. 24
M22p. 24
+448p. 24
448p. 24
+628p. 24
628p. 24
+754p. 24
754p. 24
+M22 x 1.5p. 24
M22 x 1.5p. 24
+495p. 24
495p. 24
+691p. 24
691p. 24
+847p. 24
847p. 24
+M24p. 24
M24p. 24
+569p. 24
569p. 24
+800p. 24
800p. 24
+960p. 24
960p. 24
+M24 x 2p. 24
M24 x 2p. 24
+624p. 24
624p. 24
+879p. 24
879p. 24
+1036p. 24
1036p. 24
+M27p. 24
M27p. 24
+840p. 24
840p. 24
+1184p. 24
1184p. 24
+1520p. 24
1520p. 24
+M27 X 2p. 24
M27 X 2p. 24
+918p. 24
918p. 24
+1263p. 24
1263p. 24
+1536p. 24
1536p. 24
+M30p. 24
M30p. 24
+1136p. 24
1136p. 24
+1608p. 24
1608p. 24
+1920p. 24
1920p. 24
+M30 x 2p. 24
M30 x 2p. 24
+1255p. 24
1255p. 24
+1804p. 24
1804p. 24
+2156p. 24
2156p. 24
+3/4“ – 10 UNCp. 24
3/4“ – 10 UNCp. 24
+276p. 24
276p. 24
+388p. 24
388p. 24
+464p. 24
464p. 24
+3/4“ – 16 UNCp. 24
3/4“ – 16 UNCp. 24
+308p. 24
308p. 24
+432p. 24
432p. 24
+520p. 24
520p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Coefficient of friction m tot. = 0,14p. 24
mp. 24
These values result in a 90% utilization of the yield pointp. 24
+Thread diameterp. 24
Thread diameterp. 24
+Tightening torques Nmp. 24
Tightening torques Nmp. 24
+10.9p. 24
10.9p. 24
+M12x1.5p. 24
M12x1.5p. 24
+100p. 24
100p. 24
+M14x1.5p. 24
M14x1.5p. 24
+150p. 24
150p. 24
+M18x1.5p. 24
M18x1.5p. 24
+300 – 350p. 24
300 – 350p. 24
+M20x1.5p. 24
M20x1.5p. 24
+400 – 500p. 24
400 – 500p. 24
+M22x1.5p. 24
M22x1.5p. 24
+500 – 600p. 24
500 – 600p. 24
The values specified in the table apply for screws:p. 25
+l black oiledp. 25
l black oiledp. 25
l with surface protection A4Cp. 25
l with surface protection DACROMETp. 25
+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. 25
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. 25
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. 25
+Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 25
+Tightening torques for screws with UNC thread,p. 25
+Tightening torques for screws with UNC thread,p. 25
+Coefficient of friction m tot. = 0,14p. 25
mp. 25
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 25
+Screw dimensionp. 25
Screw dimensionp. 25
+Tightening torques Nmp. 25
Tightening torques Nmp. 25
+8.8p. 25
8.8p. 25
+10.9p. 25
10.9p. 25
+12.9p. 25
12.9p. 25
+1/4“ – 20p. 25
1/4“ – 20p. 25
+11p. 25
11p. 25
+15p. 25
15p. 25
+19p. 25
19p. 25
+5/16“ – 18p. 25
5/16“ – 18p. 25
+23p. 25
23p. 25
+32p. 25
32p. 25
+39p. 25
39p. 25
+3/8“ – 16p. 25
3/8“ – 16p. 25
+39p. 25
39p. 25
+55p. 25
55p. 25
+66p. 25
66p. 25
+7/16“ – 14p. 25
7/16“ – 14p. 25
+62p. 25
62p. 25
+87p. 25
87p. 25
+105p. 25
105p. 25
+1/2“ – 13p. 25
1/2“ – 13p. 25
+96p. 25
96p. 25
+135p. 25
135p. 25
+160p. 25
160p. 25
+9/16“ – 12p. 25
9/16“ – 12p. 25
+140p. 25
140p. 25
+200p. 25
200p. 25
+235p. 25
235p. 25
+5/8“ – 11p. 25
5/8“ – 11p. 25
+195p. 25
195p. 25
+275p. 25
275p. 25
+330p. 25
330p. 25
+3/4“ – 10p. 25
3/4“ – 10p. 25
+345p. 25
345p. 25
+485p. 25
485p. 25
+580p. 25
580p. 25
+7/8“ – 9p. 25
7/8“ – 9p. 25
+560p. 25
560p. 25
+770p. 25
770p. 25
+940p. 25
940p. 25
+1“ – 8p. 25
1“ – 8p. 25
+850p. 25
850p. 25
+1200p. 25
1200p. 25
+1450p. 25
1450p. 25
+1 1/8“ – 7p. 25
1 1/8“ – 7p. 25
+1200p. 25
1200p. 25
+1700p. 25
1700p. 25
+2000p. 25
2000p. 25
+1 1/4“ – 7p. 25
1 1/4“ – 7p. 25
+1700p. 25
1700p. 25
+2400p. 25
2400p. 25
+2900p. 25
2900p. 25
+1 3/8“ – 6p. 25
1 3/8“ – 6p. 25
+2200p. 25
2200p. 25
+3100p. 25
3100p. 25
+3700p. 25
3700p. 25
+1 1/2“ – 6p. 25
1 1/2“ – 6p. 25
+3000p. 25
3000p. 25
+4200p. 25
4200p. 25
+5100p. 25
5100p. 25
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 25
+Tightening torques for screws with UNF thread,p. 25
+Tightening torques for screws with UNF thread,p. 25
+Coefficient of friction m tot. = 0,14p. 26
mp. 26
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 25
+Screw dimensionp. 25
Screw dimensionp. 25
+Tightening torques Nmp. 25
Tightening torques Nmp. 25
+8.8p. 25
8.8p. 25
+10.9p. 25
10.9p. 25
+12.9p. 25
12.9p. 25
+1/4“ – 28p. 25
1/4“ – 28p. 25
+13p. 25
13p. 25
+18p. 25
18p. 25
+22p. 25
22p. 25
+5/16“ – 24p. 25
5/16“ – 24p. 25
+25p. 25
25p. 25
+35p. 25
35p. 25
+42p. 25
42p. 25
+3/8“ – 24p. 25
3/8“ – 24p. 25
+45p. 25
45p. 25
+63p. 25
63p. 25
+76p. 25
76p. 25
+7/16“ – 20p. 25
7/16“ – 20p. 25
+70p. 25
70p. 25
+100p. 25
100p. 25
+120p. 25
120p. 25
+1/2“ – 20p. 25
1/2“ – 20p. 25
+110p. 25
110p. 25
+155p. 25
155p. 25
+185p. 25
185p. 25
+9/16“ – 18p. 25
9/16“ – 18p. 25
+155p. 25
155p. 25
+220p. 25
220p. 25
+260p. 25
260p. 25
+5/8“ – 18p. 25
5/8“ – 18p. 25
+220p. 25
220p. 25
+310p. 25
310p. 25
+370p. 25
370p. 25
+3/4“ – 16p. 25
3/4“ – 16p. 25
+385p. 25
385p. 25
+540p. 25
540p. 25
+650p. 25
650p. 25
+7/8“ -14p. 25
7/8“ -14p. 25
+620p. 25
620p. 25
+870p. 25
870p. 25
+1050p. 25
1050p. 25
+1“ – 12p. 26
1“ – 12p. 26
+930p. 26
930p. 26
+1300p. 26
1300p. 26
+1600p. 26
1600p. 26
+1 1/8“ – 12p. 26
1 1/8“ – 12p. 26
+1350p. 26
1350p. 26
+1900p. 26
1900p. 26
+2300p. 26
2300p. 26
+1 1/4“ – 12p. 26
1 1/4“ – 12p. 26
+1900p. 26
1900p. 26
+2700p. 26
2700p. 26
+3200p. 26
3200p. 26
+1 3/8“ – 12p. 26
1 3/8“ – 12p. 26
+2600p. 26
2600p. 26
+3700p. 26
3700p. 26
+4400p. 26
4400p. 26
+1 1/2“ – 12p. 26
1 1/2“ – 12p. 26
+3300p. 26
3300p. 26
+4600p. 26
4600p. 26
+5600p. 26
5600p. 26
+2 Technical datap. 27
2 Technical datap. 27
Technical datap. 28
Fig. 12p. 28
+Dimensions in mmp. 28
Dimensions in mmp. 28
+Ap. 28
Ap. 28
+Bp. 28
Bp. 28
+Hp. 28
Hp. 28
+H2p. 28
+Hp. 28
2p. 28
+Kp. 28
Kp. 28
+Lp. 28
Lp. 28
+Wp. 28
Wp. 28
+BF 300 C, S340p. 28
BF 300 C, S340p. 28
+2200p. 28
2200p. 28
+1740p. 28
1740p. 28
+3350p. 28
3350p. 28
+2700p. 28
2700p. 28
+170p. 28
170p. 28
+4950p. 28
4950p. 28
+1700p. 28
1700p. 28
+The right for technical modifications remains reservedp. 28
The right for technical modifications remains reservedp. 29
+At a pressure of (166. bar, the valve seat must be fuel leak tightp. 30
At a pressure of (166. bar, the valve seat must be fuel leak tightp. 30
+Travel pumpsp. 30
Travel pumpsp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bosch-Rexrothp. 30
Bosch-Rexrothp. 30
+Typep. 30
Typep. 30
+A10VGp. 30
A10VGp. 30
+Quantityp. 30
Quantityp. 30
+2p. 30
2p. 30
+Systemp. 30
Systemp. 30
+Axial piston/swash platep. 30
Axial piston/swash platep. 30
+Max. displacementp. 30
Max. displacementp. 30
+cm3/revp. 30
+cmp. 30
3p. 30
+28p. 30
28p. 30
+Max. flow capacityp. 30
Max. flow capacityp. 30
+l/minp. 30
l/minp. 30
+109p. 30
109p. 30
+Maximum pressurep. 30
Maximum pressurep. 30
+barp. 30
barp. 30
+370 – 390p. 30
370 – 390p. 30
+Charge pressurep. 30
Charge pressurep. 30
+barp. 30
barp. 30
+24 – 26p. 30
24 – 26p. 30
+High pressure limitationp. 30
High pressure limitationp. 30
+Pressure override valvep. 30
Pressure override valvep. 30
+Travel motorsp. 30
Travel motorsp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bosch-Rexrothp. 30
Bosch-Rexrothp. 30
+Typep. 30
Typep. 30
+A6VEp. 30
A6VEp. 30
+Quantityp. 30
Quantityp. 30
+2p. 30
2p. 30
+Systemp. 30
Systemp. 30
+Axial piston/bent axlep. 30
Axial piston/bent axlep. 30
+Max. displacement (stage 1)p. 30
Max. displacement (stage 1)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+28.1p. 30
28.1p. 30
+Min. displacement (stage 2)p. 30
Min. displacement (stage 2)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+0p. 30
0p. 30
+Travel gearp. 30
Travel gearp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bonfigliolip. 30
Bonfigliolip. 30
+Typep. 30
Typep. 30
+705 Cp. 30
705 Cp. 30
+Systemp. 30
Systemp. 30
+Planetary gear with integrated brakep. 30
Planetary gear with integrated brakep. 30
+Reduction ratiop. 30
Reduction ratiop. 30
+1:80p. 30
1:80p. 30
+Quantityp. 30
Quantityp. 30
+2p. 30
2p. 30
+Continuous torquep. 30
Continuous torquep. 30
+Nmp. 30
Nmp. 30
+6000p. 30
6000p. 30
+Maximum torquep. 30
Maximum torquep. 30
+Nmp. 30
Nmp. 30
+13500p. 30
13500p. 30
+Maximum input speedp. 30
Maximum input speedp. 30
+rpmp. 30
rpmp. 30
+5600p. 30
5600p. 30
+Brake: Brake torquep. 30
+Brake: Brake torquep. 30
Brake:p. 30
+Nmp. 30
Nmp. 30
+180-220p. 30
180-220p. 30
+Brake releasing pressurep. 30
Brake releasing pressurep. 30
+barp. 30
barp. 30
+24 – 26p. 30
24 – 26p. 30
+Service pumpp. 30
Service pumpp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bosch-Rexrothp. 30
Bosch-Rexrothp. 30
+Typep. 30
Typep. 30
+A10VOp. 30
A10VOp. 30
+Systemp. 30
Systemp. 30
+Gear pumpp. 30
Gear pumpp. 30
+Quantityp. 30
Quantityp. 30
+1p. 30
1p. 30
+Displacementp. 30
Displacementp. 30
+cm3/revp. 30
+cmp. 30
3p. 30
+190p. 30
190p. 30
+Fastening flangep. 30
Fastening flangep. 30
+SAE A 2-holep. 30
SAE A 2-holep. 30
+Nominal pressurep. 30
Nominal pressurep. 30
+barp. 30
barp. 30
+276p. 30
276p. 30
+Maximum speedp. 30
Maximum speedp. 30
+rpmp. 30
rpmp. 30
+3000p. 30
3000p. 30
+Pump –> tamper and vibration (stage 1)p. 30
Pump –> tamper and vibration (stage 1)p. 30
+Manufacturerp. 30
Manufacturerp. 30
+Haldexp. 30
Haldexp. 30
+Typep. 30
Typep. 30
+WP09p. 30
WP09p. 30
+Systemp. 30
Systemp. 30
+Gear pumpp. 30
Gear pumpp. 30
+Quantityp. 30
Quantityp. 30
+1p. 30
1p. 30
+Displacementp. 30
Displacementp. 30
+cm3/revp. 30
+cmp. 30
3p. 30
+190p. 30
190p. 30
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+276p. 31
276p. 31
+Maximum speedp. 31
Maximum speedp. 31
+rpmp. 31
rpmp. 31
+3000p. 31
3000p. 31
+Tamper motorp. 31
Tamper motorp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+SNM2p. 31
SNM2p. 31
+Systemp. 31
Systemp. 31
+Gear motorp. 31
Gear motorp. 31
+Displacementp. 31
Displacementp. 31
+cm3/Up. 31
+cmp. 31
3p. 31
+14.4p. 31
14.4p. 31
+Maximum pressurep. 31
Maximum pressurep. 31
+barp. 31
barp. 31
+280p. 31
280p. 31
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+250p. 31
250p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+1800 – 2000p. 31
1800 – 2000p. 31
+Vibration motorp. 31
Vibration motorp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+SNM2p. 31
SNM2p. 31
+Systemp. 31
Systemp. 31
+Gear motorp. 31
Gear motorp. 31
+Displacementp. 31
Displacementp. 31
+cm3/Up. 31
+cmp. 31
3p. 31
+8.4p. 31
8.4p. 31
+Maximum pressurep. 31
Maximum pressurep. 31
+barp. 31
barp. 31
+280p. 31
280p. 31
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+250p. 31
250p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+2650 – 2850p. 31
2650 – 2850p. 31
+Pump –> auger drive left (stage 2)p. 31
Pump –> auger drive left (stage 2)p. 31
+Manufacturerp. 31
Manufacturerp. 31
+Haldexp. 31
Haldexp. 31
+Typep. 31
Typep. 31
+WP09p. 31
WP09p. 31
+Systemp. 31
Systemp. 31
+Gear pumpp. 31
Gear pumpp. 31
+Quantityp. 31
Quantityp. 31
+1p. 31
1p. 31
+Displacementp. 31
Displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+80p. 31
80p. 31
+Pressurep. 31
Pressurep. 31
+barp. 31
barp. 31
+230 – 250p. 31
230 – 250p. 31
+Maximum speedp. 31
Maximum speedp. 31
+rpmp. 31
rpmp. 31
+4000p. 31
4000p. 31
+Motor for augersp. 31
Motor for augersp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+OMS 160p. 31
OMS 160p. 31
+Systemp. 31
Systemp. 31
+Orbital motorp. 31
Orbital motorp. 31
+Max. displacement.p. 31
Max. displacement.p. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+160p. 31
160p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+80 – 84p. 31
80 – 84p. 31
+Quantityp. 31
Quantityp. 31
+2p. 31
2p. 31
+Pump 3-stage (drive of right auger, as well as conveyor belt left & right)p. 31
Pump 3-stage (drive of right auger, as well as conveyor belt left & right)p. 31
+Manufacturerp. 31
Manufacturerp. 31
+Haldexp. 31
Haldexp. 31
+Typep. 31
Typep. 31
+WP09p. 31
WP09p. 31
+Systemp. 31
Systemp. 31
+Gear pumpp. 31
Gear pumpp. 31
+Quantityp. 31
Quantityp. 31
+1p. 31
1p. 31
+Displacementp. 31
Displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+80p. 31
80p. 31
+Pressurep. 31
Pressurep. 31
+barp. 31
barp. 31
+230 – 250p. 31
230 – 250p. 31
+Maximum speedp. 31
Maximum speedp. 31
+rpmp. 31
rpmp. 31
+4000p. 31
4000p. 31
+Scraper belt motorsp. 31
Scraper belt motorsp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+OMS 160p. 31
OMS 160p. 31
+Systemp. 31
Systemp. 31
+Orbital motorp. 31
Orbital motorp. 31
+Max. displacement.p. 32
Max. displacement.p. 32
+cm3/revp. 32
+cmp. 32
3p. 32
+160p. 32
160p. 32
+Rated speedp. 32
Rated speedp. 32
+rpmp. 32
rpmp. 32
+60 – 64p. 32
60 – 64p. 32
+Quantityp. 32
Quantityp. 32
+2p. 32
2p. 32
+Pump for cleaning kitp. 32
Pump for cleaning kitp. 32
+Manufacturerp. 32
Manufacturerp. 32
+Flowjetp. 32
Flowjetp. 32
+Typep. 32
Typep. 32
+Duplex 2 seriesp. 32
Duplex 2 seriesp. 32
+Systemp. 32
Systemp. 32
+Dual piston pumpp. 32
Dual piston pumpp. 32
+Quantityp. 32
Quantityp. 32
+1p. 32
1p. 32
+Displacement (high pressure variant)p. 32
Displacement (high pressure variant)p. 32
+l/minp. 32
l/minp. 32
+8.32p. 32
8.32p. 32
+Displacement (medium and low pressure variant)p. 32
Displacement (medium and low pressure variant)p. 32
+l/minp. 32
l/minp. 32
+6.05p. 32
6.05p. 32
+Maximum pressurep. 32
Maximum pressurep. 32
+barp. 32
barp. 32
+6.8p. 32
6.8p. 32
The following noise and vibration data acc. top. 33
– EC Machine Regulation edition 2006/42/ECp. 33
– the noise regulation 2000/14/EG, noise protection guideline 2003/10/ECp. 33
– Vibration Protection Regulation 2002/44/ECp. 33
were determined during conditions typical for this type of equipment and by application of harmonized standards.p. 33
During operation these values may vary because of the existing operating conditions.p. 33
+Noise valuep. 33
Noise valuep. 33
Sound pressure level on the place of the operator:p. 33
+Lp. 33
pAp. 33
Guaranteed sound power level:p. 33
+Lp. 33
WAp. 33
+Wear your personal noise protection means (ear defenders) before starting operation.p. 33
Wear your personal noise protection means (ear defenders) before starting operation.p. 33
+Vibration valuep. 33
Vibration valuep. 33
Vibration of the entire body (driver’s seat)p. 33
+The weighted effective acceleration value determined acc. to ISO 7096, isp. 33
£p. 33
2p. 33
Hand-arm vibration valuesp. 33
+The weighted effective acceleration value, determined acc. to EN 500/ISO 5349, isp. 33
£p. 33
2p. 33
+3 Maintenancep. 35
3 Maintenancep. 35
+3.1 General notes on maintenancep. 36
3.1 General notes on maintenancep. 36
+When performing maintenance work always comply with the appropriate safety regulations.p. 36
When performing maintenance work always comply with the appropriate safety regulations.p. 36
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. 36
The terms right/left correspond with travel direction forward.p. 36
+l Always clean machine and engine thoroughly before starting maintenance work.p. 36
l Always clean machine and engine thoroughly before starting maintenance work.p. 36
l Do not touch hot engine parts.p. 36
l For maintenance work stand the machine on level ground.p. 36
l Always remove the main battery switch for all maintenance work.p. 36
l Perform maintenance work only with the engine shut down.p. 36
l Relieve hydraulic pressures before working on hydraulic lines.p. 36
l Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 36
+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. 36
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. 36
Keep used filters in a separate waste container and dispose of environmentally.p. 36
Catch biodegradable oils separately.p. 36
+Notes on the fuel systemp. 36
Notes on the fuel systemp. 36
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 36
+l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 36
l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 36
l Drums with inside zinc lining are not suitable to store fuel.p. 36
l When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.p. 36
l Do not let the hose stir up the slurry at the bottom of the drum.p. 36
l The fuel drum must rest for a longer period of time before drawing off fuel.p. 36
l The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 36
+Notes on the performance of the enginep. 36
Notes on the performance of the enginep. 36
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. 36
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. 36
+Notes on the cooling systemp. 36
Notes on the cooling systemp. 36
Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 36
The coolant is prepared by mixing a cooling system protection agent (ethylene glycol) into the coolant.p. 36
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. 36
+Notes on the hydraulic systemp. 36
Notes on the hydraulic systemp. 36
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. 36
+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. 36
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. 36
l Seal external leaks immediately. If necessary inform the responsible customer service.p. 36
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. 36
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. 36
l Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 36
l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 36
+3.2 Fuels and lubricantsp. 37
3.2 Fuels and lubricantsp. 37
+Engine oilp. 37
Engine oilp. 37
Qualityp. 37
Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used.p. 37
+Only engine oils of APIp. 37
American Petroleum Institutep. 37
+Engine oils of API-classification CF-4, CG-4 and CH-4 must not be used.p. 37
Engine oils of API-classification CF-4, CG-4 and CH-4 must not be used.p. 37
Oil viscosityp. 37
Multi-purpose oils should be generally used.p. 37
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. 37
Optimal operating conditions can be achieved by using the following oil viscosity chart as a reference.p. 37
+Ambient temperaturep. 37
+Ambient temperaturep. 37
Ambient temperaturep. 37
+Viscosityp. 37
+Viscosityp. 37
Viscosityp. 37
+over 25 °C!p. 37
over 25 °C!p. 37
+SAE 30p. 37
SAE 30p. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
+0°C to 25°Cp. 37
0°C to 25°Cp. 37
+SAE 20p. 37
SAE 20p. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
+below 0 °Cp. 37
below 0 °Cp. 37
+SAE 10Wp. 37
SAE 10Wp. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
Oil change intervalsp. 37
The longest permissible time lubrication oil should remain in an engine is 1 year.p. 37
If the 500 operating hours are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.p. 37
+Fuelsp. 37
Fuelsp. 37
Qualityp. 37
Cetan index number: The recommended minimum index number for the Cetan value is 45. A Cetan index number higher than 50 should preferably be used, especially at ambient temperatures below -20°C (-4 °F) and when working at altitudes of 1500 m (5000 …p. 37
Diesel fuel specifications: With respect to the percentage (ppm) of sulphur the fuel used in the engine must comply with all relevant exhaust emission regulations in the are of use of the engine.p. 37
It is highly recommended to use a fuel with a sulphur content of less than 0,10% (1000 ppm).p. 37
When using a diesel fuel with a high sulphur content of 0.50% (5000 ppm) to 1.0% (10.000 ppm), the engine oil change intervals must be halved.p. 37
+Do not use any fuels with a sulphur content of more than 1,0% (10000ppm).p. 37
Do not use any fuels with a sulphur content of more than 1,0% (10000ppm).p. 37
It is recommended to use diesel fuel that complies with the specifications EN590 or ASTM D975.p. 37
Diesel fuel with the designation no. 2-D is a distillate fuel with low volatility, which is especially suitable for industrial engines and heavy-duty commercial vehicles (SAE J313 JUN87).p. 37
+Since this engine complies with the exhaust gas standard acc. to EPAp. 37
United States Environmental Protection Agencyp. 37
In order to fulfil these requirements you should, as an alternative to no. 2-D, also use diesel fuel no. 2-D S500 or S15; with ambient temperatures below -10°C (+14 °F) the diesel fuel no. 1-D S500 or S15 should be used for no. 1-D.p. 37
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. 37
Winter fuelp. 37
+Fire hazard!p. 37
Fire hazard!p. 37
Diesel fuels must never be mixed with gasoline.p. 37
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.p. 37
+Coolantp. 37
Coolantp. 37
Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1.p. 37
Under particularly extreme temperature conditions you should consult the service representation of the engine manufacturer with respect to the anti-freeze agent to be used.p. 37
There are various types of anti-freeze agents available. For this engine you should use ethylene glycol.p. 38
Before filling in the coolant mixed with anti-freeze agent the radiator must be flushed with clean water. This procedure should be repeated two to three times to clean the inside of radiator and engine block.p. 38
Mixing the anti-freeze agent: Prepare a mixture of 50 % anti-freeze agent and 50 % low mineral, clean water. Stirr well before filling it into the radiator. The method for mixing water and anti-freeze agent depends on the brand of the anti-freeze age…p. 38
Add anti-freeze agent: If the coolant level drops because of evaporation,only clean water is to be used for topping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio.p. 38
+Do not mix different coolants and additives of any other kind.p. 38
Do not mix different coolants and additives of any other kind.p. 38
Do not use any radiator cleaning agent after the anti- freeze agent has been mixed in. The anti-freeze agent also contains a corrosion protection agent. If this mixes with cleaning agent it may cause the development of sludge, which could damage the …p. 38
Anti-freeze concentrationp. 38
+50%p. 38
50%p. 38
-37 °Cp. 38
+Coolant must be disposed of environmentally.p. 38
Coolant must be disposed of environmentally.p. 38
+Mineral oil based hydraulic oilp. 38
Mineral oil based hydraulic oilp. 38
+The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mmp. 38
2p. 38
2p. 38
+Gear oilp. 38
Gear oilp. 38
+For the gearboxes use only ,ulti-purpose gear oils ISO VG 220 of API-GL5-class with a minimum viscosity of 20 mmp. 38
2p. 38
This is a hypoid lubricant of highest quality class for extremely loaded transmissions.p. 38
The additives in this oil ensure low wear lubrication under all operating conditions.p. 38
+Lubrication greasep. 38
Lubrication greasep. 38
For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G.p. 38
3.3 Table of fuels and lubricantsp. 39
+Assemblyp. 39
Assemblyp. 39
+Fuel or lubricantp. 39
Fuel or lubricantp. 39
+Quantityp. 39
Quantityp. 39
+Summerp. 39
Summerp. 39
+Winterp. 39
Winterp. 39
+Attentionp. 39
+Attentionp. 39
Attentionp. 39
Observe the level marksp. 39
+Motorp. 39
Motorp. 39
+– Engine oilp. 39
– Engine oilp. 39
+Engine oil API: CF or CI-4p. 39
Engine oil API: CF or CI-4p. 39
+approx. 11.2 litresp. 39
approx. 11.2 litresp. 39
+SAE 10W-40 (-20 °C to +40 °C)p. 39
SAE 10W-40 (-20 °C to +40 °C)p. 39
(BOMAG 009 920 06; 20 l)p. 39
+SAE 10W-30 (-15 °C to +30 °C)p. 39
SAE 10W-30 (-15 °C to +30 °C)p. 39
+SAE 15W-40 (-15 °C to + 40 °C)p. 39
SAE 15W-40 (-15 °C to + 40 °C)p. 39
+SAE 30 (+5 °C to +30 °C)p. 39
SAE 30 (+5 °C to +30 °C)p. 39
+SAE 10 (-30 °C to -5 °C)p. 39
SAE 10 (-30 °C to -5 °C)p. 39
+– Fuelp. 39
– Fuelp. 39
+Dieselp. 39
Dieselp. 39
+Winter diesel fuelp. 39
Winter diesel fuelp. 39
+approx. 100 litresp. 39
approx. 100 litresp. 39
+– Coolantp. 39
– Coolantp. 39
+Mixture of water and anti-freeze agentp. 39
Mixture of water and anti-freeze agentp. 39
(BOMAG 009 940 08; 20 l)p. 39
(Specification see "Fuels and lubricants – coolant")p. 39
+approx. 14 litresp. 39
approx. 14 litresp. 39
+Hydraulic systemp. 39
Hydraulic systemp. 39
+Hydraulic oil (ISO), HLP 46p. 39
Hydraulic oil (ISO), HLP 46p. 39
(BOMAG PN 009 930 09; 20 l) or ester based biodegradable hydraulic oilp. 39
+approx. 80 litresp. 39
approx. 80 litresp. 39
+Crawler track drive gearp. 39
Crawler track drive gearp. 39
+Gear oil SAE 80W-140, API GL-5p. 39
Gear oil SAE 80W-140, API GL-5p. 39
(BOMAG 009 925 07; 20 l)p. 39
+approx. 3.2 l eachp. 39
approx. 3.2 l eachp. 39
+Lubrication points, generalp. 39
Lubrication points, generalp. 39
+High pressure grease (lithium saponified)p. 39
High pressure grease (lithium saponified)p. 39
+as requiredp. 39
as requiredp. 39
3.4 Running-in instructionsp. 40
+The following maintenance work must be performed when running in new machines or overhauled engines:p. 40
The following maintenance work must be performed when running in new machines or overhauled engines:p. 40
+Up to approx. 250 operating hours check the engine oil level twice every day.p. 40
Up to approx. 250 operating hours check the engine oil level twice every day.p. 40
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. 40
After a running-in time of 30 minutesp. 40
+l Retighten the V-beltp. 40
l Retighten the V-beltp. 40
After 50 operating hoursp. 40
+l Change engine oil and oil filter cartridgep. 40
l Change engine oil and oil filter cartridgep. 40
l Check the tension of the fan V-beltp. 40
l Grease the auger drive chainp. 40
l Hopper, check scrapers and rubber apronp. 40
After 250 operating hoursp. 40
+l Tighten all bolted connections on air intake, exhaust, oil sump and engine mountsp. 40
l Tighten all bolted connections on air intake, exhaust, oil sump and engine mountsp. 40
l Retighten the bolted connections on the machine.p. 40
l Grease the auger drive chainp. 40
l Hopper, check scrapers and rubber apronp. 40
l Oil change in track drive gearp. 40
3.5 Maintenance tablep. 41
+No.p. 41
No.p. 41
+Maintenance workp. 41
Maintenance workp. 41
+Commentp. 41
Commentp. 41
+every 10 operating hours, dailyp. 41
every 10 operating hours, dailyp. 41
+every 50 oper. hoursp. 41
every 50 oper. hoursp. 41
+every 250 oper. hoursp. 41
every 250 oper. hoursp. 41
+every 500 oper. hoursp. 41
every 500 oper. hoursp. 41
+every 1000 oper. hoursp. 41
every 1000 oper. hoursp. 41
+every 2000 oper. hoursp. 41
every 2000 oper. hoursp. 41
+every 3000 oper. hoursp. 41
every 3000 oper. hoursp. 41
+as requiredp. 41
as requiredp. 41
+5.6p. 41
5.6p. 41
+Checking the engine oil levelp. 41
Checking the engine oil levelp. 41
+Dipstick markp. 41
Dipstick markp. 41
+Xp. 41
Xp. 41
+5.7p. 41
5.7p. 41
+Check the fuel levelp. 41
Check the fuel levelp. 41
+Instrument clusterp. 41
Instrument clusterp. 41
+Xp. 41
Xp. 41
+5.8p. 41
5.8p. 41
+Check the coolant levelp. 41
Check the coolant levelp. 41
+Xp. 41
Xp. 41
+5.9p. 41
5.9p. 41
+Check the hydraulic oil levelp. 41
Check the hydraulic oil levelp. 41
+Inspection glassp. 41
Inspection glassp. 41
+Xp. 41
Xp. 41
+5.10p. 41
5.10p. 41
+Lubricate the machinep. 41
Lubricate the machinep. 41
+Xp. 41
Xp. 41
+5.11p. 41
5.11p. 41
+Check fuel lines and clampsp. 41
Check fuel lines and clampsp. 41
+Xp. 41
Xp. 41
+5.12p. 41
5.12p. 41
+Service the generator V-beltp. 41
Service the generator V-beltp. 41
+Xp. 41
Xp. 41
+5.13p. 41
5.13p. 41
+Check the radiator hoses and hose clampsp. 41
Check the radiator hoses and hose clampsp. 41
+Xp. 41
Xp. 41
+5.14p. 41
5.14p. 41
+Service the scraper beltp. 41
Service the scraper beltp. 41
+Xp. 41
Xp. 41
+5.15p. 41
5.15p. 41
+Service the scraper belt drive chainp. 41
Service the scraper belt drive chainp. 41
+Xp. 41
Xp. 41
+5.16p. 41
5.16p. 41
+Service the augerp. 41
Service the augerp. 41
+Xp. 41
Xp. 41
+5.17p. 41
5.17p. 41
+Grease the gliding surface of the screed mobile sectionp. 41
Grease the gliding surface of the screed mobile sectionp. 41
+Xp. 41
Xp. 41
+5.18p. 41
5.18p. 41
+Lubricate the machinep. 41
Lubricate the machinep. 41
+Xp. 41
Xp. 41
+5.19p. 41
5.19p. 41
+Check the central lubrication system, top upp. 41
Check the central lubrication system, top upp. 41
+Xp. 41
Xp. 41
+5.20p. 41
5.20p. 41
+Clean the cooling fins on engine and hydraulic oil coolerp. 41
Clean the cooling fins on engine and hydraulic oil coolerp. 41
+Xp. 41
Xp. 41
+5.21p. 41
5.21p. 41
+Check the oil level in track drive gearp. 41
Check the oil level in track drive gearp. 41
+Xp. 41
Xp. 41
+5.22p. 41
5.22p. 41
+Service the battery, check the main battery switchp. 41
Service the battery, check the main battery switchp. 41
+pole greasep. 41
pole greasep. 41
+Xp. 41
Xp. 41
+5.23p. 41
5.23p. 41
+Checking the condition and tension of the screed heating generator V-belt, tensioning and if necessary replacing the V-beltp. 41
Checking the condition and tension of the screed heating generator V-belt, tensioning and if necessary replacing the V-beltp. 41
+Xp. 41
Xp. 41
+5.24p. 41
5.24p. 41
+Change engine oil and oil filter cartridgep. 41
+Change engine oil and oil filter cartridgep. 41
Running-in instructions: Oil change after 50 and 500 operating hours, then every 500 operating hoursp. 42
+min. 1x per yearp. 41
min. 1x per yearp. 41
see foot notep. 41
+Xp. 41
Xp. 41
+5.25p. 41
5.25p. 41
+Check the anti-freeze concentration and the condition of the coolantp. 41
Check the anti-freeze concentration and the condition of the coolantp. 41
+Xp. 41
Xp. 41
+5.26p. 41
5.26p. 41
+Replace the fuel filterp. 41
Replace the fuel filterp. 41
+Xp. 41
Xp. 41
+5.27p. 42
5.27p. 42
+Change the fuel filter, bleed the fuel systemp. 42
Change the fuel filter, bleed the fuel systemp. 42
+Xp. 42
Xp. 42
+5.28p. 42
5.28p. 42
+Drain the fuel tank sludgep. 42
Drain the fuel tank sludgep. 42
+Xp. 42
Xp. 42
+5.29p. 42
5.29p. 42
+Check track, track drivep. 42
Check track, track drivep. 42
+Xp. 42
Xp. 42
+5.30p. 42
5.30p. 42
+Check, adjust tamper bar and floor platesp. 42
Check, adjust tamper bar and floor platesp. 42
+Xp. 42
Xp. 42
+5.31p. 42
5.31p. 42
+Check, adjust the valve clearancep. 42
Check, adjust the valve clearancep. 42
+Intake and exhaust valve: 0.15 mmp. 42
Intake and exhaust valve: 0.15 mmp. 42
+Xp. 42
Xp. 42
+5.32p. 42
5.32p. 42
+Change hydraulic oil and filterp. 42
+Change hydraulic oil and filterp. 42
Also in case of repair in the hydraulic system.p. 42
+at least every 2 yearsp. 42
at least every 2 yearsp. 42
see foot notep. 42
+Xp. 42
Xp. 42
+5.33p. 42
5.33p. 42
+Check the engine mountsp. 42
Check the engine mountsp. 42
+Xp. 42
Xp. 42
+5.34p. 42
5.34p. 42
+Oil change in track drive gearp. 42
+Oil change in track drive gearp. 42
Running-in instructions: Oil change after 250 and 1000 operating hours, then every 1000 operating hoursp. 42
+see foot notep. 42
see foot notep. 42
+Xp. 42
Xp. 42
+5.35p. 42
5.35p. 42
+Checking hopper, scrapers and rubber apronp. 42
Checking hopper, scrapers and rubber apronp. 42
+Xp. 42
Xp. 42
+5.36p. 42
5.36p. 42
+Change the coolantp. 42
Change the coolantp. 42
+Xp. 42
Xp. 42
+5.37p. 42
5.37p. 42
+Check the fuel injection nozzlesp. 42
Check the fuel injection nozzlesp. 42
+only by authorized service personnelp. 42
only by authorized service personnelp. 42
+Xp. 42
Xp. 42
+5.38p. 42
5.38p. 42
+Check the turbo chargerp. 42
Check the turbo chargerp. 42
+only by authorized service personnelp. 42
only by authorized service personnelp. 42
+Xp. 42
Xp. 42
+5.39p. 42
5.39p. 42
+Check the fuel injection pumpp. 42
Check the fuel injection pumpp. 42
+only by authorized service personnelp. 42
only by authorized service personnelp. 42
+Xp. 42
Xp. 42
+5.40p. 42
5.40p. 42
+Air filter maintenancep. 42
Air filter maintenancep. 42
+at least 1x every year, safety cartridge at least every 2 yearsp. 42
at least 1x every year, safety cartridge at least every 2 yearsp. 42
+Xp. 42
Xp. 42
+5.41p. 42
5.41p. 42
+Check, clean the water separatorp. 42
Check, clean the water separatorp. 42
+Xp. 42
Xp. 42
+5.42p. 42
5.42p. 42
+Replace heating elementsp. 42
Replace heating elementsp. 42
+Xp. 42
Xp. 42
+5.43p. 42
5.43p. 42
+Preparing the machine for a longer restp. 42
Preparing the machine for a longer restp. 42
+Xp. 42
Xp. 42
+5.44p. 42
5.44p. 42
+Tightening torquesp. 42
Tightening torquesp. 42
+Xp. 42
Xp. 42
+4 E-Plan wiring diagramsp. 43
+4 E-Plan wiring diagramsp. 43
4.1 Understanding E-Plan circuit diagramsp. 44
+Electric circuit diagramsp. 44
Electric circuit diagramsp. 44
+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. 44
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. 44
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 44
+l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 44
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 44
l The sequence in which current flows through the individual elements in the electric circuit.p. 44
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.p. 44
l Pin assignment of plug-and-socket connections.p. 44
+Structure of a wiring diagramp. 44
Structure of a wiring diagramp. 44
+l Cover sheet, see section "Cover sheet"p. 44
l Cover sheet, see section "Cover sheet"p. 44
l Table of contents, see section "Table of contents"p. 44
l Structuring symbol overview, see section "Structuring symbol overview"p. 44
+The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 44
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 44
+l Sheets with illustration of function, see section"Sheets with illustration of function"p. 44
l Sheets with illustration of function, see section"Sheets with illustration of function"p. 44
l List of fuels and lubricants, see "List of fuels and lubricants"p. 44
l Terminal strip overview, see section "Terminal strip overview"p. 44
l Plug overview, see section "Plug overview"p. 44
l Pin overview, see section "Pin overview"p. 44
Cover sheetp. 45
+The cover sheet, see examplep. 45
(Fig. 13)p. 45
Fig. 13 Example: Cover sheetp. 45
Table of contentsp. 46
+The table of contents, see examplep. 46
(Fig. 14)p. 46
Fig. 14 Example: Table of contentsp. 46
Sheets with representations of functionsp. 47
+l The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 47
l The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 47
l All sheets are successively numbered.p. 47
+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. 47
(Fig. 15)p. 47
Fig. 15 Example: Sheet with functionsp. 47
+Current pathsp. 47
+Current pathsp. 47
(Fig. 15)p. 47
+l Current paths are successively numbered from 0 to 9.p. 47
l Current paths are successively numbered from 0 to 9.p. 47
+Potential cross referencesp. 47
+Potential cross referencesp. 47
(Fig. 15)p. 47
+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. 47
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. 47
+Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current path 1.p. 47
Example: Potential 15_54 +SEAT/16.1p. 47
+SEATp. 47
+Relay cross referencesp. 48
+Relay cross referencesp. 48
(Fig. 15)p. 48
+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. 48
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. 48
+Example: The relay cross-reference (p. 48
Example:p. 48
-K61/4.2p. 48
List of componentp. 49
+The list of components, see examplep. 49
(Fig. 16)p. 49
Fig. 16 Example: List of componentsp. 49
An electric component is a part, assembly or device in an electrical installation.p. 49
+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. 49
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. 49
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. 49
+Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 49
Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 49
Overview of terminal stripsp. 50
+The overview of terminal strips, see axamplep. 50
(Fig. 17)p. 50
Fig. 17 Example: Terminal strip overview X1p. 50
Overview of plugsp. 51
+The overview of plugs, see examplep. 51
(Fig. 18)p. 51
The following information is listed for each plug:p. 51
+l Contact numberingp. 51
l Contact numberingp. 51
l Structuring symbolsp. 51
l Function textp. 51
l Use in wiring diagram.p. 51
Fig. 18 Example: Plug overview X0p. 51
Overview of pinsp. 52
+The overview of pins, see examplep. 52
(Fig. 19)p. 52
Fig. 19 Example: Overview of pins, control A66p. 52
4.2 Circuit symbols in E-Planp. 53
+Circuit symbolp. 53
Circuit symbolp. 53
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. 53
Fig. 20 Example: Circuit symbolp. 53
+1 Current sourcep. 53
1 Current sourcep. 53
2 Conductorp. 53
3 Switchp. 53
4 Groundp. 53
5 Filament lampp. 53
6 Filament lamp with two luminous elementsp. 53
7 Voltmeterp. 53
8 Amperemeterp. 53
9 Resistancep. 53
10 Fusep. 53
11 Terminal stripp. 53
12 Plugp. 53
+Different symbols are used to simplify the differentiation of terminal strips 11p. 53
(Fig. 20)p. 53
+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. 53
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. 53
Representation of electric devicesp. 54
Electronic devices and components are increasingly used in the construction equipment industry. Controls with software, control elements (e.g. joystics and man / machine interfaces, such as e.g. screens, LC-Displays) are frequently used to represent …p. 54
+Black-Box representationp. 54
+Black-Box representationp. 54
(Fig. 21)p. 54
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. 54
The Blackbox representation is mainly used if there is no differentiated information (e.g. signals from pins) available from the sub-supplier.p. 54
Fig. 21 Example: Central lubrication systemp. 54
+Identification of externally supplied documentationp. 54
(Fig. 22)p. 54
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. 54
Fig. 22 Example: Identification of externally supplied documentationp. 54
+PLC representationp. 54
+PLC representationp. 54
(Fig. 23)p. 54
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. 54
Fig. 23 PLC representationp. 55
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. 55
Identification of similar, adjacent switching symbolsp. 55
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. 55
+Example: -X0 36 and -X0 37p. 55
(Fig. 23)p. 55
In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol.p. 55
4.3 Identification of switch blocks in the wiring diagramp. 56
+Switches of modular designp. 56
Switches of modular designp. 56
+l For normally open contacts the contact symbols "_3/_4" are used.p. 56
l For normally open contacts the contact symbols "_3/_4" are used.p. 56
l For normally closed contacts the contact symbols "_1/_2" are used.p. 56
In combination with the contact block numbering described above each individual connection is clearly defined.p. 56
Fig. 24p. 56
Example:p. 56
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. 56
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. 56
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. 56
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. 56
4.4 Designation of components in the wiring diagramp. 57
+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. 57
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. 57
Control lights, warning buzzer, warning lightp. 57
+Kp. 57
Kp. 57
+Relaysp. 57
Relaysp. 57
+Mp. 57
Mp. 57
+Starter, pumps, motorsp. 57
Starter, pumps, motorsp. 57
+Pp. 57
Pp. 57
+Operating hour meter, general gaugesp. 57
Operating hour meter, general gaugesp. 57
+Rp. 57
Rp. 57
+Transducers, resistorsp. 57
Transducers, resistorsp. 57
+Sp. 57
Sp. 57
+Switches, momentary contact switchesp. 57
Switches, momentary contact switchesp. 57
+Vp. 57
Vp. 57
+Diodep. 57
Diodep. 57
+Xp. 57
Xp. 57
+Terminalp. 57
Terminalp. 57
+Yp. 57
Yp. 57
+Solenoid valvesp. 57
Solenoid valvesp. 57
4.5 Terminal designations in wiring diagramp. 58
+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. 58
+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. 58
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. 58
+Terminal designationp. 58
Terminal designationp. 58
+Meaningp. 58
Meaningp. 58
+15p. 58
15p. 58
+Switch plus (after battery) : Output of ignition switchp. 58
Switch plus (after battery) : Output of ignition switchp. 58
+15ap. 58
15ap. 58
+Output from dropping resistor to ignition coil and starterp. 58
Output from dropping resistor to ignition coil and starterp. 58
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 58
Battery changeover relay 12V / 24V return line to battery 2 minusp. 58
+31bp. 58
31bp. 58
+Return line to battery minus or ground via switch or relay (switched minus)p. 58
Return line to battery minus or ground via switch or relay (switched minus)p. 58
+31cp. 58
31cp. 58
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 58
Battery changeover relay 12V / 24V return line to battery 1 minusp. 58
+49p. 58
49p. 58
+Input flasher relayp. 58
Input flasher relayp. 58
+49ap. 58
49ap. 58
+Output flasher relayp. 58
Output flasher relayp. 58
+49bp. 58
49bp. 58
+Flasher relay output 2nd flasher circuitp. 58
Flasher relay output 2nd flasher circuitp. 58
+49cp. 58
49cp. 58
+Flasher relay output 3rd flasher circuitp. 58
Flasher relay output 3rd flasher circuitp. 58
+50p. 58
50p. 58
+Starter, starter controlp. 58
Starter, starter controlp. 58
+50ap. 58
50ap. 58
+Battery changeover relay, output for starter controlp. 58
Battery changeover relay, output for starter controlp. 58
+53p. 58
53p. 58
+Wiper motor input (+)p. 58
Wiper motor input (+)p. 58
+53ap. 58
53ap. 58
+Wiper motor (+) end limit shut downp. 58
Wiper motor (+) end limit shut downp. 58
+53bp. 58
53bp. 58
+Wiper shunt windingp. 58
Wiper shunt windingp. 58
+56p. 58
56p. 58
+Head lightp. 58
Head lightp. 58
+56ap. 58
56ap. 58
+Head light, travel light and travel light controlp. 58
Head light, travel light and travel light controlp. 58
+56bp. 58
56bp. 58
+Head lights, dimmed head lightp. 58
Head lights, dimmed head lightp. 58
+56dp. 58
56dp. 58
+Head lights, flash lightp. 58
Head lights, flash lightp. 58
+57p. 58
57p. 58
+Parking light for motor cycles (abroad also for cars and trucks)p. 58
Parking light for motor cycles (abroad also for cars and trucks)p. 58
+57ap. 58
57ap. 58
+Parking lightp. 58
Parking lightp. 58
+57Lp. 58
57Lp. 58
+Parking light leftp. 58
Parking light leftp. 58
+57Rp. 58
57Rp. 58
+Parking light rightp. 58
Parking light rightp. 58
+58p. 58
58p. 58
+Side lights, tail light, number plate light, dashboard lightp. 58
Side lights, tail light, number plate light, dashboard lightp. 58
+58bp. 58
58bp. 58
+Tail light changeover for single axle trailersp. 58
Tail light changeover for single axle trailersp. 58
+58cp. 58
58cp. 58
+Trailer plug for single core wired and trailer fused tail lightp. 58
Trailer plug for single core wired and trailer fused tail lightp. 58
+58dp. 58
58dp. 58
+Adjustable dashboard light, tail light and side lightp. 58
Adjustable dashboard light, tail light and side lightp. 58
+58Lp. 58
58Lp. 58
+Side light, leftp. 58
Side light, leftp. 58
+58Rp. 58
58Rp. 58
+Side light, rightp. 58
Side light, rightp. 58
+61p. 58
61p. 58
+Generator controlp. 58
Generator controlp. 58
+75p. 58
75p. 58
+Radio, cigarette lighterp. 58
Radio, cigarette lighterp. 58
+76p. 58
76p. 58
+Loudspeakerp. 58
Loudspeakerp. 58
+87p. 58
87p. 58
+Relay contact on breaker and two-way contact, inputp. 58
Relay contact on breaker and two-way contact, inputp. 58
+87ap. 59
87ap. 59
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 59
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 59
+87bp. 59
87bp. 59
+Relay contact on breaker and two-way contact, output 2p. 59
Relay contact on breaker and two-way contact, output 2p. 59
+87cp. 59
87cp. 59
+Relay contact on breaker and two-way contact, output 3p. 59
Relay contact on breaker and two-way contact, output 3p. 59
+87zp. 59
87zp. 59
+Relay contact on breaker and two-way contact, input 1p. 59
Relay contact on breaker and two-way contact, input 1p. 59
+87yp. 59
87yp. 59
+Relay contact on breaker and two-way contact, input 2p. 59
Relay contact on breaker and two-way contact, input 2p. 59
+87xp. 59
87xp. 59
+Relay contact on breaker and two-way contact, input 3p. 59
Relay contact on breaker and two-way contact, input 3p. 59
+88p. 59
88p. 59
+Relay contact for makerp. 59
Relay contact for makerp. 59
+88ap. 59
88ap. 59
+Relay contact on maker and two-way contact, (maker side) output 1p. 59
Relay contact on maker and two-way contact, (maker side) output 1p. 59
+88bp. 59
88bp. 59
+Relay contact on maker and two-way contact, (maker side) output 2p. 59
Relay contact on maker and two-way contact, (maker side) output 2p. 59
+88cp. 59
88cp. 59
+Relay contact on maker and two-way contact, (maker side) output 3p. 59
Relay contact on maker and two-way contact, (maker side) output 3p. 59
+88zp. 59
88zp. 59
+Relay contact on maker, input 1p. 59
Relay contact on maker, input 1p. 59
+88yp. 59
88yp. 59
+Relay contact on maker, input 2p. 59
Relay contact on maker, input 2p. 59
+88xp. 59
88xp. 59
+Relay contact on maker, input 3p. 59
Relay contact on maker, input 3p. 59
+B+p. 59
B+p. 59
+Battery positivep. 59
Battery positivep. 59
+B-p. 59
B-p. 59
+Battery minusp. 59
Battery minusp. 59
+D+p. 59
D+p. 59
+Dynamo Plusp. 59
Dynamo Plusp. 59
+D-p. 59
D-p. 59
+Dynamo Minusp. 59
Dynamo Minusp. 59
+DFp. 59
DFp. 59
+Dynamo field (generator excitation current)p. 59
Dynamo field (generator excitation current)p. 59
+DF1p. 59
DF1p. 59
+Dynamo field 1 (generator excitation current)p. 59
Dynamo field 1 (generator excitation current)p. 59
+DF2p. 59
DF2p. 59
+Dynamo field 2 (generator excitation current)p. 59
Dynamo field 2 (generator excitation current)p. 59
+5 Electricsp. 61
5 Electricsp. 61
ECOMODEp. 62
Fig. 1p. 62
The standard BOMAG ECOMODE ensures a clean environmental balance. Due to the active engine management power is made available for the driver when it is needed and is reduced again when permitted by the application. Intelligent sensors in connection w…p. 62
Fig. 2p. 63
+The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 63
+The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 63
The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 63
+The actuator M39 acts directly on the motor power leverp. 63
(Fig. 1)p. 63
+The motor is a permanently controlled DC-motor, which is triggered by the ESX-control A34 via the changeover relay K176 (1)p. 63
(Fig. 3)p. 63
The position of the drive axle is detected by an integrated potentiometer. The potentiometer is positively connected with the drive shaft of the control element and serves the purpose of feeding back the output shaft position.p. 63
The gearbox has been designed with three stages. Internal stops protect the gearbox against damage. The gear on the drive shaft is a toothed segment which determines the internal mechanical stops. The defined limitation of adjusting speed contributes…p. 63
Functional principle of ECO modep. 63
The ESX-control (A34) regulates the control command in dependence onp. 63
The following settings result in an increase in engine speed:p. 63
+l Switching on the screed heatingp. 63
l Switching on the screed heatingp. 63
l Activating the load functionp. 63
l Extending/retracting the extendable screed left/rightp. 63
l Manual operation of the scraper belt left/right in forwardp. 63
l Manual operation of the auger left/right in forwardp. 63
l Opening/closing the hopper wings left/right.p. 63
Fig. 3p. 64
Fig. 4p. 64
5.2 Glow plugs, R81-R84p. 65
+During the pre-heating and starting process the glow plugs are energized through relay K14.p. 65
During the pre-heating and starting process the glow plugs are energized through relay K14.p. 65
During the preheating process the control lamp is switched on for 10 seconds and switched off again when starting.p. 65
Fig. 5p. 65
+1 Glow plugsp. 65
1 Glow plugsp. 65
2 Glow plug cablep. 65
+l Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 65
Continuity testp. 65
+l Remove the glow plug.p. 65
l Remove the glow plug.p. 65
Fig. 6p. 65
+l Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 65
+l Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 65
l Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 65
+l If the measured value does not correspond with the factory specification, the glow plug (29p. 65
(Fig. 6)p. 65
+Factory specification for resistance approx. 0.95 Ohm in cold condition.p. 65
Factory specification for resistance approx. 0.95 Ohm in cold condition.p. 65
Assemblyp. 65
+Align the recess to the connecting side when assembling the seal (1)p. 65
+Align the recess to the connecting side when assembling the seal (1)p. 65
(Fig. 6)p. 65
Tightening torque: 7.7 to 9.3 Nm.p. 65
Speed sensors, B191 and B192
Fig. 1p. 66
+The BF300_p. 66
Cp. 66
5.4 Oil pressure switch (B06)p. 67
Fig. 1p. 67
The oil pressure switch is mounted on the cylinder block and is connected to the lubrication oil channel.p. 67
+l At a pressure of less than 0.4 bar the oil pressure switch switches to motor ground.p. 67
l At a pressure of less than 0.4 bar the oil pressure switch switches to motor ground.p. 67
Fig. 1p. 67
+n redp. 67
+n redp. 67
np. 67
Engine oil pressure too low, engine is shut down after 10 seconds.p. 67
5.5 Coolant temperature switch (B53)p. 67
Fig. 1p. 67
The temperature switch is arranged in the coolant circuit of the engine in such a way, that its tip is surrounded by coolant.p. 67
+l Should the engine overheat, the temperature switch will switch to engine ground.p. 67
l Should the engine overheat, the temperature switch will switch to engine ground.p. 67
Fig. 1p. 67
+b redp. 67
+b redp. 67
bp. 67
lights if engine overheats. After 8 seconds the warning buzzer will sound, vibration will be switched off and the travel speed reduced.p. 67
5.6 Air filter vacuum switch (B03)p. 68
Fig. 1 Vacuum switchp. 68
+l The vacuum switch 1p. 68
+l The vacuum switch 1p. 68
(Fig. 1)p. 68
Fig. 1p. 68
+a yellowp. 68
+a yellowp. 68
ap. 68
lights if combustion air filter cartridge is soiled, clean or replace if necessary.p. 68
5.7 Coolant float switch (B55)p. 68
Fig. 1p. 68
+l In case of a too low coolant level the float switch will switch to ground.p. 68
l In case of a too low coolant level the float switch will switch to ground.p. 68
Fig. 1p. 68
+o redp. 68
+o redp. 68
op. 68
flashes when the coolant (filling) level is too low. Engine is shut down after 10 seconds.p. 68
5.8 Charge control lightp. 69
Fig. 1p. 69
+l The control lamp lights up if a ground signal is applied to the generator terminal (L).p. 69
l The control lamp lights up if a ground signal is applied to the generator terminal (L).p. 69
Fig. 1p. 69
+p yellowp. 69
+p yellowp. 69
pp. 69
Charge control lamp, lights if the battery is not being charged. Check the V-belt, if necessary repair the generator.p. 69
5.9 Glow plugsp. 69
Fig. 1p. 69
During the preheating process the control lamp is switched on for 10 seconds and switched off again when starting.p. 69
Fig. 1p. 69
+l yellowp. 69
+l yellowp. 69
lp. 69
lights during preheating (for cold starting).p. 69
5.10 Water separator in fuel filter (B124))p. 70
Fig. 1p. 70
+l With water in the filter the sensor will switch to ground.p. 70
l With water in the filter the sensor will switch to ground.p. 70
Fig. 1p. 70
+k yellowp. 70
+k yellowp. 70
kp. 70
lights when the water proportion in the transparent section of the fuel pre-filter reaches the contacts.p. 70
5.11 Level sensor in diesel tank (R03)p. 70
Fig. 1p. 70
+l The analog level switch is a variable resistance to ground.p. 70
l The analog level switch is a variable resistance to ground.p. 70
Fig. 1p. 70
+sp. 70
+sp. 70
sp. 70
Fuel level gaugep. 70
Fig. 2p. 70
Main battery switchp. 70
+Position "I"p. 70
Position "I"p. 70
Normal position, operationp. 70
Position "II"p. 71
Separates batteries from the on- board electrics in case of cable fire and fire in the engine compartment as well as protection against unauthorized use.p. 71
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 71
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 71
5.12 Fusesp. 71
5.13 Fuse assignmentp. 72
+Fire hazard!p. 72
+Fire hazard!p. 72
Fire hazard!p. 72
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 72
+Central electricsp. 72
Central electricsp. 72
The central electrics is located on the right hand side under the driver's platform.p. 72
+l Slide the operator's platform to the left against the stop.p. 72
l Slide the operator's platform to the left against the stop.p. 72
l Remove the cover from the fuse box.p. 72
Fig. 3p. 72
+Terminalp. 72
Terminalp. 72
+Fusep. 72
Fusep. 72
+Amperagep. 72
Amperagep. 72
+Designationp. 72
Designationp. 72
+X1:1p. 72
X1:1p. 72
+F13p. 72
F13p. 72
+15 Ap. 72
15 Ap. 72
+Start switchp. 72
Start switchp. 72
+X1:2p. 72
X1:2p. 72
+F157p. 72
F157p. 72
+30 Ap. 72
30 Ap. 72
+Magnetic switch starterp. 72
Magnetic switch starterp. 72
+X1:4p. 72
X1:4p. 72
+F67p. 72
F67p. 72
+15 Ap. 72
15 Ap. 72
+Control, potential 30p. 72
Control, potential 30p. 72
+X1:5p. 72
X1:5p. 72
+not usedp. 72
not usedp. 72
+X1:6p. 72
X1:6p. 72
+F170p. 72
F170p. 72
+40 Ap. 72
40 Ap. 72
+Release of hydraulics and travel functionsp. 72
Release of hydraulics and travel functionsp. 72
+X1:10p. 72
X1:10p. 72
+not usedp. 72
not usedp. 72
+X1:11p. 72
X1:11p. 72
+not usedp. 72
not usedp. 72
+X1:12p. 72
X1:12p. 72
+F05p. 72
F05p. 72
+15 Ap. 72
15 Ap. 72
+Socketp. 72
Socketp. 72
+X1:13p. 72
X1:13p. 72
+F23p. 72
F23p. 72
+10 Ap. 72
10 Ap. 72
+Warning hornp. 72
Warning hornp. 72
+X1:14p. 72
X1:14p. 72
+F148p. 72
F148p. 72
+10 Ap. 72
10 Ap. 72
+Control, potential 15p. 72
Control, potential 15p. 72
+X1:15p. 72
X1:15p. 72
+F182p. 72
F182p. 72
+5 Ap. 72
5 Ap. 72
+Sensorsp. 72
Sensorsp. 72
+X1:16p. 72
X1:16p. 72
+F175p. 72
F175p. 72
+15 Ap. 72
15 Ap. 72
+Screed heating, potential 15p. 72
Screed heating, potential 15p. 72
+X1:17p. 72
X1:17p. 72
+not usedp. 72
not usedp. 72
+X1:18p. 72
X1:18p. 72
+not usedp. 72
not usedp. 72
+X1:19p. 72
X1:19p. 72
+not usedp. 72
not usedp. 72
+X1:20p. 72
X1:20p. 72
+F104p. 72
F104p. 72
+15 Ap. 72
15 Ap. 72
+Working head lights, frontp. 72
Working head lights, frontp. 72
+X1:21p. 72
X1:21p. 72
+F22p. 72
F22p. 72
+25 Ap. 72
25 Ap. 72
+Working head lights, rearp. 72
Working head lights, rearp. 72
+X1:22p. 72
X1:22p. 72
+F41p. 72
F41p. 72
+10 Ap. 72
10 Ap. 72
+Flashing beaconp. 72
Flashing beaconp. 72
+X1:23p. 73
X1:23p. 73
+F189p. 73
F189p. 73
+15 Ap. 73
15 Ap. 73
+Cleaning systemp. 73
Cleaning systemp. 73
+X1:24p. 73
X1:24p. 73
+F190p. 73
F190p. 73
+15 Ap. 73
15 Ap. 73
+Spraying systemp. 73
Spraying systemp. 73
+X1:25p. 73
X1:25p. 73
+F30p. 73
F30p. 73
+15 Ap. 73
15 Ap. 73
+Seat heatingp. 73
Seat heatingp. 73
+X1:26p. 73
X1:26p. 73
+F16p. 73
F16p. 73
+15 Ap. 73
15 Ap. 73
+Central lubrication systemp. 73
Central lubrication systemp. 73
+X1:27p. 73
X1:27p. 73
+F27p. 73
F27p. 73
+15 Ap. 73
15 Ap. 73
+Windscreen wiper/washerp. 73
Windscreen wiper/washerp. 73
+X1:30p. 73
X1:30p. 73
+F180p. 73
F180p. 73
+10 Ap. 73
10 Ap. 73
+Sensorsp. 73
Sensorsp. 73
+X1:31p. 73
X1:31p. 73
+F173p. 73
F173p. 73
+15 Ap. 73
15 Ap. 73
+Automatic functionsp. 73
Automatic functionsp. 73
+X1:32p. 73
X1:32p. 73
+F174p. 73
F174p. 73
+15 Ap. 73
15 Ap. 73
+Conveyor systemp. 73
Conveyor systemp. 73
+X1:33p. 73
X1:33p. 73
+F179p. 73
F179p. 73
+10 Ap. 73
10 Ap. 73
+Scraper beltp. 73
Scraper beltp. 73
+X1:34p. 73
X1:34p. 73
+F181p. 73
F181p. 73
+10 Ap. 73
10 Ap. 73
+Augerp. 73
Augerp. 73
+X1:35p. 73
X1:35p. 73
+F184p. 73
F184p. 73
+10 Ap. 73
10 Ap. 73
+Screed height adjustmentp. 73
Screed height adjustmentp. 73
+X1:36p. 73
X1:36p. 73
+F171p. 73
F171p. 73
+10 Ap. 73
10 Ap. 73
+Travel systemp. 73
Travel systemp. 73
+X1:37p. 73
X1:37p. 73
+F177p. 73
F177p. 73
+10 Ap. 73
10 Ap. 73
+Hopper wingsp. 73
Hopper wingsp. 73
+X1:38p. 73
X1:38p. 73
+F194p. 73
F194p. 73
+10 Ap. 73
10 Ap. 73
+Screed mobile sectionp. 73
Screed mobile sectionp. 73
+X1:39p. 73
X1:39p. 73
+F192p. 73
F192p. 73
+10 Ap. 73
10 Ap. 73
+Extraction of asphalt vapoursp. 73
Extraction of asphalt vapoursp. 73
+X1:40p. 73
X1:40p. 73
+F187p. 73
F187p. 73
+15 Ap. 73
15 Ap. 73
+Straight crossfalls/screedp. 73
Straight crossfalls/screedp. 73
Main fusesp. 74
The main fuses are located on the left hand side under the driver's platform.p. 74
+l Slide the operator's platform to the right against the stop.p. 74
l Slide the operator's platform to the right against the stop.p. 74
l Remove the cover from the fuse box.p. 74
Fig. 4p. 74
+Fusep. 74
Fusep. 74
+Amperagep. 74
Amperagep. 74
+Designationp. 74
Designationp. 74
+F00p. 74
F00p. 74
+125 Ap. 74
125 Ap. 74
+Main battery fusep. 74
Main battery fusep. 74
+F48p. 74
F48p. 74
+40 Ap. 74
40 Ap. 74
Preheating systemp. 74
+5.14 Component overviewp. 75
+5.14 Component overviewp. 75
Fig. 5p. 75
+Pos.p. 75
Pos.p. 75
+Descriptionp. 75
Descriptionp. 75
+1p. 75
1p. 75
+E-throttle actuatorp. 75
E-throttle actuatorp. 75
+2p. 75
2p. 75
+Charge pressure filterp. 75
Charge pressure filterp. 75
+3p. 75
3p. 75
+Main fusesp. 75
Main fusesp. 75
+4p. 75
4p. 75
+Batteriesp. 75
Batteriesp. 75
+5p. 75
5p. 75
+Control panel with switches, warning lights, potentiometers, travel lever and multi-function displaysp. 75
Control panel with switches, warning lights, potentiometers, travel lever and multi-function displaysp. 75
+6p. 75
6p. 75
+Brake releasing valvep. 75
Brake releasing valvep. 75
+7p. 75
7p. 75
+Generatorp. 75
Generatorp. 75
Fig. 6p. 76
+Pos.p. 76
Pos.p. 76
+Descriptionp. 76
Descriptionp. 76
+8p. 76
8p. 76
+Screed heating control panel and Load Control System (LCS)p. 76
Screed heating control panel and Load Control System (LCS)p. 76
+9p. 76
9p. 76
+Working hydraulics (valves, etc.)p. 76
Working hydraulics (valves, etc.)p. 76
+10p. 76
10p. 76
+Fuel pre-filterp. 76
Fuel pre-filterp. 76
+11p. 76
11p. 76
+Water separatorp. 76
Water separatorp. 76
+12p. 76
12p. 76
+Fuel pumpp. 76
Fuel pumpp. 76
+13p. 76
13p. 76
+Hydraulic oil tankp. 76
Hydraulic oil tankp. 76
+14p. 76
14p. 76
+Travel pumpsp. 76
Travel pumpsp. 76
+15p. 76
15p. 76
+Service pumpp. 76
Service pumpp. 76
+16p. 76
16p. 76
+Central electrics with fuse boxp. 76
Central electrics with fuse boxp. 76
+17p. 76
17p. 76
+Travel motorp. 76
Travel motorp. 76
+18p. 76
18p. 76
+Valve block for hydraulic crown adjustmentp. 76
Valve block for hydraulic crown adjustmentp. 76
+19p. 76
19p. 76
+Valve block for vibrationp. 76
Valve block for vibrationp. 76
+20p. 76
20p. 76
+Valve block for tampingp. 76
Valve block for tampingp. 76
+21p. 76
21p. 76
+Valve block to extend and retract the extendible screedp. 76
Valve block to extend and retract the extendible screedp. 76
+5.17 View of operator's standp. 78
Overview of wiring loomsp. 78
+1 Wiring loom, engine BF300p. 78
+1 Wiring loom, engine BF300p. 78
1 Wiring loom, engine BF300p. 78
1 Battery cable, red 35mmp. 79
+1 Battery cable, red 35mmp. 79
+1 Battery cable, red 35mmp. 79
+1 Battery cable, red 35mmp. 79
2p. 79
+2 Battery cable, black 70mmp. 79
2p. 79
+3 Battery cable, red 70mmp. 79
2p. 79
1 Wiring loom BF300 — pre-heating systemp. 80
+1 Wiring loom BF300 — pre-heating systemp. 80
+1 Wiring loom BF300 — pre-heating systemp. 80
1 Wiring loom BF300 — pre-heating systemp. 80
1 Battery cable, red 35mmp. 81
+1 Battery cable, red 35mmp. 81
+1 Battery cable, red 35mmp. 81
+1 Battery cable, red 35mmp. 81
2p. 81
+2 Battery cable, black 35mmp. 81
2p. 81
+3 Battery cable, red 70mmp. 81
2p. 81
+4 Battery cable, black 70mmp. 81
2p. 81
+5 Battery cable, black 70mmp. 81
2p. 81
1 Wiring loom BF300, hydraulic valvesp. 83
+1 Wiring loom BF300, hydraulic valvesp. 83
+1 Wiring loom BF300, hydraulic valvesp. 83
1 Wiring loom BF300, hydraulic valvesp. 83
1 Wiring loom BF300, hydraulic valves on screedp. 84
+1 Wiring loom BF300, hydraulic valves on screedp. 84
+1 Wiring loom BF300, hydraulic valves on screedp. 84
1 Wiring loom BF300, hydraulic valves on screedp. 84
1 Wiring loom BF300, screed control panelsp. 85
+1 Wiring loom BF300, screed control panelsp. 85
+1 Wiring loom BF300, screed control panelsp. 85
1 Wiring loom BF300, screed control panelsp. 85
+5.17 View of operator's standp. 86
5.16 Control elementsp. 86
+5.17 View of operator's standp. 87
5.17 View of operator's standp. 87
Fig. 7p. 87
+1p. 87
1p. 87
+A15 Instrument clusterp. 87
+A15 Instrument clusterp. 87
A15p. 87
+18p. 87
18p. 87
+R07 Rotary switch for working speedp. 87
+R07 Rotary switch for working speedp. 87
R07p. 87
+2p. 87
2p. 87
+not usedp. 87
not usedp. 87
+19p. 87
19p. 87
+S217 Operating mode switch transport/workp. 87
+S217 Operating mode switch transport/workp. 87
S217p. 87
+3p. 87
3p. 87
+S197 Asphalt fume extractionp. 87
+S197 Asphalt fume extractionp. 87
S197p. 87
Optional equipmentp. 87
+20p. 87
20p. 87
+S03 Warning hornp. 87
+S03 Warning hornp. 87
S03p. 87
+4p. 87
4p. 87
+S225 Switch to reverse the conveyor beltp. 87
+S225 Switch to reverse the conveyor beltp. 87
S225p. 87
+21p. 87
21p. 87
+not usedp. 87
not usedp. 87
+5p. 87
5p. 87
+A81 Display and warning elementsp. 87
+A81 Display and warning elementsp. 87
A81p. 87
+22p. 87
22p. 87
+S04, Push button for parking brakep. 87
+S04, Push button for parking brakep. 87
S04p. 87
+6p. 87
6p. 87
+S236 Switch for auger height adjustmentp. 87
+S236 Switch for auger height adjustmentp. 87
S236p. 87
+23p. 87
23p. 87
+S120 Rotary switch for engine speed/ ECO-modep. 87
+S120 Rotary switch for engine speed/ ECO-modep. 87
S120p. 87
+7p. 87
7p. 87
+not usedp. 87
not usedp. 87
+24p. 87
24p. 87
+S261 Control panel for chain controlp. 87
+S261 Control panel for chain controlp. 87
S261p. 87
+8p. 87
8p. 87
+S16 Rotary switch for working lights, frontp. 87
+S16 Rotary switch for working lights, frontp. 87
S16p. 87
+25p. 87
25p. 87
+S243, S244 Control panel for levellingp. 87
+S243, S244 Control panel for levellingp. 87
S243, S244p. 87
+9p. 87
9p. 87
+S26 Rear working lightp. 87
+S26 Rear working lightp. 87
S26p. 87
+26p. 87
26p. 87
+S220 Speed range selector switchp. 87
+S220 Speed range selector switchp. 87
S220p. 87
+10p. 87
10p. 87
+not usedp. 87
not usedp. 87
+27p. 87
27p. 87
+A45 Steering wheelp. 87
+A45 Steering wheelp. 87
A45p. 87
+11p. 87
11p. 87
+Push button for electro-hydraulicsp. 87
Push button for electro-hydraulicsp. 87
+28p. 87
28p. 87
+Dashboard lightp. 87
Dashboard lightp. 87
+12p. 87
12p. 87
+S01 Emergency stop switchp. 87
+S01 Emergency stop switchp. 87
S01p. 87
+29p. 87
29p. 87
+S237, S238, S239, S240 Screed width control panelp. 87
+S237, S238, S239, S240 Screed width control panelp. 87
S237, S238, S239, S240p. 87
+13p. 87
13p. 87
+S250 Push button for partial screed load reliefp. 87
+S250 Push button for partial screed load reliefp. 87
5.32 Checking the voltage supply for the control unitp. 104
+Power supply for a control unit, generalp. 104
Power supply for a control unit, generalp. 104
All electronic switching and control units require an electric power supply to be able to work. If the plus or minus supply is faulty, the control unit will work incorrectly or fail.p. 104
+The following describes the electric power supply for the ESX-control.p. 104
The following describes the electric power supply for the ESX-control.p. 104
+(Fig. 13) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete representation can be found in the wiring diagram of the machine.p. 104
(Fig. 13)p. 104
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the procedures for line testing are generally the same.p. 104
Fig. 13 Circuitry examplep. 104
+1p. 104
1p. 104
Engine blockp. 104
+ESXp. 104
ESXp. 104
Control unitp. 104
+F00p. 104
F00p. 104
Main fusep. 104
+Fx,Fxxp. 104
Fx,Fxxp. 104
Fuses potential 30p. 104
+Fxxxp. 104
Fxxxp. 104
Fuses potential 15p. 104
+Gp. 104
Gp. 104
Generatorp. 104
+G01p. 104
G01p. 104
Batteryp. 104
+GNDp. 104
GNDp. 104
Housing earthp. 104
+H08p. 104
H08p. 104
Charge control lightp. 104
+S00p. 104
S00p. 104
Ignition switchp. 104
+S01p. 104
S01p. 104
Emergency stop switchp. 104
+Pin 28p. 104
Pin 28p. 104
Voltage supply for controlp. 104
+Pin 54p. 104
Pin 54p. 104
if the signal (12/24 Volt) is applied, the control is switched onp. 104
+Pin 55p. 104
Pin 55p. 104
Ground supply for controlp. 104
+Pin 56 to 60p. 104
Pin 56 to 60p. 104
Voltage supply for outputsp. 104
+GNDp. 104
GNDp. 104
Housing earthp. 104
Fault in current supply, generalp. 105
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides of control units are in most cases connected to the vehicle mains supply via several cables, so that several parallel current branches ex…p. 105
Fig. 14 Circuitry examplep. 105
The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply voltage.p. 105
The following faults may occur:p. 105
+l Line interruption in a plus supply linep. 105
l Line interruption in a plus supply linep. 105
l high voltage drop in a plus supply linep. 105
l line interruption on the minus sidep. 105
Measuring principle for line testingp. 106
+When a line conducts an electric current, a voltage drop will occur in the line (Up. 106
Vp. 106
Vp. 106
+l the available amperage (I) andp. 106
l the available amperage (I) andp. 106
+l the electric resistance (Rp. 106
linep. 106
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Identical marginal conditions are therefore used in all of the following examples:p. 106
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.p. 106
12 V / 21 W – lamp as load in a 12 Volt vehicle network.p. 106
24 V / 21 W – lamp as load in a 24 Volt vehicle network.p. 106
+Test stepsp. 106
Test stepsp. 106
1. Switch off the ignition.p. 106
2. Unplug the control unit from wiring loom.p. 106
+3. If available connect the Pinboxp. 106
(Fig. 15)p. 106
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as necessary. Repeat the measurement.p. 106
+The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 106
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 106
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.p. 106
Fig. 15 Pinbox for 68 pole ESX controlp. 106
General measuring setup to check a supply line (plus side)p. 107
Fig. 16 Measuring arrangement 12 Voltp. 107
+1p. 107
1p. 107
Supply line, plus sidep. 107
+2p. 107
2p. 107
+Plug contact in wiring loom plug on control or Pinboxp. 107
(Fig. 15)p. 107
+Ep. 107
Ep. 107
Lamp, 12V / 21 Wattp. 107
+Pp. 107
Pp. 107
Multimeterp. 107
+G01p. 107
G01p. 107
Battery as voltage source, 12Vp. 107
+Up. 107
+Up. 107
Vp. 107
Voltage drop caused by the lamp currentp. 107
Setpointp. 107
+The voltage drop Up. 107
Vp. 107
Setpointp. 107
£p. 107
General measuring setup to check a return line (minus side)p. 108
Fig. 17 Measuring arrangement 12 Voltp. 108
+1p. 108
1p. 108
Return line, minus sidep. 108
+2p. 108
2p. 108
+Plug contact in wiring loom plug on control or Pinboxp. 108
(Fig. 15)p. 108
+Ep. 108
Ep. 108
Lamp, 12V / 21 Wattp. 108
+Pp. 108
Pp. 108
Multimeterp. 108
+G01p. 108
G01p. 108
Battery as voltage source, 12Vp. 108
+Up. 108
+Up. 108
Vp. 108
Voltage drop caused by the lamp currentp. 108
Setpointp. 108
+The voltage drop Up. 108
Vp. 108
Setpointp. 108
£p. 108
Connection example to check the plus line between battery and plug pin 28p. 109
Fig. 18p. 109
+Xp. 109
Xp. 109
+Wiring loom plug disconnected from control unit or Pinboxp. 109
(Fig. 15)p. 109
+Pp. 109
Pp. 109
Multimeterp. 109
+S00p. 109
S00p. 109
+Ignition switched on. Setpoint : E is bright. Up. 109
Vp. 109
+S00p. 109
S00p. 109
+Ignition switched off. Setpoint : E is dark. Up. 109
Vp. 109
Connection example to check the minus line between battery and plug pin 55p. 110
Fig. 19p. 110
+Pp. 110
Pp. 110
Multimeterp. 110
+Xp. 110
Xp. 110
+Wiring loom plug disconnected from control unit or Pinboxp. 110
(Fig. 15)p. 110
+Ep. 110
Ep. 110
+Setpoint : E is bright. Up. 110
Vp. 110
Test protocol for ESXp. 111
+E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 111
E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 111
E lamp 24V / 21W in 24V vehicle network, to load the current branches.p. 111
G01, batteryp. 111
P multimeter, measuring range: DCp. 111
+Plug pinp. 111
Plug pinp. 111
+Notep. 111
Notep. 111
+Setpointsp. 111
Setpointsp. 111
+28p. 111
28p. 111
+Ignition ONp. 111
Ignition ONp. 111
E between plug pin 28 and battery minusp. 111
P between battery plus and plug pin 28p. 111
E is bright,p. 111
+Up. 111
Vp. 111
+28p. 111
28p. 111
+Ignition OFFp. 111
Ignition OFFp. 111
E between plug pin 28 and battery plusp. 111
P between battery minus and plug pin 28p. 111
E is dark,p. 111
+Up. 111
Vp. 111
+54p. 111
54p. 111
+Ignition OFF, emergency stop not operatedp. 111
Ignition OFF, emergency stop not operatedp. 111
E between plug pin 54 and battery minusp. 111
P between battery plus and plug pin 54p. 111
E is bright,p. 111
+Up. 111
Vp. 111
+54p. 111
54p. 111
+Ignition OFF, emergency stop operatedp. 111
Ignition OFF, emergency stop operatedp. 111
E between plug pin 54 and battery minusp. 111
P between battery plus and plug pin 54p. 111
E is dark,p. 111
+Up. 111
Vp. 111
+55p. 111
55p. 111
+Ignition OFFp. 111
Ignition OFFp. 111
E between plug pin 55 and battery minusp. 111
P between battery plus and plug pin 55p. 111
E is bright,p. 111
+Up. 111
Vp. 111
+56, 57, 58, 59, 60p. 111
56, 57, 58, 59, 60p. 111
+Ignition OFFp. 111
Ignition OFFp. 111
E between plug pin 56, 57, 58, 59, 60 and battery minusp. 111
P between battery plus and plug pin 56, 57, 58, 59, 60p. 111
E is bright,p. 111
+Up. 111
Vp. 111
+If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 111
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 111
Example 1:p. 111
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons. Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.p. 111
Example 2:p. 111
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch and the corresponding plug pin.p. 111
5.33 Diagnostics conceptp. 112
+Introductionp. 112
Introductionp. 112
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble shooting proce…p. 112
+Fault description and questioning of the customerp. 112
Fault description and questioning of the customerp. 112
After the customer has explained his complaint(s) the engineer has to ask further questions to track down the cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examination and a possible test d…p. 112
Fig. 20p. 112
+(1) Fault memorized in error logp. 112
(1) Fault memorized in error logp. 112
+Clear cause?p. 112
Clear cause?p. 112
+l If the fault message leaves no doubt, repair work may be started immediately.p. 112
l If the fault message leaves no doubt, repair work may be started immediately.p. 112
+(2) No fault memorized in the error log at the time of initial questioningp. 112
(2) No fault memorized in the error log at the time of initial questioningp. 112
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even gets worse …p. 112
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming sensor information and outgoing command values on a control unit. This requires profound knowledge of system and components.p. 112
+Consideration, if the error log has not recorded a faultp. 112
Consideration, if the error log has not recorded a faultp. 112
+l What could be the cause of the complaint?p. 112
l What could be the cause of the complaint?p. 112
l Which measuring possibilities are available?p. 112
Localizing faultsp. 113
+Line or component?p. 113
Line or component?p. 113
Fig. 21p. 113
+l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 113
l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 113
l Checking the voltage supply for the control unitp. 113
l Checking the sensor linesp. 113
l Checking the actor linesp. 113
Sequence after the fault is foundp. 114
Fig. 22p. 114
+6 Input codesp. 115
+6 Input codesp. 115
Input codes — display: Functions and operationp. 116
+Display functions and operationp. 116
Display functions and operationp. 116
+The main LC-displayp. 116
(Fig. 23)p. 116
+l Display of operating hours as well as error and input codes (1)p. 116
l Display of operating hours as well as error and input codes (1)p. 116
l Button right (2)p. 116
l Button left (3)p. 116
l Tool symbol (4) (only visible in Service mode)p. 116
Fig. 23 LC-Displayp. 116
Input of codes (input codes)p. 116
+The brake needs to be activated to be able to access input mode!p. 116
The brake needs to be activated to be able to access input mode!p. 116
+Calling up input modep. 116
Calling up input modep. 116
+Actionp. 116
Actionp. 116
+Resultp. 116
Resultp. 116
+— Press button left and button right at the same time for at least two seconds.p. 116
+— Press button left and button rightp. 116
at the same timep. 116
twop. 116
+— The display shows "0000"p. 116
+— The display showsp. 116
"0000"p. 116
+— The leftp. 116
"0"p. 116
+One can change the numerical value of the display by using the buttons one after the other:p. 116
One can change the numerical value of the display by using the buttons one after the other:p. 116
The left hand button to change the numbers in ascending mode (0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 0, …).p. 116
+The right hand button to move on to the next digit (p. 116
0p. 116
0p. 116
0p. 116
0p. 116
0p. 116
+Calling up service modep. 116
Calling up service modep. 116
+Actionp. 116
Actionp. 116
+Resultp. 116
Resultp. 116
+— Enter code 0001.p. 116
+— Enter codep. 116
0001p. 116
+— The system changes to service mode.p. 116
— The system changes to service mode.p. 116
— The display shows the tool symbol.p. 116
+6.2 Automatic calibration of travel system currentsp. 117
In order to ensure sensitive and exact functioning of the travel system, the start currents of the travel pumps must be calibrated. This must be carried out for both drive sides for both forward and reverse.p. 117
The start currents must always be calibrated:p. 117
+l after the installation of the travel pumps in the factory.p. 117
l after the installation of the travel pumps in the factory.p. 117
l after work on the travel pump.p. 117
l after replacing a travel pump.p. 117
l after replacing the ESX-control.p. 117
The procedure is identical for both sides:p. 117
Once you have entered the corresponding code, the control current for the solenoid valve on the travel pump is increased in steps of 5 mA, starting with a predetermined value for minimum current.p. 117
+After each increase in current the system waitsp. 117
3 secondsp. 117
+The following must be ensured before making settings:p. 117
The following must be ensured before making settings:p. 117
– the machine is standing on a level surface.p. 117
– there is sufficient space in direction forward and reverse (the machine moves during the calibration process)p. 117
+During the adjustment procedure:p. 117
During the adjustment procedure:p. 117
– Do not leave the machine!p. 117
– Watch the area around the machine to exclude any dangers for other persons!p. 117
+The calibration must only be made atp. 117
+The calibration must only be made atp. 117
operating temperaturep. 117
+To stop the machine during the adjustment process:p. 117
To stop the machine during the adjustment process:p. 117
– Return the travel lever to "Neutral" orp. 117
– press the Emergency Stop button orp. 117
– switch off the ignition.p. 117
Calibrating the travel system currentsp. 117
+Pay attention to the section "Input Codes Display General"!p. 117
Pay attention to the section "Input Codes Display General"!p. 117
+In order to be able to perform the function "Automatic calibration of travel currents" you need to carry out the following actions:p. 117
In order to be able to perform the function "Automatic calibration of travel currents" you need to carry out the following actions:p. 117
– Start the engine.p. 117
– Turn the rotary button for "ECO mode" to "ECO",p. 117
– Turn the rotary button "Working speed" at least to position "5"p. 118
– Set the travel speed range switch to "fast" (rabbit)p. 118
– Move the travel lever forward and move the machine for approx. 5 metersp. 118
– shift the travel lever to "Neutral".p. 118
+Automatic calibration of travel system currents:p. 118
Automatic calibration of travel system currents:p. 118
+Actionp. 118
+Actionp. 118
Actionp. 118
+Resultp. 118
+Resultp. 118
Resultp. 118
+— Enter code 0001.p. 118
+— Enter codep. 118
0001p. 118
+— The system changes to service mode.p. 118
— The system changes to service mode.p. 118
— The display shows the tool symbol.p. 118
+— Make sure that the "ECO mode" switch is in position "ECO".p. 118
— Make sure that the "ECO mode" switch is in position "ECO".p. 118
— Set the travel speed range switch to position "slow" (turtle).p. 118
+— Shift the travel lever to "Neutral"p. 118
— Shift the travel lever to "Neutral"p. 118
+— Enter code 1090.p. 118
+— Enter codep. 118
1090p. 118
+— The teach function "Travel currents" is activated.p. 118
— The teach function "Travel currents" is activated.p. 118
— The display shows "0 0 0 0".p. 118
Note:p. 118
The machine can no longer be operated with the travel lever. This is only possible again after the teach process has been completed and after the machine has been restarted!p. 118
+— Enter code 1091.p. 118
+— Enter codep. 118
1091p. 118
+The "Travel current teach function" for the left side is activated.p. 118
+The "Travel current teach function" for thep. 118
leftp. 118
— The display shows "4 4 4 4 4".p. 118
+— Shift the travel lever forward.p. 118
+— Shift the travel leverp. 118
forwardp. 118
+— Teaching starts with the first current value.p. 118
— Teaching starts with the first current value.p. 118
— The display shows the actual mA value.p. 118
— Once the machine moves, the corresponding mA value is saved.p. 118
— Once the value has been saved the display will show "1 1 1 1 1".p. 118
— After a short while the display will show 5 5 5 5 5".p. 118
+— Shift the travel lever reverse.p. 118
+— Shift the travel leverp. 118
reversep. 118
+— Teaching starts with the first current value.p. 118
— Teaching starts with the first current value.p. 118
— The display shows the actual mA value.p. 118
— Once the machine moves, the corresponding mA value is saved.p. 118
— Once the value has been saved the display will show "1 1 1 1 1".p. 118
+— Shift the travel lever to "Neutral"p. 119
— Shift the travel lever to "Neutral"p. 119
+— The display shows "0 0 0 0".p. 119
— The display shows "0 0 0 0".p. 119
+— Enter code 1092.p. 119
+— Enter codep. 119
1092p. 119
+The "Travel current teach function" for the right side is activated.p. 119
+The "Travel current teach function" for thep. 119
rightp. 119
— The display shows "4 4 4 4 4".p. 119
+— Shift the travel lever forward.p. 119
+— Shift the travel leverp. 119
forwardp. 119
+— Teaching starts with the first current value.p. 119
— Teaching starts with the first current value.p. 119
— The display shows the actual mA value.p. 119
— Once the machine moves, the corresponding mA value is saved.p. 119
— Once the value has been saved the display will show "1 1 1 1 1".p. 119
— After a short while the display will show 5 5 5 5 5".p. 119
+— Shift the travel lever reverse.p. 119
+— Shift the travel leverp. 119
reversep. 119
+— Teaching starts with the first current value.p. 119
— Teaching starts with the first current value.p. 119
— The display shows the actual mA value.p. 119
— Once the machine moves, the corresponding mA value is saved.p. 119
— Once the value has been saved the display will show "1 1 1 1 1".p. 119
— This is followed by "2 2 2 2 2" (–> saving completed).p. 119
— The machine can now be controlled with the travel lever again.p. 119
— Changes only become effective after a restart of the machine.p. 119
— END.p. 119
+Should the code "2 2 2 2 2" not appear, the calibration wasp. 119
+Should the code "2 2 2 2 2" not appear, the calibration wasp. 119
notp. 119
+6.3 Automatic calibration of travel system currentsp. 120
+The following must be ensured before making settings:p. 120
The following must be ensured before making settings:p. 120
– the machine is standing on a level surface.p. 120
– there is sufficient space in direction forward and reverse (the machine moves during the teaching process)p. 120
+During the adjustment procedure:p. 120
During the adjustment procedure:p. 120
– Do not leave the machine!p. 120
– Watch the area around the machine to exclude any dangers for other persons!p. 120
+The calibration must only be made atp. 120
+The calibration must only be made atp. 120
operating temperaturep. 120
+To stop the machine during the calibration process:p. 120
To stop the machine during the calibration process:p. 120
– press the Emergency Stop button orp. 120
– return the travel lever to "Neutral" orp. 120
– press the parking brake switch. (Parking brake)p. 120
Calibrating the travel system currents manuallyp. 120
+Pay attention to the section "Input Codes Display General"!p. 120
Pay attention to the section "Input Codes Display General"!p. 120
+Manual calibration of travel system currents:p. 121
Manual calibration of travel system currents:p. 121
+Actionp. 121
+Actionp. 121
Actionp. 121
+Resultp. 121
+Resultp. 121
Resultp. 121
+— Enter code 0001.p. 121
+— Enter codep. 121
0001p. 121
+— The system changes to service mode.p. 121
— The system changes to service mode.p. 121
— The display shows the tool symbol.p. 121
+— Shift the travel lever to "Neutral"p. 121
— Shift the travel lever to "Neutral"p. 121
— Turn the steering wheel to middle position. (locks noticeably)p. 121
— Set the speed potentiometer to "0".p. 121
+— Enter code 1095.p. 121
+— Enter codep. 121
1095p. 121
+— The calibration function "Travel currents" is activated.p. 121
— The calibration function "Travel currents" is activated.p. 121
— The display shows "0 0 0 0".p. 121
— The LEDs for steering direction are flashing.p. 121
Note:p. 121
The machine can no longer be operated with the steering wheel.p. 121
+— Enter code 1096.p. 121
+— Enter codep. 121
1096p. 121
+— The calibration function "Travel currents" for forward is activated.p. 121
+— The calibration function "Travel currents" forp. 121
forwardp. 121
— The display shows "4 4 4 4 4".p. 121
+— Shift the travel lever forward.p. 121
+— Shift the travel leverp. 121
forwardp. 121
— Set the speed potentiometer between "4" and "5".p. 121
+— Calibration for forward movement of both track drives starts.p. 121
— Calibration for forward movement of both track drives starts.p. 121
— The display shows the surge current correction value in mA.p. 121
+— Move the steering wheel to left and right.p. 121
— Move the steering wheel to left and right.p. 121
+— The display shows the surge current correction value with respect to the steering wheel displacement.p. 121
— The display shows the surge current correction value with respect to the steering wheel displacement.p. 121
Note:p. 121
Depending on the steering wheel displacement the surge current correction value will be added to or subtracted from the basic value.p. 121
+Once the desired surge current has been reached:p. 121
Once the desired surge current has been reached:p. 121
— Attention: Hold the steering wheel in this position!p. 121
— Shift the travel lever to "Neutral"p. 121
— Set the speed potentiometer to "0".p. 121
+— The display shows "1 1 1 1 1".p. 121
— The display shows "1 1 1 1 1".p. 121
— The adjusted value is saved.p. 121
— The display shows "0 0 0 0".p. 121
+— Turn the steering wheel to "Neutral"p. 121
— Turn the steering wheel to "Neutral"p. 121
+— Enter code 1097.p. 121
+— Enter codep. 121
1097p. 121
+— The calibration function "Travel currents" for reverse is activated.p. 121
+— The calibration function "Travel currents" forp. 121
reversep. 121
— The display shows "5 5 5 5 5".p. 121
+— Shift the travel lever reverse.p. 122
+— Shift the travel leverp. 122
reversep. 122
— Set the speed potentiometer between "4" and "5".p. 122
+— Calibration for reverse movement of both track drives starts.p. 122
— Calibration for reverse movement of both track drives starts.p. 122
— The display shows the surge current correction value in mA.p. 122
+— Move the steering wheel to left and right.p. 122
— Move the steering wheel to left and right.p. 122
+— The display shows the surge current correction value with respect to the steering wheel displacement.p. 122
— The display shows the surge current correction value with respect to the steering wheel displacement.p. 122
Note:p. 122
Depending on the steering wheel displacement the surge current correction value will be added to or subtracted from the basic value.p. 122
+Once the desired surge current has been reached:p. 122
Once the desired surge current has been reached:p. 122
Attention: Hold the steering wheel in this position!p. 122
— Shift the travel lever to "Neutral"p. 122
+— The display shows "1 1 1 1 1".p. 122
— The display shows "1 1 1 1 1".p. 122
— The adjusted value is saved.p. 122
— The display shows "3 3 3 3 3".p. 122
+— Set the speed potentiometer to "0".p. 122
— Set the speed potentiometer to "0".p. 122
+— The display shows "2 2 2 2 2".p. 122
— The display shows "2 2 2 2 2".p. 122
+— Turn the steering wheel to "Neutral"p. 122
— Turn the steering wheel to "Neutral"p. 122
+— The LEDs for steering direction have stopped flashing.p. 122
— The LEDs for steering direction have stopped flashing.p. 122
— The machine can now be controlled with the steering wheel again.p. 122
— END.p. 122
+Should the calibrationp. 122
+Should the calibrationp. 122
notp. 122
+6.4 Teaching the E-throttle function:p. 123
Teaching the E-throttle functionp. 123
+Take notice of the section "Input codes Display General"!p. 123
Take notice of the section "Input codes Display General"!p. 123
+Teaching the E-throttle function:p. 123
Teaching the E-throttle function:p. 123
+Actionp. 123
+Actionp. 123
Actionp. 123
+Resultp. 123
+Resultp. 123
Resultp. 123
+— Switch on the ignition.p. 123
— Switch on the ignition.p. 123
+Note: Dop. 123
Note:p. 123
notp. 123
+— Enter code 0001.p. 123
+— Enter codep. 123
0001p. 123
+— The system changes to service mode.p. 123
— The system changes to service mode.p. 123
— The display shows the tool symbol.p. 123
+— Enter code 5038.p. 123
+— Enter codep. 123
5038p. 123
+— The teach function "Teach E-throttle function" is activated.p. 123
— The teach function "Teach E-throttle function" is activated.p. 123
+— Enter code 5039.p. 123
+— Enter codep. 123
5039p. 123
+— The function E-throttle lower value is activated.p. 123
+— The function E-throttlep. 123
lower valuep. 123
+— The E-throttle actuator in the engine compartmentp. 123
clicksp. 123
+Note: This clicking sound indicates that the coupling of the actuator has been opened.p. 123
Note:p. 123
— The corresponding position value appears in the display.p. 123
+Note: The value must be lower than 500. Otherwise you must adjust the lever of the `E-throttle actuator.p. 123
Note:p. 123
+— Shift the lever of the injection pump fully to min (idle speed) and hold it in this position.p. 123
+— Shift the lever of the injection pump fully top. 123
min (idle speed)p. 123
+Note: This makes sure that the lever is actually in position "min".p. 123
Note:p. 123
+— The E-throttle actuator in the engine compartment clicks.p. 123
+— The E-throttle actuator in the engine compartmentp. 123
clicksp. 123
— A valid value has been taught.p. 123
+— Enter code 5040.p. 123
+— Enter codep. 123
5040p. 123
+— The function E-throttle upper value is activated.p. 123
+— The function E-throttlep. 123
upper valuep. 123
+— The E-throttle actuator in the engine compartmentp. 123
clicksp. 123
+Note: This clicking sound indicates that the coupling of the actuator has been opened.p. 123
Note:p. 123
— The corresponding position value appears in the display.p. 123
+— Shift the lever of the injection pump fully to maximum (full speed) and hold it in this position.p. 123
+— Shift the lever of the injection pump fully top. 123
maximum (full speed)p. 123
+— The E-throttle actuator in the engine compartment clicks.p. 123
+— The E-throttle actuator in the engine compartmentp. 123
clicksp. 123
— A valid value has been taught.p. 123
+— Enter code 5041.p. 123
+— Enter codep. 123
5041p. 123
+— The E-throttle function is terminated.p. 123
— The E-throttle function is terminated.p. 123
— END.p. 123
+6.5 Teaching the L.C.S. functionp. 124
Teaching the LCS functionp. 124
+The L.C.S. Control panelp. 124
(Fig. 24)p. 124
+l Work potentiometer (1)p. 124
l Work potentiometer (1)p. 124
l Stop potentiometer (2)p. 124
l Timer potentiometer (3)p. 124
Fig. 24 LCS operationp. 124
Fig. 25 Screed adjustmentp. 124
+Lower the screed to be able to teach the L.C.S. function.p. 124
Lower the screed to be able to teach the L.C.S. function.p. 124
+The switch “a”p. 124
(Fig. 25)p. 124
+Take notice of the section "Input codes Display General"!p. 124
Take notice of the section "Input codes Display General"!p. 124
+During this teach function the travel lever mustp. 124
+During this teach function the travel lever mustp. 124
alwaysp. 124
+Teaching the LCS function:p. 125
Teaching the LCS function:p. 125
+Actionp. 125
+Actionp. 125
Actionp. 125
+Resultp. 125
+Resultp. 125
Resultp. 125
+— Start the engine.p. 125
— Start the engine.p. 125
+— Turn all potentiometers on the LCS control panel to "min".p. 125
— Turn all potentiometers on the LCS control panel to "min".p. 125
+— Enter code 0001.p. 125
+— Enter codep. 125
0001p. 125
+— The system changes to service mode.p. 125
— The system changes to service mode.p. 125
— The display shows the tool symbol.p. 125
+— Enter code 3006.p. 125
+— Enter codep. 125
3006p. 125
+— The teach function "Teach LCS" is activated.p. 125
— The teach function "Teach LCS" is activated.p. 125
— The display shows "0 0 0 0".p. 125
+— Enter code 3007.p. 125
+— Enter codep. 125
3007p. 125
+— The function LCS maximum work pressure is activated.p. 125
+— The function LCSp. 125
maximum work pressurep. 125
— The display shows "4 4 4 4 4".p. 125
+— Set the work potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 125
— Set the work potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 125
+— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 125
— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 125
+— Turn the timer potentiometer from "min" to "max" and back to "min".p. 125
— Turn the timer potentiometer from "min" to "max" and back to "min".p. 125
+— The display shows "1 1 1 1 1".p. 125
— The display shows "1 1 1 1 1".p. 125
— This is followed by "3 3 3 3 3".p. 125
+— Turn the work potentiometer to "min".p. 125
— Turn the work potentiometer to "min".p. 125
+— The display shows "2 2 2 2 2".p. 125
— The display shows "2 2 2 2 2".p. 125
— This is followed by "0 0 0 0".p. 125
+— Enter code 3008.p. 125
+— Enter codep. 125
3008p. 125
+— The function LCS maximum stop pressure is activated.p. 125
+— The function LCSp. 125
maximum stop pressurep. 125
+— Set the stop potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 125
— Set the stop potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 125
+— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 125
— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 125
+— Turn the timer potentiometer from "min" to "max" and back to "min".p. 125
— Turn the timer potentiometer from "min" to "max" and back to "min".p. 125
+— The display shows "1 1 1 1 1".p. 125
— The display shows "1 1 1 1 1".p. 125
— This is followed by "3 3 3 3 3".p. 125
+— Turn the stop potentiometer to "min".p. 125
— Turn the stop potentiometer to "min".p. 125
+— The display shows "2 2 2 2 2".p. 125
— The display shows "2 2 2 2 2".p. 125
— This is followed by "0 0 0 0".p. 125
+— Enter code 0000.p. 125
+— Enter codep. 125
0000p. 125
+— This quits the service mode.p. 125
— This quits the service mode.p. 125
— END.p. 125
+6.6 Travel signal by button for max. screed reliefp. 126
+This function is a so-calledp. 126
+This function is a so-calledp. 126
limp home functionp. 126
As long as the function "Travel signal by push button for maximum screed relief" is activated, the button for maximum screed relief is not available to the operator! However, the Load Control System (LCS) does still work.p. 126
Fig. 26 Push button for maximum screed reliefp. 126
+Take notice of the section "Input codes Display General"!p. 126
Take notice of the section "Input codes Display General"!p. 126
+Activation of the function "Travel signal by push button for maximum screed relief":p. 126
Activation of the function "Travel signal by push button for maximum screed relief":p. 126
+Actionp. 126
+Actionp. 126
Actionp. 126
+Resultp. 126
+Resultp. 126
Resultp. 126
+— Switch on the ignition.p. 126
— Switch on the ignition.p. 126
+Note: Dop. 126
Note:p. 126
notp. 126
+— Enter code 0001.p. 126
+— Enter codep. 126
0001p. 126
+— The system changes to service mode.p. 126
— The system changes to service mode.p. 126
— The display shows the tool symbol.p. 126
+— Enter code 1100.p. 126
+— Enter codep. 126
1100p. 126
+— Changes to the travel system parameters are now possible.p. 126
— Changes to the travel system parameters are now possible.p. 126
+— Enter code 1121.p. 126
+— Enter codep. 126
1121p. 126
+— The function "Travel signal by push button for maximum screed relief" is activated.p. 126
— The function "Travel signal by push button for maximum screed relief" is activated.p. 126
+To drive the machine the operator must now:p. 126
To drive the machine the operator must now:p. 126
– Shift both travel control lever forward (or backward).p. 126
+–p. 126
At the same timep. 126
(Fig. 26)p. 126
+– Travel lever in "Neutral" stops the machine.p. 127
– Travel lever in "Neutral" stops the machine.p. 127
+Once the fault(s) no longer exist (e.g. after a repair) this functionp. 127
+Once the fault(s) no longer exist (e.g. after a repair) this functionp. 127
deactivatesp. 127
automaticallyp. 127
There is also the possibility to switch off this function manually.p. 127
+Deactivation of the function "Travel signal by push button for maximum screed relief":p. 127
Deactivation of the function "Travel signal by push button for maximum screed relief":p. 127
+Actionp. 127
+Actionp. 127
Actionp. 127
+Resultp. 127
+Resultp. 127
Resultp. 127
+— Switch on the ignition.p. 127
— Switch on the ignition.p. 127
+Note: Dop. 127
Note:p. 127
notp. 127
+— Enter code 0001.p. 127
+— Enter codep. 127
0001p. 127
+— The system changes to service mode.p. 127
— The system changes to service mode.p. 127
— The display shows the tool symbol.p. 127
+— Enter code 1100.p. 127
+— Enter codep. 127
1100p. 127
+— Changes to the travel system parameters are now possible.p. 127
— Changes to the travel system parameters are now possible.p. 127
+— Enter code 1122.p. 127
+— Enter codep. 127
1122p. 127
+— The function "Travel signal by push button for maximum screed relief" is deactivated.p. 127
— The function "Travel signal by push button for maximum screed relief" is deactivated.p. 127
+6.7 Resetting to factory settingsp. 128
+Pay attention to the section "Input Codes Display General"!p. 128
Pay attention to the section "Input Codes Display General"!p. 128
+The machine will not move as long as the code "7860" is displayed.p. 128
The machine will not move as long as the code "7860" is displayed.p. 128
+Resetting to factory settings:p. 128
Resetting to factory settings:p. 128
+Actionp. 128
+Actionp. 128
Actionp. 128
+Resultp. 128
+Resultp. 128
Resultp. 128
+— Switch on the ignition.p. 128
— Switch on the ignition.p. 128
+Note: Dop. 128
Note:p. 128
notp. 128
+— Enter code 0001.p. 128
+— Enter codep. 128
0001p. 128
+— The system changes to service mode.p. 128
— The system changes to service mode.p. 128
— The display shows the tool symbol.p. 128
+— Enter code 7010.p. 128
+— Enter codep. 128
7010p. 128
+— The display shows "7 8 6 0".p. 128
— The display shows "7 8 6 0".p. 128
+— Press the right button to confirm "7860".p. 128
— Press the right button to confirm "7860".p. 128
+— The ESX runs a reset.p. 128
— The ESX runs a reset.p. 128
+— Switch off the ignition.p. 128
— Switch off the ignition.p. 128
— Switch on the ignition.p. 128
+— The display shows "7 8 6 0".p. 128
— The display shows "7 8 6 0".p. 128
+— Enter code 0001.p. 128
+— Enter codep. 128
0001p. 128
+— The system changes to service mode.p. 128
— The system changes to service mode.p. 128
— The display shows the tool symbol.p. 128
+— Enter code 7010.p. 128
+— Enter codep. 128
7010p. 128
+— Use the left hand button to select code 7865 (explanations see below).p. 128
+— Use the left hand button to select codep. 128
7865p. 128
— Press the right button to confirm.p. 128
+— The ESX runs another reset.p. 128
— The ESX runs another reset.p. 128
+— Switch off the ignition.p. 128
— Switch off the ignition.p. 128
— Switch on the ignition.p. 128
+— The display shows "7 8 6 5".p. 128
— The display shows "7 8 6 5".p. 128
+— Enter code 0000.p. 128
+— Enter codep. 128
0000p. 128
+— This quits the service mode.p. 128
— This quits the service mode.p. 128
— END.p. 128
Explanation of codes:p. 128
+l 7860 –> "reset"p. 128
+l 7860 –> "reset"p. 128
l 7860p. 128
+l 7861 –> "Wheel machine"p. 128
l 7861p. 128
+l 7865 –> "Track machine"p. 128
l 7865p. 128
+6.8 Showing stored faultsp. 129
+This function can only be activated / deactivated if the parking brake has been activated!p. 129
This function can only be activated / deactivated if the parking brake has been activated!p. 129
+Dop. 129
notp. 129
+Display of logged errors:p. 129
Display of logged errors:p. 129
+Actionp. 129
+Actionp. 129
Actionp. 129
+Resultp. 129
+Resultp. 129
Resultp. 129
+— Switch on the ignition.p. 129
— Switch on the ignition.p. 129
+Note: Dop. 129
Note:p. 129
notp. 129
+— Enter code 0700.p. 129
+— Enter codep. 129
0700p. 129
+— The system changes to the mode "Show logged errors".p. 129
— The system changes to the mode "Show logged errors".p. 129
— The error codes logged in the ESX appear flashing in the display.p. 129
Note:p. 129
+If more than only one error codes has been logged, these codes are displayed inp. 129
three secondp. 129
+If there arep. 129
nop. 129
– – – – –p. 129
+— Enter code 0701.p. 129
+— Enter codep. 129
0701p. 129
+— The mode "Show logged errors" is terminated.p. 129
— The mode "Show logged errors" is terminated.p. 129
+Apart from the logged error codes the current faults (if present) are also displayed.p. 129
Apart from the logged error codes the current faults (if present) are also displayed.p. 129
+6.9 Showing saved faults with operating hoursp. 130
+This function can only be activated / deactivated if the parking brake has been activated!p. 130
This function can only be activated / deactivated if the parking brake has been activated!p. 130
+Dop. 130
notp. 130
+Display of logged errors:p. 130
Display of logged errors:p. 130
+Actionp. 130
+Actionp. 130
Actionp. 130
+Resultp. 130
+Resultp. 130
Resultp. 130
+— Switch on the ignition.p. 130
— Switch on the ignition.p. 130
+Note: Dop. 130
Note:p. 130
notp. 130
+— Enter code 0705.p. 130
+— Enter codep. 130
0705p. 130
+— The system changes to the mode "Show logged errors with operating hours".p. 130
— The system changes to the mode "Show logged errors with operating hours".p. 130
— The error codes logged in the ESX appear flashing in the display.p. 130
+— Press the left hand button.p. 130
— Press the left hand button.p. 130
Attention: three possible options!p. 130
+— Option 1: No error code logged in the ESX:p. 130
+—p. 130
Option 1p. 130
+–> The display shows "p. 130
– – – – –p. 130
+—p. 130
Option 2p. 130
–> The display shows the error code. Continue with "One error code".p. 130
+—p. 130
Option 3p. 130
–> The display first shows only one error code. Continue with "Several error codes".p. 130
+One error code:p. 130
One error code:p. 130
— Press the left hand button again.p. 130
+— The display does not change, the logged error code flashes. Continue with "Show operating hours of error code".p. 130
— The display does not change, the logged error code flashes. Continue with "Show operating hours of error code".p. 130
+Several error codes:p. 130
Several error codes:p. 130
— Press the left hand button again.p. 130
+— The display changes. Each actuation of the left hand button brings you to the next error code, until the first one appears again. Continue with "Show operating hours of error code".p. 130
— The display changes. Each actuation of the left hand button brings you to the next error code, until the first one appears again. Continue with "Show operating hours of error code".p. 130
+Showing the operating hours for the error code:p. 130
Showing the operating hours for the error code:p. 130
— Press the right hand button.p. 130
+— The operating hours at which the corresponding error code has been logged are displayed. ("When did the error occur the last time?")p. 130
— The operating hours at which the corresponding error code has been logged are displayed. ("When did the error occur the last time?")p. 130
+Showing the number of occurrence of this error:p. 130
Showing the number of occurrence of this error:p. 130
— Press the right hand button again.p. 130
+The display shows the number of occurrence of the corresponding error since the error log had been deleted the last time. ("How often has the error been detected?")p. 130
The display shows the number of occurrence of the corresponding error since the error log had been deleted the last time. ("How often has the error been detected?")p. 130
+— Enter code 0706.p. 130
+— Enter codep. 130
0706p. 130
+— The mode "Show logged errors with operating hours" is terminated.p. 130
— The mode "Show logged errors with operating hours" is terminated.p. 130
+Apart from the logged error codes the current faults (if present) are also displayed.p. 130
Apart from the logged error codes the current faults (if present) are also displayed.p. 130
+6.10 Deleting the fault logp. 131
+This function can only be activated / deactivated if the parking brake has been activated!p. 131
This function can only be activated / deactivated if the parking brake has been activated!p. 131
+Dop. 131
notp. 131
+Deleting logged errors:p. 131
Deleting logged errors:p. 131
+Actionp. 131
+Actionp. 131
Actionp. 131
+Resultp. 131
+Resultp. 131
Resultp. 131
+— Switch on the ignition.p. 131
— Switch on the ignition.p. 131
+Note: Dop. 131
Note:p. 131
notp. 131
+— Enter code 0710.p. 131
+— Enter codep. 131
0710p. 131
+— Switch off the ignition.p. 131
— Switch off the ignition.p. 131
— Switch on the ignition.p. 131
+— All logged error codes have been deleted.p. 131
— All logged error codes have been deleted.p. 131
+6.11 Driving against the closed brakep. 132
+Activation of this mode is only possible from software version 0.21!p. 132
Activation of this mode is only possible from software version 0.21!p. 132
+Activate function "Driving against the closed brake":p. 132
Activate function "Driving against the closed brake":p. 132
+Actionp. 132
+Actionp. 132
Actionp. 132
+Resultp. 132
+Resultp. 132
Resultp. 132
+— Start the engine.p. 132
— Start the engine.p. 132
— Shift the travel lever to "Neutral"p. 132
+— Enter code 0001.p. 132
+— Enter codep. 132
0001p. 132
+— The system changes to service mode.p. 132
— The system changes to service mode.p. 132
— The display shows the tool symbol.p. 132
+— Enter code 0500.p. 132
+— Enter codep. 132
0500p. 132
+— The mode "Driving against the closed brake" is activated.p. 132
— The mode "Driving against the closed brake" is activated.p. 132
+— The LED for brakep. 132
flashesp. 132
+— Shift the travel lever to "forward" ("reverse").p. 132
— Shift the travel lever to "forward" ("reverse").p. 132
— Set the speed potentiometer to "> 0".p. 132
+— The display shows "0 0 0 0".p. 132
— The display shows "0 0 0 0".p. 132
+— Shift the travel lever to "Neutral"p. 132
— Shift the travel lever to "Neutral"p. 132
— Set the speed potentiometer to "> 0".p. 132
+— The display shows "0 0 0 0".p. 132
— The display shows "0 0 0 0".p. 132
+— Enter code 0501.p. 132
+— Enter codep. 132
0501p. 132
+— The mode "Driving against the closed brake" is deactivated.p. 132
— The mode "Driving against the closed brake" is deactivated.p. 132
+— The LED for brakep. 132
lightsp. 132
— The display shows "0 0 0 0".p. 132
+— Enter code 0000.p. 132
+— Enter codep. 132
0000p. 132
+— This quits the service mode.p. 132
— This quits the service mode.p. 132
— END.p. 132
+6.12 Adapting the engine speedp. 133
+On the finisher BF300 the transmission ratio of the belt drive for the generator (power generation for screed heating) was adapted from a certain serial number. The diameter of the generator V-belt pulley was thereby changed. In the software versionp. 133
+On the finisher BF300 the transmission ratio of the belt drive for the generator (power generation for screed heating) was adapted from a certain serial number. The diameter of the generator V-belt pulley was thereby changed. In the software versionp. 133
v0.27p. 133
+Serial numbers, from which the changed V-belt drive has been installed:p. 133
Serial numbers, from which the changed V-belt drive has been installed:p. 133
+l BF300_P – S340 VE : 821837681008 – …p. 133
l BF300_P – S340 VE : 821837681008 – …p. 133
l BF300_P – S340 TVE : 821837811013 – …p. 133
l BF300_C – S340 TVE : 821837821017 – …p. 133
+The engine speedp. 133
+The engine speedp. 133
mustp. 133
v0.27p. 133
+Take notice of the section "Input codes Display General"!p. 133
Take notice of the section "Input codes Display General"!p. 133
+Adapting the engine speed:p. 133
Adapting the engine speed:p. 133
+Actionp. 133
+Actionp. 133
Actionp. 133
+Resultp. 133
+Resultp. 133
Resultp. 133
+— Switch on the ignition.p. 133
— Switch on the ignition.p. 133
+Note: Dop. 133
Note:p. 133
notp. 133
+— Enter code 0001.p. 133
+— Enter codep. 133
0001p. 133
+— The system changes to service mode.p. 133
— The system changes to service mode.p. 133
— The display shows the tool symbol.p. 133
+— Enter code 5046.p. 133
+— Enter codep. 133
5046p. 133
+— The engine speed is adapted to the original settings (old generator).p. 133
— The engine speed is adapted to the original settings (old generator).p. 133
+— Enter code 0000.p. 133
+— Enter codep. 133
0000p. 133
+— This quits the service mode.p. 133
— This quits the service mode.p. 133
— END.p. 133
+6.13 Deactivating/activating automatic speed range change when corneringp. 134
+The travel speed of the finisher can be changed from transport speed (rabbit = "High") to working speed (turtle = "Low"with the help of the speed range selector switchp. 134
+The travel speed of the finisher can be changed from transport speed (rabbit = "High") to working speed (turtle = "Low"with the help of the speed range selector switchp. 134
(Fig. 25)p. 134
Upon delivery the control contains a function that switches automatically from "High" to "Low", if the machine does not steer in accordance with the steering commands.p. 134
The function "Automatic change to working speed" can be disabled.p. 134
If the function "Change to working speed" has been deactivated:p. 134
+l Automatic switching from "High" to "Low" is ligated.p. 134
l Automatic switching from "High" to "Low" is ligated.p. 134
l The operator can choose between "High" and "Low".p. 134
Fig. 27 Travel speed range switchp. 134
+Pay attention to the section "Input Codes Display General"!p. 134
Pay attention to the section "Input Codes Display General"!p. 134
+Deactivating the function "Change to working speed":p. 134
Deactivating the function "Change to working speed":p. 134
+Actionp. 134
+Actionp. 134
Actionp. 134
+Resultp. 134
+Resultp. 134
Resultp. 134
+— Switch on the ignition.p. 134
— Switch on the ignition.p. 134
+Note: Dop. 134
Note:p. 134
notp. 134
+— Enter code 0001.p. 134
+— Enter codep. 134
0001p. 134
+— The system changes to service mode.p. 134
— The system changes to service mode.p. 134
— The display shows the tool symbol.p. 134
+— Enter code 1100.p. 134
+— Enter codep. 134
1100p. 134
+— The function "Setting the machine type code" is activated.p. 134
— The function "Setting the machine type code" is activated.p. 134
+— Enter code 1113.p. 134
+— Enter codep. 134
1113p. 134
+— The function "change to working speed" is deactivated.p. 134
+— The function "change to working speed" isp. 134
deactivatedp. 134
+— Switch off the ignition.p. 134
— Switch off the ignition.p. 134
+— END.p. 134
— END.p. 134
+Activating the function "Change to working speed":p. 135
Activating the function "Change to working speed":p. 135
+Actionp. 135
+Actionp. 135
Actionp. 135
+Resultp. 135
+Resultp. 135
Resultp. 135
+— Switch on the ignition.p. 135
— Switch on the ignition.p. 135
+Note: Dop. 135
Note:p. 135
notp. 135
+— Enter code 0001.p. 135
+— Enter codep. 135
0001p. 135
+— The system changes to service mode.p. 135
— The system changes to service mode.p. 135
— The display shows the tool symbol.p. 135
+— Enter code 1100.p. 135
+— Enter codep. 135
1100p. 135
+— The function "Setting the machine type code" is activated.p. 135
— The function "Setting the machine type code" is activated.p. 135
+— Enter code 1112.p. 135
+— Enter codep. 135
1112p. 135
+— The function "change to working speed" is activated.p. 135
+— The function "change to working speed" isp. 135
activatedp. 135
+— Switch off the ignition.p. 135
— Switch off the ignition.p. 135
+— END.p. 135
— END.p. 135
+6.14 Deactivating / activating the speed sensor(s)p. 136
+During operation the control permanently monitors all signals from the connected sensors. Should a speed sensor or part of its cable be defect, the movement of the machine may be affected. This defect will be detected and shown in the display in form…p. 136
During operation the control permanently monitors all signals from the connected sensors. Should a speed sensor or part of its cable be defect, the movement of the machine may be affected. This defect will be detected and shown in the display in form…p. 136
+l 1031p. 136
l 1031p. 136
l 1032p. 136
+In order to be able to continue operation of the machine despite the displayed error code, there is a possibility to deactivate the monitoring of the speed sensors.p. 136
In order to be able to continue operation of the machine despite the displayed error code, there is a possibility to deactivate the monitoring of the speed sensors.p. 136
+Pay attention to the section "Input Codes Display General"!p. 136
Pay attention to the section "Input Codes Display General"!p. 136
+Deactivating the function "Monitoring of speed sensors":p. 136
Deactivating the function "Monitoring of speed sensors":p. 136
+Actionp. 136
+Actionp. 136
Actionp. 136
+Resultp. 136
+Resultp. 136
Resultp. 136
+— Switch on the ignition.p. 136
— Switch on the ignition.p. 136
+Note: Dop. 136
Note:p. 136
notp. 136
+— Enter code 0001.p. 136
+— Enter codep. 136
0001p. 136
+— The system changes to service mode.p. 136
— The system changes to service mode.p. 136
— The display shows the tool symbol.p. 136
+— Enter code 1100.p. 136
+— Enter codep. 136
1100p. 136
+— The function "Setting the machine type code" is activated.p. 136
— The function "Setting the machine type code" is activated.p. 136
+— Enter code 1009.p. 136
+— Enter codep. 136
1009p. 136
+— The function "recording of speed signal" is deactivated.p. 136
+— The function "recording of speed signal" isp. 136
deactivatedp. 136
+Note: From now on the system will ignore a missing signal from the speed sensor.p. 136
Note:p. 136
+— Enter code 1100.p. 136
+— Enter codep. 136
1100p. 136
+— The function "Setting the machine type code" is activated.p. 136
— The function "Setting the machine type code" is activated.p. 136
+— Enter code 1111.p. 136
+— Enter codep. 136
1111p. 136
+— The function "monitoring the closed electric circuit" is deactivated.p. 136
+— The function "monitoring the closed electric circuit" isp. 136
deactivatedp. 136
+Note: From now on the system will ignore a possible cable breakage of the speed sensor.p. 136
Note:p. 136
+— Switch off the ignition.p. 136
— Switch off the ignition.p. 136
+— END.p. 136
— END.p. 136
+Once the defect on the speed sensor has been rectified, the monitoring function must be enabled again.p. 136
Once the defect on the speed sensor has been rectified, the monitoring function must be enabled again.p. 136
+Activating the function "Monitoring of speed sensors":p. 137
Activating the function "Monitoring of speed sensors":p. 137
+Actionp. 137
+Actionp. 137
Actionp. 137
+Resultp. 137
+Resultp. 137
Resultp. 137
+— Switch on the ignition.p. 137
— Switch on the ignition.p. 137
+Note: Dop. 137
Note:p. 137
notp. 137
+— Enter code 0001.p. 137
+— Enter codep. 137
0001p. 137
+— The system changes to service mode.p. 137
— The system changes to service mode.p. 137
— The display shows the tool symbol.p. 137
+— Enter code 1100.p. 137
+— Enter codep. 137
1100p. 137
+— The function "Setting the machine type code" is activated.p. 137
— The function "Setting the machine type code" is activated.p. 137
+— Enter code 1008.p. 137
+— Enter codep. 137
1008p. 137
+— The function "recording of speed signal" is activated.p. 137
+— The function "recording of speed signal" isp. 137
activatedp. 137
+Note: From now on the system expects a signal from the speed sensor.p. 137
Note:p. 137
+— Enter code 1100.p. 137
+— Enter codep. 137
1100p. 137
+— The function "Setting the machine type code" is activated.p. 137
— The function "Setting the machine type code" is activated.p. 137
+— Enter code 1110.p. 137
+— Enter codep. 137
1110p. 137
+— The function "monitoring the closed electric circuit" is activated.p. 137
+— The function "monitoring the closed electric circuit" isp. 137
activatedp. 137
+Note: From now on the system will monitor the wiring of the speed sensor.p. 137
Note:p. 137
+— Switch off the ignition.p. 137
— Switch off the ignition.p. 137
+— END.p. 137
— END.p. 137
+7 Replacement of componentsp. 139
+7 Replacement of componentsp. 139
How to proceed when replacing components?p. 140
+Forewordp. 140
Forewordp. 140
Each machine is adjusted individually ex factory. Should the replacement of machine parts become necessary during the operating period of the machine, there is always a possibility to repeat these adjustments.p. 140
BOMAG thereby does without any expensive special tools, but gives the service personnel the possibility tom make adjustments and settings easily and simply by just using the display on the machine. The chapter "Electrics finisher input codes" contain…p. 140
+Replacing the contgrol (ESX)p. 140
Replacing the contgrol (ESX)p. 140
Since the central control (ESX) saves all data and values, all teach procedures listed in the chapter "Electrics finisher input codes" must be carried out.p. 140
+Compliance with the specified sequence of procedures is mandatory!p. 140
Compliance with the specified sequence of procedures is mandatory!p. 140
Carry out the following teach procedure(s):p. 140
+l Input codes — reset to factory settings (Code:p. 140
+l Input codes — reset to factory settings (Code:p. 140
7861p. 140
Pp. 140
7865p. 140
Cp. 140
+l Input codes – automatic calibration of currents for travel system (p. 140
onlyp. 140
Cp. 140
+l If necessary: Input codes – manual calibration of currents for travel system (p. 140
onlyp. 140
Cp. 140
l Input codes — teaching E-throttle functionp. 140
l If necessary: Input codes – adapt engine speed.p. 140
+Replacement of travel pump(s)p. 140
Replacement of travel pump(s)p. 140
Carry out the following teach procedure(s):p. 140
+l Input codes – automatic calibration of currents for travel system (p. 140
+l Input codes – automatic calibration of currents for travel system (p. 140
onlyp. 140
Cp. 140
+l If necessary: Input codes – manual calibration of currents for travel system (p. 140
l Input codes — teaching E-throttle functionp. 140
+The following components can be replaced without a subsequent teach procedure:p. 140
The following components can be replaced without a subsequent teach procedure:p. 140
+l The displayp. 140
l The displayp. 140
+l The diesel engine (p. 140
Attention:p. 140
l All switches in the instrument panel and the lateral contro, panels.p. 140
+8 Enginep. 141
8 Enginep. 141
+8.5 Check the coolant levelp. 142
8.1 Featuresp. 142
+Generalp. 142
Generalp. 142
All BOMAG finishers BF300 are powered by powerful 4-cylinder KUBOTA engines with direct fuel injection, turbocharger and 4-valve technology. Engines which impress by their homogeneous development of power with low fuel consumption and low CO2 emissio…p. 142
Fig. 28p. 142
The standard BOMAG ECOMODE ensures a clean environmental balance. Due to the active engine management power is made available for the driver when it is needed and is reduced again when permitted by the application. Intelligent sensors in connection w…p. 142
Engine blockp. 142
Fig. 29 Engine blockp. 142
+1 Crankcase 1p. 142
1 Crankcase 1p. 142
2 Crankcase 2p. 142
+The engine has two separate crankcases – crankcase 1p. 142
(Fig. 29)p. 142
The cylinders are designed without liners, which ensures excellent cooling, lower tensions and good abrasion resistance.p. 142
Semi-floating valve coverp. 143
A recessed rubber seal ensures a distance of approx. 0.5 mm between valve cover and cylinder head. This reduces the development of noise on the cylinder head.p. 143
Fig. 30p. 143
+1 Valve coverp. 143
1 Valve coverp. 143
2 Rubber sealp. 143
Cylinder headp. 143
The engine has a 4-valve system with one cylinder head, which is designed with dual intake channels.p. 143
Fig. 31p. 143
+1 Intakep. 143
1 Intakep. 143
2 Exhaustp. 143
Central Direct Injection System (E-CDIS)p. 144
The engines are equipped with the central direct injection system (E-CDIS = Center Direct Injection System) with the injection nozzle arranged vertically in the centre of the cylinder.p. 144
The system injects the fuel directly into the centre of the cylinder.p. 144
Fig. 32p. 144
+1 Exhaust valvesp. 144
1 Exhaust valvesp. 144
2 Pistonp. 144
3 Injection nozzlep. 144
4 Intake valvesp. 144
+8.5 Check the coolant levelp. 144
8.2 Cooling systemp. 144
+Thermostatp. 144
Thermostatp. 144
Conventional thermostat valves (type outlet water temperature) open against the coolant flow. In this design the pressure (steam pressure + water pump output pressure) influences the opening/closing performance of the valve.p. 144
The valve could thus be delayed at a specified opening temperature and then suddenly open above the specified temperature. This is referred to as overshoot phenomenon. The overshoot problem also leads to a subharmonic phenomenon. Too much water coole…p. 144
A repetitive cycle of such overshoot and subharmonic phenomena is referred to as water temperature hunting. This overshoot problem not only adversely affects the cooling system components, but also the engine and related components.p. 144
+In order to tackle this problem the V3 is equipped with a flow control thermostat. The valve is provided with a recess 4p. 144
(Fig. 34)p. 144
Fig. 33p. 144
+1 Coolant temperaturep. 144
1 Coolant temperaturep. 144
2 Timep. 144
3 Overshootingp. 144
+4 (Fig. 34) Recessp. 144
4 (Fig. 34)p. 144
Fig. 34p. 145
Lower bypassp. 145
+The engines of series V3 are designed with lower bypass, which ensures better cooling performance of the radiator. At low coolant temperature in the engine the thermostat 1p. 145
(Fig. 35)p. 145
Fig. 35 Bypass closedp. 145
+If the temperature exceeds the thermostat opening temperature, the thermostat 1p. 145
(Fig. 36)p. 145
This enhances the cooling power of the radiator.p. 145
Fig. 36 Bypass openp. 145
+8.5 Check the coolant levelp. 146
8.3 Removing and installing the thermostatp. 146
Fig. 1p. 146
+1 Thermostat coverp. 146
1 Thermostat coverp. 146
2 Thermostat cover sealp. 146
3 Thermostatp. 146
4 Borep. 146
+l Unscrew the thermostat cover fastening screws and take off the thermostat cover (1)p. 146
+l Unscrew the thermostat cover fastening screws and take off the thermostat cover (1)p. 146
(Fig. 1)p. 146
l Remove the thermostat (3).p. 146
For assemblyp. 146
+l Assemble the thermostat cover (3) with the hole (4) facing towards the front cover side.p. 146
l Assemble the thermostat cover (3) with the hole (4) facing towards the front cover side.p. 146
+8.5 Check the coolant levelp. 146
8.4 Checking the thermostat in disassembled statep. 146
+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. 74,5°C to 78,5°C the thermostat is…p. 146
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. 74,5°C to 78,5°C the thermostat is…p. 146
Fig. 1p. 146
+l Measure and write down the measurement "a" on the thermostatp. 146
+l Measure and write down the measurement "a" on the thermostatp. 146
(Fig. 1)p. 146
+"a" = beginning of stroke at approx. 74.5°C to 78.5°C (T1)p. 146
"a" = beginning of stroke at approx. 74.5°C to 78.5°C (T1)p. 146
"b" = end of stroke at approx. 90 °C (T2)p. 146
Fig. 2p. 146
+l Warm up the thermostat in a water bathp. 146
+l Warm up the thermostat in a water bathp. 146
(Fig. 2)p. 146
+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. 146
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. 146
The water must thereby be stirred continuously, to ensure even temperature distribution.p. 146
The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.p. 147
Fig. 3p. 147
+l Measure and write down the measurement "b" on the thermostat .p. 147
+l Measure and write down the measurement "b" on the thermostat .p. 147
(Fig. 3)p. 147
l Calculate the stroke.p. 147
Stroke = b – ap. 147
+The stroke at the given temperature (T2) should be approx. 8 mm.p. 147
The stroke at the given temperature (T2) should be approx. 8 mm.p. 147
+8.5 Check the coolant levelp. 147
8.5 Check the coolant levelp. 147
+Danger of scalding!p. 147
+Danger of scalding!p. 147
Danger of scalding!p. 147
Do not remove the cap from the compensation tank when the engine is still hot.p. 147
Fill up coolant only when the engine is cold.p. 147
+If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 147
If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 147
Do not use radiator sealant to seal leaks.p. 147
For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 147
+l Open the engine flap and secure it.p. 147
l Open the engine flap and secure it.p. 147
Fig. 4p. 147
+l Check the coolant level in the compensation tankp. 147
+l Check the coolant level in the compensation tankp. 147
(Fig. 4)p. 147
l Top up coolant, if necessary.p. 147
Fig. 5p. 147
+l To top up unscrew the filler capp. 147
+l To top up unscrew the filler capp. 147
(Fig. 5)p. 147
+8.6 Check the anti-freeze concentration and the condition of the coolantp. 148
8.6 Check the anti-freeze concentration and the condition of the coolantp. 148
+Danger of scalding!p. 148
+Danger of scalding!p. 148
Danger of scalding!p. 148
Check the anti-freeze concentration only when the engine is cold.p. 148
+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. 148
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. 148
For coolant quality refer to the "table of fuels and lubricants".p. 148
Do not mix different coolants and additives, see section "Fuelds and Lubricants – Coolant".p. 148
If the coolant is contaminated by corrosion residues or other suspended matter, flush the cooling system, see section "Changing the coolant".p. 148
+Catch coolant and dispose of environmentally.p. 148
Catch coolant and dispose of environmentally.p. 148
Fig. 6p. 148
+l Unscrew the radiator capp. 148
+l Unscrew the radiator capp. 148
(Fig. 6)p. 148
l Check the condition of the coolant.p. 148
l Screw the cover back on again.p. 148
+8.7 Change the coolantp. 148
8.7 Change the coolantp. 148
+Danger of scalding!p. 148
+Danger of scalding!p. 148
Danger of scalding!p. 148
Do not remove the cap from the compensation tank when the engine is still hot.p. 148
Change the coolant only when the engine is cold.p. 148
+Do not start the engine after draining off the coolant.p. 148
Do not start the engine after draining off the coolant.p. 148
Thoroughly flush the engine if the coolant is contaminated by corrosion residues or other suspended matter.p. 148
When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.p. 148
Do not mix different coolants and additives of any other kind.p. 148
Change the coolant at the latest after two years.p. 148
For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 148
+Catch coolant and dispose of environmentally.p. 148
Catch coolant and dispose of environmentally.p. 148
Fig. 7p. 148
+l Unscrew the capp. 148
+l Unscrew the capp. 148
(Fig. 7)p. 148
Fig. 8p. 149
+l Unscrew the plug, let the coolant run out and catch itp. 149
+l Unscrew the plug, let the coolant run out and catch itp. 149
(Fig. 8)p. 149
l Screw the plug back in once all coolant has run out.p. 149
l Check the condition of the coolant.p. 149
l Thoroughly flush the engine if the coolant is contaminated by corrosion residues or other suspended matter.p. 149
l Fill in clean water.p. 149
l Start the engine and flush the cooling system out for a short while.p. 149
l Drain all water off.p. 149
Fig. 9p. 149
+l Fill in coolant up to theMAX markp. 149
+l Fill in coolant up to theMAX markp. 149
(Fig. 9)p. 149
l Start the diesel engine and run it warm to operating temperature.p. 149
l Let the engine cool down and check the coolant level again, top up if necessary.p. 149
+8.8 Checking radiator hoses and hose clampsp. 149
8.8 Checking radiator hoses and hose clampsp. 149
+Danger of burning!p. 149
+Danger of burning!p. 149
Danger of burning!p. 149
Perform inspection work only after the engine has cooled down and with the engine stopped.p. 149
+If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately.p. 149
If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately.p. 149
Take care that no contaminants enter into the air intake system, since this could damage the engine!p. 149
Fig. 10p. 149
+l Check the condition and tight fit of all radiator hoses and hose clampsp. 149
+l Check the condition and tight fit of all radiator hoses and hose clampsp. 149
(Fig. 10)p. 149
+l Check the condition and tight fit of all air intake lines and hose clamps.p. 149
l Check the condition and tight fit of all air intake lines and hose clamps.p. 149
+8.9 Clean the cooling fins on engine and hydraulic oil coolerp. 150
8.9 Clean the cooling fins on engine and hydraulic oil coolerp. 150
+Danger of injury!p. 150
+Danger of injury!p. 150
Danger of injury!p. 150
Perform cleaning work only after the engine has cooled down and with the engine stopped.p. 150
+Do not damage any cooling fins on the cooler core when cleaning.p. 150
Do not damage any cooling fins on the cooler core when cleaning.p. 150
+Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this reason you should always seal any oil or fuel leaks in the vicinity of the cooling fan o…p. 150
Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this reason you should always seal any oil or fuel leaks in the vicinity of the cooling fan o…p. 150
+Cleaning with compressed airp. 150
Cleaning with compressed airp. 150
+Start to blow out from the exhaust side.p. 150
Start to blow out from the exhaust side.p. 150
Fig. 11p. 150
+l Blow the coolerp. 150
+l Blow the coolerp. 150
(Fig. 11)p. 150
+Cleaning with cold cleansing agentp. 150
Cleaning with cold cleansing agentp. 150
+Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 150
Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 150
+l Spray the engine with a suitable cleansing agent, e.g. cold cleanser, let it soak in for a while and spray it off with a strong water jet.p. 150
l Spray the engine with a suitable cleansing agent, e.g. cold cleanser, let it soak in for a while and spray it off with a strong water jet.p. 150
l Run the engine warm for a while to avoid corrosion.p. 150
+8.10 Checking the engine oil levelp. 150
8.10 Checking the engine oil levelp. 150
+The machine must be in horizontal position.p. 150
+The machine must be in horizontal position.p. 150
The machine must be in horizontal position.p. 150
If the engine is warm, shut it down and check the oil level after five minutes.p. 150
With a cold engine the oil level can be checked immediately.p. 150
For quality of oil refer to the "table of fuels and lubricants".p. 150
+l Open and support the engine hood.p. 150
l Open and support the engine hood.p. 150
Fig. 12p. 150
+l Pull the dipstickp. 150
+l Pull the dipstickp. 150
(Fig. 12)p. 150
l Pull the dipstick back out.p. 150
l The oil level must always be between the "MIN"- and "MAX"-marks. If the oil level is too low, top up oil to the "MAX" mark immediately.p. 150
+8.11 Changing engine oil and oil filter cartridgep. 151
8.11 Changing engine oil and oil filter cartridgep. 151
+Danger of scalding!p. 151
+Danger of scalding!p. 151
Danger of scalding!p. 151
When draining off hot oil.p. 151
By hot oil when unscrewing the engine oil filter.p. 151
+Drain the engine oil only when the engine is warm.p. 151
Drain the engine oil only when the engine is warm.p. 151
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 151
+Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 151
Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 151
Fig. 13p. 151
+l Unscrew the drain hosep. 151
+l Unscrew the drain hosep. 151
(Fig. 13)p. 151
l Fasten the drain hose again in place.p. 151
Fig. 14p. 151
+l Unscrew the filter cartridge (1)p. 151
+l Unscrew the filter cartridge (1)p. 151
(Fig. 14)p. 151
l Wipe the sealing face clean.p. 151
l Cover the rubber seal of the new engine oil filter slightly with clean oil.p. 151
l Spin the new fuel filter cartridge on and tighten it hand tight.p. 151
+l Fill in new engine oil through the oil filler neck (2).p. 151
l Fill in new engine oil through the oil filler neck (2).p. 151
+l Screw the cap back on again.p. 151
l Screw the cap back on again.p. 151
Fig. 15p. 151
+l After a short test run check the oil level on the dipstickp. 151
+l After a short test run check the oil level on the dipstickp. 151
(Fig. 15)p. 151
l Check filter cartridge and drain plug for leaks.p. 151
+8.13 Replace the fuel filterp. 152
8.12 Fuel systemp. 152
+Regulatorp. 152
Regulatorp. 152
Fig. 16 Regulatorp. 152
The engine is equipped with a separate injection pump, combined with the small mechanical multi- function governor from Kubota. It also contains a torque limitation mechanism to control the maximum peak torque. This mechanism maintains the engine spe…p. 152
The governor is a mechanical governor which controls the fuel injection quantity over all speed ranges from idle speed to maximum speed by using spring force to simply compensate the centrifugal force of the governor weights.p. 152
Governor during startingp. 152
+If no centrifugal force acts on the governor weights (2)p. 152
(Fig. 17)p. 152
Fig. 17 Governor during startingp. 152
+1 Start springp. 152
1 Start springp. 152
2 Governor weightp. 152
Governor at idle speedp. 153
+The throttle lever (2)p. 153
(Fig. 18)p. 153
When the fork lever (1) is tensioned, both the spring bolt (3) and the for lever (5) will move in direction of arrow A to hold back the governor weights (6). The centrifugal force of the governor weights (6) is compensated in combination with the sta…p. 153
Fig. 18 Governor at idle speedp. 153
+1 Fork leverp. 153
1 Fork leverp. 153
2 Throttle leverp. 153
3 Spring boltp. 153
4 Start springp. 153
5 Fork leverp. 153
6 Governor weightp. 153
7 Governor springp. 153
Governor at nominal speedp. 153
+When the throttle control lever (2)p. 153
(Fig. 18)p. 153
(Fig. 18)p. 153
(Fig. 18)p. 153
(Fig. 19)p. 153
+When the engine is overloaded the engine speed will drop together with the centrifugal force of the governor weights (6)p. 153
(Fig. 18)p. 153
(Fig. 18)p. 153
Fig. 19 Governor at nominal speedp. 153
+1 Maximum speed without loadp. 153
1 Maximum speed without loadp. 153
2 Output power limitation screwp. 153
3 Torque limitation screwp. 153
Governor when shutting down the enginep. 154
+Interrupting the electric power to the shut-down solenoid (1) will release the centrifugal force of the solenoid, whereby the solenoid armature is ejected and moves the governor rack to position Bp. 154
(Fig. 20)p. 154
In order to shut down the engine manually, the shut- down lever must be shifted to the left.p. 154
Fig. 20 Governor when shutting down the enginep. 154
+1 Shut-down solenoidp. 154
1 Shut-down solenoidp. 154
2 Stop lever axlep. 154
2-stage nozzlep. 154
The nozzle holder, which is fitted with two springs, was designed for the reduction of nitrogen oxide and particle emissions.p. 154
The nozzle holder with two springs limits the valve stroke during initial opening of the valve in order to throttle the injection quantity. Main injection takes place when the line pressure has sufficiently increased and is able to open the needle va…p. 154
This results in the following characteristics.p. 155
+l Improved engine stability at low and medium speeds.p. 155
l Improved engine stability at low and medium speeds.p. 155
l Reduced speed oscillations and speed jumps.p. 155
l Reduced noise development at idle speed.p. 155
l Reduced idle speed due to improved engine stability.p. 155
l Stabilized fuel injection characteristics of injection pump and nozzle system and simplified adaptation of the governor characteristics to the engine requirements.p. 155
Initial opening pressurep. 155
The force generated by the high pressure of the fuel supplied by the injection pump presses the needle valve up. Once this force exceeds the rated force of the first spring the needle valve in the nozzle will move the first push rod up and open the v…p. 155
Second opening pressurep. 155
Once the first push rod has been lifted in the pre- stroke, it will touch the second push rod. Since the rated force of the second spring acts on the second push rod, the combined forces of the first and second springs will act on the needle valve, w…p. 155
+8.13 Replace the fuel filterp. 155
8.13 Replace the fuel filterp. 155
+Fire hazard! Health hazard!p. 155
+Fire hazard! Health hazard!p. 155
Fire hazard! Health hazard!p. 155
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 155
Do not inhale any fuel fumes.p. 155
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filter.p. 155
Ensure strict cleanliness! Thoroughly clean the area around the fuel filter.p. 155
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 155
+Any fuel must be caught and disposed of in an environmentally friendly manner.p. 155
Any fuel must be caught and disposed of in an environmentally friendly manner.p. 155
Fig. 22p. 155
+l Loosen and unscrew fuel filter cartridge (1)p. 155
+l Loosen and unscrew fuel filter cartridge (1)p. 155
(Fig. 22)p. 155
l Clean the sealing face on the filter carrier from any dirt.p. 155
l Slightly oil the rubber seal on the new filter cartridge.p. 155
+l Turn the new filter cartridge on by hand, until the seal contacts.p. 155
l Turn the new filter cartridge on by hand, until the seal contacts.p. 155
l Tighten the filter element for another half turn.p. 155
l Check the filter cartridge for leaks after a short test run.p. 155
+8.14 Checking, cleaning the water separatorp. 156
8.14 Checking, cleaning the water separatorp. 156
+Fire hazard! Health hazard!p. 156
+Fire hazard! Health hazard!p. 156
Fire hazard! Health hazard!p. 156
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 156
Do not inhale any fuel fumes.p. 156
+Any fuel must be caught and disposed of in an environmentally friendly manner.p. 156
Any fuel must be caught and disposed of in an environmentally friendly manner.p. 156
+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 check the filter bowl initially every day, later as required, for s…p. 156
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 check the filter bowl initially every day, later as required, for s…p. 156
If a too high quantity is drained off, the filter needs to be bled, see section "Replacing the fuel pre-cleaner cartridge".p. 156
Fig. 23p. 156
+l If the "water in fuel" warning light (b)p. 156
+l If the "water in fuel" warning light (b)p. 156
(Fig. 23)p. 156
Fig. 24p. 156
+l Slacken the drain plugp. 156
+l Slacken the drain plugp. 156
(Fig. 24)p. 156
l Turn the plug tightly back in. Check for leaks, if necessary use a new seal ring.p. 156
+Once the water separator is empty the warning lamp for water in fuel must go out.p. 156
Once the water separator is empty the warning lamp for water in fuel must go out.p. 156
+8.15 Changing the fuel filter, bleeding the fuel systemp. 157
8.15 Changing the fuel filter, bleeding the fuel systemp. 157
+Fire hazard! Health hazard!p. 157
+Fire hazard! Health hazard!p. 157
Fire hazard! Health hazard!p. 157
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 157
Do not inhale any fuel fumes.p. 157
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filter.p. 157
Ensure strict cleanliness! Thoroughly clean the area around the fuel filter.p. 157
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 157
+Any fuel must be caught and disposed of in an environmentally friendly manner.p. 157
Any fuel must be caught and disposed of in an environmentally friendly manner.p. 157
Fig. 25p. 157
+l Tighten the cable on the water separatorp. 157
+l Tighten the cable on the water separatorp. 157
(Fig. 25)p. 157
l (1) Loosen the bleeding screw and drain off fuel from the bleeding screw.p. 157
l (2) Loosen and unscrew the fuel pre-filter cartridge using an appropriate filter wrench.p. 157
l (3) Unscrew the water separator from the filter cartridge.p. 157
l (4) Apply a thin coat of oil to the rubber seal of the water separator.p. 157
l (5) Turn the water separator on by hand, until the seal contacts, then tighten hand-tight.p. 157
l (6) Apply a thin coat of oil to the rubber seal of the filter element.p. 157
l (7) Turn the filter cartridge on by hand, until the seal contacts, then tighten hand-tight.p. 157
l Plug the water sensor cable back on.p. 157
+Bleed the fuel systemp. 157
Bleed the fuel systemp. 157
+The fuel system is equipped with an electric fuel pump. Tom purge the system switch on the ignition and wait about 15 seconds before starting the engine.p. 157
The fuel system is equipped with an electric fuel pump. Tom purge the system switch on the ignition and wait about 15 seconds before starting the engine.p. 157
+8.16 Check fuel lines and clampsp. 158
8.16 Check fuel lines and clampsp. 158
+Danger of burning!p. 158
+Danger of burning!p. 158
Danger of burning!p. 158
Perform inspection work only after the engine has cooled down and with the engine stopped.p. 158
+If fuel lines or hose clamps are found to be damaged, the corresponding parts must be immediately repaired or replaced.p. 158
If fuel lines or hose clamps are found to be damaged, the corresponding parts must be immediately repaired or replaced.p. 158
After replacing lines or hose clamps the fuel system needs to be bled.p. 158
Removed or new fuel lines must be closed with clean cloths on both ends, to make sure that no dirt will enter into the fuel system. Dirt particles can destroy the injection pump.p. 158
Fig. 26p. 158
+l Check the condition and tight fit of all hose clamps (1)p. 158
+l Check the condition and tight fit of all hose clamps (1)p. 158
(Fig. 26)p. 158
+8.17 Check the fuel injection nozzlesp. 158
8.17 Check the fuel injection nozzlesp. 158
+This work must only be performed by authorized service personnel.p. 158
+This work must only be performed by authorized service personnel.p. 158
This work must only be performed by authorized service personnel.p. 158
+8.18 Check the fuel injection timingp. 159
8.18 Check the fuel injection timingp. 159
+This work must only be performed by authorized service personnel.p. 159
+This work must only be performed by authorized service personnel.p. 159
This work must only be performed by authorized service personnel.p. 159
+8.19 Check the fuel injection pumpp. 159
8.19 Check the fuel injection pumpp. 159
+This work must only be performed by authorized service personnel.p. 159
+This work must only be performed by authorized service personnel.p. 159
This work must only be performed by authorized service personnel.p. 159
+8.20 Servicing the generator V-beltp. 160
8.20 Servicing the generator V-beltp. 160
+Checking the condition and tightness of V-beltsp. 160
Checking the condition and tightness of V-beltsp. 160
Fig. 27p. 160
+l Check the entire circumference of the V-beltp. 160
+l Check the entire circumference of the V-beltp. 160
(Fig. 27)p. 160
l Check with thumb pressure (2) whether the V-belt can be depressed more than 10 to 12 mm between the V-belt pulleys, retighten if necessary.p. 160
+Tightening the V-beltp. 160
Tightening the V-beltp. 160
+l To retighten loosen the fastening screws (1)p. 160
+l To retighten loosen the fastening screws (1)p. 160
(Fig. 27)p. 160
l Tighten the V-belt, until it can be depressed no more than 10 to 12 mm by thumb pressure.p. 160
l Finally tighten the fastening screws again.p. 160
+Replacing the V-beltp. 160
Replacing the V-beltp. 160
+l Loosen fastening screws (1)p. 160
+l Loosen fastening screws (1)p. 160
(Fig. 27)p. 160
l Lift up the generator.p. 160
l Take off the old V-belt and install a new one.p. 160
l Tighten the V-belt, until it can be depressed no more than 10 to 12 mm by thumb pressure.p. 160
l Retighten the fastening screws (1).p. 160
+8.21 Air filter maintenancep. 160
8.21 Air filter maintenancep. 160
+Do not start the engine after having removed the air filter.p. 160
+Do not start the engine after having removed the air filter.p. 160
Do not start the engine after having removed the air filter.p. 160
If necessary, the air filter may be cleaned up to six times. After one year at the latest it must be replaced together with the safety element.p. 160
Cleaning does not make sense if the air filter element is covered with a sooty deposit.p. 160
Do not use gasoline or hot fluids to clean the filter element.p. 160
After cleaning the air filter must be inspected for damage using a torch.p. 160
Do not continue to use a damaged air filter element. If in doubt use a new air filter.p. 160
If the air filter is damaged, the safety element must be replaced as well.p. 160
The safety element must not be cleaned.p. 160
+We generally recommend to renew the air filter. A new filter element is far less expensive than a possible engine damage.p. 160
We generally recommend to renew the air filter. A new filter element is far less expensive than a possible engine damage.p. 160
Fig. 28p. 160
+Service of the air filter is also due when the air filter warning light (h)p. 160
(Fig. 28)p. 160
+Once the air filter warning lamp lights up, work may be continued until the end of the day.p. 160
Once the air filter warning lamp lights up, work may be continued until the end of the day.p. 160
+l Open the engine hood completely and secure it.p. 160
l Open the engine hood completely and secure it.p. 160
Fig. 29p. 161
+l Loosen both locking hooksp. 161
+l Loosen both locking hooksp. 161
(Fig. 29)p. 161
Fig. 30p. 161
+l Pull out the main filter elementp. 161
+l Pull out the main filter elementp. 161
(Fig. 30)p. 161
l Clean housing, housing cover and dust discharge valve.p. 161
+Danger of injury!p. 161
Danger of injury!p. 161
Wear protective clothing (goggles, gloves).p. 161
Fig. 31p. 161
+l Blow the air filterp. 161
+l Blow the air filterp. 161
(Fig. 31)p. 161
Fig. 32p. 161
+l Examine the air filter with a torch for cracks and holes in the paper bellowsp. 161
+l Examine the air filter with a torch for cracks and holes in the paper bellowsp. 161
(Fig. 32)p. 161
+l In case of damage replace the air filter and the safety element.p. 161
l In case of damage replace the air filter and the safety element.p. 161
Fig. 33p. 161
+l Slide the air filter carefully into the housingp. 161
+l Slide the air filter carefully into the housingp. 161
(Fig. 33)p. 161
+The dust discharge valve must point vertically downwards.p. 161
The dust discharge valve must point vertically downwards.p. 161
Make sure that the cover locks engage correctly.p. 161
+l Reassemble the housing cover.p. 161
l Reassemble the housing cover.p. 161
+Replacing the safety elementp. 161
Replacing the safety elementp. 161
+The safety element must not be cleaned and should not be used again after it has been removed.p. 161
The safety element must not be cleaned and should not be used again after it has been removed.p. 161
The safety element must be replaced:p. 161
+l if the air filter is damaged or has been replaced replaced.p. 161
+l if the air filter is damaged or has been replaced replaced.p. 161
l if the air filter is damaged or has been replaced replaced.p. 161
+l at the latest after 1 year.p. 162
l at the latest after 1 year.p. 162
+l if the air filter warning lamp comes on again after the air filter has been cleaned.p. 162
l if the air filter warning lamp comes on again after the air filter has been cleaned.p. 162
Fig. 34p. 162
+l Remove the housing cover and pull out the air filter.p. 162
l Remove the housing cover and pull out the air filter.p. 162
+l Pull the safety elementp. 162
(Fig. 34)p. 162
l Push in a new safety filter element.p. 162
l Insert the air filter and reassemble the housing cover.p. 162
+8.22 Check the engine mountsp. 162
8.22 Check the engine mountsp. 162
Fig. 35p. 162
+l Check the fastening of intake and exhaust tubesp. 162
+l Check the fastening of intake and exhaust tubesp. 162
(Fig. 35)p. 162
l Check sockets and clamps between air filter, exhaust turbocharger and charge air line as well as the lubrication air line for tight fit and leaks.p. 162
l Check fastening screws on oil sump and engine mounts for tight fit.p. 162
+l Check condition and tight fit of engine pillow blocks.p. 162
l Check condition and tight fit of engine pillow blocks.p. 162
+8.23 Engine conservationp. 163
8.23 Engine conservationp. 163
+If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the service department of the engine manufacturer for further details.p. 163
If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the service department of the engine manufacturer for further details.p. 163
+8.24 Check, adjust the valve clearancep. 163
8.24 Check, adjust the valve clearancep. 163
+We recommend to have this work carried out by trained personnel or our after sales service.p. 163
+We recommend to have this work carried out by trained personnel or our after sales service.p. 163
We recommend to have this work carried out by trained personnel or our after sales service.p. 163
Check the valve clearance only when the engine is cold.p. 163
Fig. 36p. 163
+l Loosen the plug connections (4)p. 163
+l Loosen the plug connections (4)p. 163
(Fig. 36)p. 163
l Unscrew and take off the injection lines (1).p. 163
l Unscrew and take off the valve cover (2).p. 163
Adjustment value for intake and exhaust valves: 0.13 mm to 0.17 mm (0.0051 in to 0.0067 in)p. 163
+Adjustment schematicp. 163
Adjustment schematicp. 163
+Cylinderp. 163
Cylinderp. 163
+Intakep. 163
Intakep. 163
+Exhaustp. 163
Exhaustp. 163
+Cylinder 1 in TDCp. 163
Cylinder 1 in TDCp. 163
+1p. 163
1p. 163
+xp. 163
xp. 163
+xp. 163
xp. 163
+2p. 163
2p. 163
+xp. 163
xp. 163
+3p. 163
3p. 163
+xp. 163
xp. 163
+4p. 163
4p. 163
+Cylinder 1 overlappingp. 163
Cylinder 1 overlappingp. 163
+1p. 163
1p. 163
+2p. 163
2p. 163
+xp. 163
xp. 163
+3p. 163
3p. 163
+xp. 163
xp. 163
+4p. 163
4p. 163
+xp. 163
xp. 163
+xp. 163
xp. 163
Fig. 37p. 164
+l 1. Set the cylinder to TDCp. 164
+l 1. Set the cylinder to TDCp. 164
(Fig. 37)p. 164
Fig. 38p. 164
+l A feeler gauge of appropriate thickness (A) must fit with little resistance between rocker armp. 164
+l A feeler gauge of appropriate thickness (A) must fit with little resistance between rocker armp. 164
(Fig. 38)p. 164
l If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.p. 164
Fig. 39p. 164
+l Loosen the counter nut (4)p. 164
+l Loosen the counter nut (4)p. 164
(Fig. 39)p. 164
l Adjust the valve clearance by the adjustment screw (3) and tighten the counter nut.p. 164
+l 1. Set the cylinder to overlapping and check the valve clearance as per adjustment schematic, adjust if necessary.p. 164
l 1. Set the cylinder to overlapping and check the valve clearance as per adjustment schematic, adjust if necessary.p. 164
Fig. 40p. 164
+l Check the valve cover gasket for damage, change if necessary.p. 164
l Check the valve cover gasket for damage, change if necessary.p. 164
+l Install the valve cover (2)p. 164
(Fig. 40)p. 164
Fig. 41p. 164
+l Reinstall the injection lines (1)p. 164
+l Reinstall the injection lines (1)p. 164
(Fig. 41)p. 164
l Make sure that the clamps (5) are correctly positioned.p. 164
l Screw in the preheating plugs (tightening torque: 8 Nm (5.9 ft.lbs)).p. 164
l Plug in the plug connections.p. 164
8.25 Engine problemsp. 165
+Faultp. 165
Faultp. 165
+Possible causep. 165
Possible causep. 165
+Remedyp. 165
Remedyp. 165
+Engine does not startp. 165
Engine does not startp. 165
+Starter defective or pinion does not engagep. 165
+Choose winter fuel and engine oil according to ambient temperatures.p. 165
Choose winter fuel and engine oil according to ambient temperatures.p. 165
+Fuel filter clogged, in winter due to paraffin separationp. 165
Fuel filter clogged, in winter due to paraffin separationp. 165
+Change the filter, use winter fuel.p. 165
Change the filter, use winter fuel.p. 165
+Fuel lines leakingp. 165
Fuel lines leakingp. 165
+Check all line connections for leaks and tighten the fittings, bleed the fuel system.p. 165
Check all line connections for leaks and tighten the fittings, bleed the fuel system.p. 165
+Battery not charged or not connectedp. 165
Battery not charged or not connectedp. 165
+Tighten the terminal clamps on the battery, check all cable connections.p. 165
Tighten the terminal clamps on the battery, check all cable connections.p. 165
+Injection valves or injection pump defectivep. 165
Injection valves or injection pump defectivep. 165
+Have examined by a specialist.p. 165
Have examined by a specialist.p. 165
+Poor starting of engine or engine works irregularly with poor powerp. 165
Poor starting of engine or engine works irregularly with poor powerp. 165
+Battery power too low, terminal clamps loose or oxidized causing the starter to turn too slowly.p. 165
Battery power too low, terminal clamps loose or oxidized causing the starter to turn too slowly.p. 165
+Check the battery charge condition, clean the terminal clamps, tighten and cover them with acid-free grease.p. 165
Check the battery charge condition, clean the terminal clamps, tighten and cover them with acid-free grease.p. 165
+Especially during winter: use of too viscous engine oilp. 165
Especially during winter: use of too viscous engine oilp. 165
+Use an engine oil compatible for the ambient temperatures.p. 165
Use an engine oil compatible for the ambient temperatures.p. 165
+Fuel supply too low, fuel system clogged by paraffin separation during winterp. 165
Fuel supply too low, fuel system clogged by paraffin separation during winterp. 165
+Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel under cold conditions.p. 165
Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel under cold conditions.p. 165
+The specified valve clearance is not correctp. 165
The specified valve clearance is not correctp. 165
+Adjust the valve clearance.p. 165
Adjust the valve clearance.p. 165
+Dry air filter cartridge soiledp. 165
Dry air filter cartridge soiledp. 165
+Clean, if necessary use a new one.p. 165
Clean, if necessary use a new one.p. 165
+Injection lines leakingp. 165
Injection lines leakingp. 165
+Check all line connections for leaks and tighten the fittings, bleed the fuel system.p. 165
Check all line connections for leaks and tighten the fittings, bleed the fuel system.p. 165
+Turbo charger defectivep. 165
Turbo charger defectivep. 165
+Have examined by a specialist.p. 165
Have examined by a specialist.p. 165
+Injection valve defectivep. 165
Injection valve defectivep. 165
+Have examined by a specialist.p. 165
Have examined by a specialist.p. 165
+Excessive exhaust smokep. 165
Excessive exhaust smokep. 165
+Engine oil level too highp. 165
Engine oil level too highp. 165
+Drain the oil down to the top dipstick mark.p. 165
Drain the oil down to the top dipstick mark.p. 165
+Dry air filter soiledp. 165
Dry air filter soiledp. 165
+Clean, if necessary use a new one.p. 165
Clean, if necessary use a new one.p. 165
+Injection nozzle defectivep. 165
Injection nozzle defectivep. 165
+Have examined by a specialist.p. 165
Have examined by a specialist.p. 165
+Poor compression because of burned or broken compression ringsp. 165
Poor compression because of burned or broken compression ringsp. 165
+Have compression rings and pistons examined by specialist.p. 165
Have compression rings and pistons examined by specialist.p. 165
+The specified valve clearance is not correctp. 165
The specified valve clearance is not correctp. 165
+Adjust the valve clearance.p. 165
Adjust the valve clearance.p. 165
+Engine overheating, engine must be shut down immediately!p. 166
Engine overheating, engine must be shut down immediately!p. 166
+Cooling fins on radiator extremely dirty (the warning light for engine oil temperature lights)p. 166
Cooling fins on radiator extremely dirty (the warning light for engine oil temperature lights)p. 166
+Clean the cooling fins.p. 166
Clean the cooling fins.p. 166
+Engine oil level too lowp. 166
Engine oil level too lowp. 166
+Top up engine oil up to the top dipstick mark.p. 166
Top up engine oil up to the top dipstick mark.p. 166
+Coolant level too lowp. 166
Coolant level too lowp. 166
+Check all lines. hoses and engine for leaks, fill up coolant. Do not use radiator sealant to seal leaks.p. 166
Check all lines. hoses and engine for leaks, fill up coolant. Do not use radiator sealant to seal leaks.p. 166
+Thermostat defectivep. 166
Thermostat defectivep. 166
+Check the thermostat, replace if necessary.p. 166
Check the thermostat, replace if necessary.p. 166
+Interior parts of radiator corrodedp. 166
Interior parts of radiator corrodedp. 166
+Clean or replace the radiator.p. 166
Clean or replace the radiator.p. 166
+Insufficient cooling air supply to the cooling fanp. 166
Insufficient cooling air supply to the cooling fanp. 166
+Remove any clogging from the cooling air ductp. 166
Remove any clogging from the cooling air ductp. 166
+V-belt loose or brokenp. 166
V-belt loose or brokenp. 166
+Tension or replace the V-beltp. 166
Tension or replace the V-beltp. 166
+Engine oil pressure too lowp. 166
Engine oil pressure too lowp. 166
+Engine oil level too low (engine oil pressure warning light comes on, warning buzzer sounds)p. 166
Engine oil level too low (engine oil pressure warning light comes on, warning buzzer sounds)p. 166
+Top up oil.p. 166
Top up oil.p. 166
+Leaks in the lubrication systemp. 166
Leaks in the lubrication systemp. 166
+Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittings.p. 166
Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittings.p. 166
+The charge control light lights during operation, the warning buzzer soundsp. 166
The charge control light lights during operation, the warning buzzer soundsp. 166
+Generator speed too lowp. 166
Generator speed too lowp. 166
+Check the V-belt tension, if necessary replace the V-belt.p. 166
Check the V-belt tension, if necessary replace the V-belt.p. 166
+Generator or regulator defectivep. 166
Generator or regulator defectivep. 166
+Have examined by a specialist.p. 166
Have examined by a specialist.p. 166
+9 Material hopper, descriptionp. 167
+9 Material hopper, descriptionp. 167
Material hopper and transportp. 168
+Material flow — overviewp. 168
Material flow — overviewp. 168
+The material is mainly conveyed by the following componentsp. 168
(Fig. 42)p. 168
+l The material hopper (1)p. 168
l The material hopper (1)p. 168
l The scraper belts (2)p. 168
l The augers (3)p. 168
Fig. 42 Material flow — overviewp. 168
+Material hopperp. 169
Material hopperp. 169
Fig. 43 Material hopperp. 169
+1 Material hopperp. 169
1 Material hopperp. 169
2 Locking systemp. 169
3 Hydraulic cylinderp. 169
+Description of functionp. 169
Description of functionp. 169
+The material hopper (1)p. 169
(Fig. 43)p. 169
3p. 169
The hydraulic cylinders (3) move the wings of the hopper (1) upwards, so that a sufficient amount of material is fed to the scraper belts at any time. Each wing can be moved independently from the other wing.p. 169
Each of the hydraulic cylinders (3) is equipped with locking systems (2) for transporting the finisher. With the cylinder (3) extended these are folded down and thus protect the piston rod during transport. Moreover, the locks (2) also make sure that…p. 169
+Scraper beltsp. 170
Scraper beltsp. 170
Fig. 44 Scraper beltsp. 170
+1 Chain tensioner for scraper belt drivep. 170
1 Chain tensioner for scraper belt drivep. 170
2 Hydraulic motorp. 170
3 Chainp. 170
4 Drive gear for scraper beltp. 170
5 Scraper belt rightp. 170
6 Scraper belt leftp. 170
7 Scraper belt tensionerp. 170
+Description of functionp. 170
Description of functionp. 170
+The scraper belts (5) & (6)p. 170
(Fig. 44)p. 170
The two scraper belts (5) & (6) made of high-tenacity steel work independently from one another an independently from the travel speed of the machine.p. 170
+Two sensors (mechanically (as so-called "Paddles") or ultrasonicp. 170
Optionp. 170
The tension of the scraper belts is adjusted with the tensioners (7) at the front of the frame.p. 170
Each scraper belt is driven by a hydraulic motor (2). The torque of the hydraulic motor is transferred with the help of a chaion, which is tensioned by a chain tensioner (1). The chain (3) runs over the drive gear (4), which drives the scraper belt.p. 170
+Augersp. 171
Augersp. 171
Fig. 45 Augersp. 171
+1 Hydraulic motorsp. 171
1 Hydraulic motorsp. 171
2 Hydraulic cylinderp. 171
3 Guide rodp. 171
4 Mounting rodp. 171
5 Augerp. 171
+Description of functionp. 171
Description of functionp. 171
+The augers (5)p. 171
(Fig. 45)p. 171
The augers (5) work independently from one another an independently from the travel speed of the machine. They are hydraulically operated via adjustable mechanical or ultrasonic sensors, by On/Off switches or proportional controls. Each auger (5) is …p. 171
The augers (5) can be adjusted in height with the hydraulic cylinders (2). The augers must be adjusted one step higher than the front edge of the screed plate (approx. 30-60 mm higher. This depends on the particle size of the material.)p. 171
The assembly flaps (4) prevent material being conveyed beyond the width of the screed.p. 171
+Care and maintenance workp. 171
+Care and maintenance workp. 171
+All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu- Trennkonzentrat, green")p. 171
before and afterp. 171
+10 Vibrating screed, descriptionp. 173
+10 Vibrating screed, descriptionp. 173
Screedp. 174
+Screed — overviewp. 174
Screed — overviewp. 174
+The screedp. 174
(Fig. 46)p. 174
+l The drawing arms (1)p. 174
l The drawing arms (1)p. 174
l The screed (2)p. 174
Fig. 46 Screed — overviewp. 174
+Drawing armsp. 175
Drawing armsp. 175
Fig. 47 Drawing armsp. 175
+1 Scalep. 175
1 Scalep. 175
2 Drawing armp. 175
3 Hydraulic cylinder (lift-out cylinder)p. 175
4 Fastening points of the screedp. 175
5 Hydraulic cylinder (levelling cylinder)p. 175
6 Hook-in pointp. 175
+Description of functionp. 175
Description of functionp. 175
+The drawing arms (2)p. 175
(Fig. 47)p. 175
The hook-in point (6) of the drawing arm (2) can be hydraulically adjusted in height. This provides a possibility to influence the layer thickness (angle of attack). The scale (1) at the upper end of the hydraulic cylinder (5), which is responsible f…p. 175
The complete screed can be lifted with the help of the hydraulic cylinders (3).p. 175
Adjusting bolts can be found at the rear fastening point of the screed (4). These can be used to preset the angle of attack, if the angle to be adjusted can not be achieved via the hydraulic cylinders (5).p. 175
+Screedp. 176
Screedp. 176
Fig. 48 Screedp. 176
+1 Screedp. 176
1 Screedp. 176
2 Exit flapp. 176
+3 Heating rodp. 176
Optionp. 176
4 Outside control standp. 176
5 Control element for electric heatingp. 176
6 Vibrator unit central screedp. 176
7 Vibrator unit extendable screedp. 176
+8 Tamper unitp. 176
Optionp. 176
+9 Tamper unitp. 176
Optionp. 176
10 Base plate central screedp. 176
11 Base plate extendable screedp. 176
+Description of functionp. 176
Description of functionp. 176
+The screed (1)p. 176
(Fig. 48)p. 176
High initial compaction by the finisher has a favourable effect on the evenness of the layer and, at the same time, enables an early start of compaction, while the mix temperatures are still high. This favourably supports the compaction effect of the…p. 176
Once the augers have distributed material in front of the screed, the material is pre-compacted by tamper elements (8), (9). The exit flaps (2) make sure that the material will not flow too far towards the outside. The exit flaps (2) can be heated by…p. 177
The crown profile of the screed can also be adjusted, in addition to the angle of attack (see section "Drawing arms"). This is possible in positive, but also in negative direction. The adjustment is made manually on the screed itself, or hydraulicall…p. 177
The base plate (10), (11) skid along the material and compact it again. The base plates (10), (11) carry the vibrator units (6), (7). Their vibration causes further compaction of the material. The heating is also mounted on the base plates (10), (11)…p. 177
From the outside control stand (4) the screed personnel is able to control the auger sensor for mix quantity regulation via a potentiometer. Moreover, the optionally available ultrasonic sensors for the scraper belts, which are also used to regulate …p. 177
+Care and maintenance workp. 177
+Care and maintenance workp. 177
+All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu- Trennkonzentrat, geen")p. 177
before and afterp. 177
+11 Travel drive, descriptionp. 179
+11 Travel drive, descriptionp. 179
Travel systemp. 180
+Track drive — overviewp. 180
Track drive — overviewp. 180
+The crawler track drivep. 180
(Fig. 49)p. 180
+l the framep. 180
l the framep. 180
l the crawler track drivep. 180
l the track tensionerp. 180
l the drive motorp. 180
l the reduction gearp. 180
Fig. 49 Track drivep. 180
+Care and maintenance workp. 181
Framep. 181
+The frame of the track drivep. 181
(Fig. 50)p. 181
Fig. 50 Framep. 181
+1 Carrier for travel gear and travel motorp. 181
1 Carrier for travel gear and travel motorp. 181
2 Frame tubep. 181
3 Carrier for track tensionerp. 181
+Care and maintenance workp. 182
Track drivep. 182
The track drive consists of two tracks with highly resistant, carriage way protecting polyurethane crawler plates. The tracks ensure high tractive power of the finisher.p. 182
Fig. 51p. 182
+1 Wheelp. 182
1 Wheelp. 182
2 Track wheelp. 182
3 Hydraulic cylinder for track tensioningp. 182
4 Crawler platep. 182
5 Supporting rollerp. 182
+Care and maintenance workp. 183
Crawler track tensionerp. 183
Fig. 52 Track tensioner — excerpt from hydraulic diagramp. 183
+The crawler track tensioners are controlled via valve (3)p. 183
(Fig. 52)p. 183
The valves (3) keep the cylinders (1) for the crawler tracks under tension with a uniform pressure level and thus realize a chain tensioning device with automatic readjustment. The so-called "shock limitation" prevents sudden pressure peaks in the hy…p. 183
+Care and maintenance workp. 184
Travel motorp. 184
Fig. 53 Travel motorp. 184
+1 Framep. 184
1 Framep. 184
2 Travel motorp. 184
+The travel motor (2)p. 184
(Fig. 53)p. 184
+Further information about the travel motor, see chapter "Technical data" and "Hydraulics".p. 184
Further information about the travel motor, see chapter "Technical data" and "Hydraulics".p. 184
+Care and maintenance workp. 185
Reduction gearp. 185
Fig. 54 Travel gearp. 185
The travel gears are planetary gears, which are each driven by a flange mounted travel motor (see section "Travel motors").p. 185
Function and designp. 185
The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor engages directly in the drive shaft. A second flange on the bearing axle side carries a gear, which engages in the crawler track.p. 185
The gearbox transfers the torque generated by the travel motor via the gearing of the gearbox to the gear for the crawler tracks.p. 185
The drive shaft carries an additional hydraulically operated spring accumulator multi-disc parking brake. Pressure is applied to the brake when the brake releasing valve is operated. This pressure works against the discs of the parking brake and rele…p. 185
+Care and maintenance workp. 185
+Care and maintenance workp. 185
+All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu- Trennkonzentrat, green")p. 185
before and afterp. 185
+12 Cleaning kit, descriptionp. 187
+12 Cleaning kit, descriptionp. 187
Cleaning kitp. 188
+Cleaning kit — overviewp. 188
Cleaning kit — overviewp. 188
+The cleaning kitp. 188
(Fig. 55)p. 188
+l the provision container (1)p. 188
l the provision container (1)p. 188
l the filter (4)p. 188
l the pump (2)p. 188
l the hose reel (6)p. 188
l the spray gun (5)p. 188
l the control board (3)p. 188
Fig. 55 Cleaning kitp. 188
+Filterp. 189
Provision containerp. 189
The provision container takes up the cleaning agent. It has a capacity of 25 litres. For filling the cleaning container the driver's stand must be moved fully to the right, so that the filler neck can be accessed.p. 189
+Filterp. 189
Filterp. 189
The filter protects the spray gun against contamination. It is a wire mesh pre-filter.p. 189
+Pumpp. 189
Pumpp. 189
The pump delivers the cleaning agent from the provision container through the filter to the spray gun. The pump is an electrically driven two-piston pump, which is able to generate a maximum pressure of approx. 6.9 bar.p. 189
+Further information about the pump, see chapter "Technical data".p. 189
Further information about the pump, see chapter "Technical data".p. 189
+Hose reelp. 189
Hose reelp. 189
The hose reel holds the hose that leads to the spray gun. After cleaning the reel wind the hose up again. Just pull the hose to unwind.p. 189
+Spray gunp. 189
Spray gunp. 189
+The spray gun serves the purpose of cleaning the machine after finishing work, but also as an aid to apply cleaning/release agentp. 189
beforep. 189
+Control panelp. 189
Control panelp. 189
The cleaning system is switched on and off by the control panel. At the same time one can use the timer to pre- select a time for the active period of the cleaning system. Once this time has expired, the cleaning system will switch off. The max. adju…p. 189
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. 194
The 10VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits. The volumetric flow is proportional to the drive speed and the displacement.p. 194
Fig. 3 A10VGp. 194
+1p. 194
1p. 194
+Drive shaftp. 194
Drive shaftp. 194
+8p. 194
8p. 194
+Valve platep. 194
Valve platep. 194
+2p. 194
2p. 194
+Retracting platep. 194
Retracting platep. 194
+9p. 194
9p. 194
+Suction portp. 194
Suction portp. 194
+3p. 194
3p. 194
+Control pistonp. 194
Control pistonp. 194
+10p. 194
10p. 194
+High pressure sidep. 194
High pressure sidep. 194
+4p. 194
4p. 194
+Control unitp. 194
Control unitp. 194
+11p. 194
11p. 194
+Cylinderp. 194
Cylinderp. 194
+5p. 194
5p. 194
+Pressure override (optional)p. 194
Pressure override (optional)p. 194
+12p. 194
12p. 194
+Pistonp. 194
Pistonp. 194
+6p. 194
6p. 194
+Low pressure sidep. 194
Low pressure sidep. 194
+13p. 194
13p. 194
+Slipper padp. 194
Slipper padp. 194
+7p. 194
7p. 194
+Auxiliary pump (optional)p. 194
Auxiliary pump (optional)p. 194
+14p. 194
14p. 194
+Swashing cradlep. 194
Swashing cradlep. 194
+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. 194
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. 194
+Hydraulic diagramp. 195
Hydraulic diagramp. 195
Fig. 4 Hydraulic diagram, A10VG EPp. 195
+Ap. 195
Ap. 195
+Work connectionp. 195
Work connectionp. 195
+PSp. 195
+Pp. 195
Sp. 195
+Control pressure inletp. 195
Control pressure inletp. 195
+Bp. 195
Bp. 195
+Work connectionp. 195
Work connectionp. 195
+Rp. 195
Rp. 195
+Ventilationp. 195
Ventilationp. 195
+Gp. 195
Gp. 195
+Pressure port for charge circuitp. 195
Pressure port for charge circuitp. 195
+T1p. 195
+Tp. 195
1p. 195
+Leak oilp. 195
Leak oilp. 195
+MAp. 195
+Mp. 195
Ap. 195
+Pressure test port, pressure Ap. 195
Pressure test port, pressure Ap. 195
+T2p. 195
+Tp. 195
2p. 195
+Leak oilp. 195
Leak oilp. 195
+MBp. 195
+Mp. 195
Bp. 195
+Pressure test port, pressure Bp. 195
Pressure test port, pressure Bp. 195
+X1 X2p. 195
+Xp. 195
1p. 195
2p. 195
+Port for control pressures, pressure in front of nozzlep. 195
Port for control pressures, pressure in front of nozzlep. 195
+Connection overviewp. 196
Connection overviewp. 196
Fig. 5p. 196
+High pressure relief and charge pressure valvep. 196
High pressure relief and charge pressure valvep. 196
Fig. 6 Valve platep. 196
High pressure relief valves with integrated boost check valves and bypass (only travel pump / for towing)p. 196
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. 196
HP-valves are always adjusted 10% higher than the pressure override.p. 196
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. 196
Bypass controlp. 197
+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 (1)p. 197
(Fig. 7)p. 197
Fig. 7 Bypass controlp. 197
+l Shut down the engine.p. 197
l Shut down the engine.p. 197
l Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direction.p. 197
l Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be noticed by the increasing resistance.p. 197
l Turn the screw half a turn into the spring cup.p. 197
Towing finishedp. 197
After towing back the screw out again. This resets the high pressure valves to their original setting.p. 197
+Tightening torque for counter nut 22 Nm.p. 197
Tightening torque for counter nut 22 Nm.p. 197
Charge pressure relief valvep. 197
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. 197
Pressure override valvep. 197
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. 197
+EP – controlp. 198
EP – controlp. 198
Fig. 8 EP – controlp. 198
+1p. 198
1p. 198
+Setscrew for mechanical neutral positionp. 198
Setscrew for mechanical neutral positionp. 198
+5p. 198
5p. 198
+Proportional solenoid valvep. 198
Proportional solenoid valvep. 198
+2p. 198
2p. 198
+Neutral setting springp. 198
Neutral setting springp. 198
+6p. 198
6p. 198
+Valve spoolp. 198
Valve spoolp. 198
+3p. 198
3p. 198
+Control pistonp. 198
Control pistonp. 198
+7p. 198
7p. 198
+Feedback leverp. 198
Feedback leverp. 198
+4p. 198
4p. 198
+Control chamberp. 198
Control chamberp. 198
Fig. 9 EP controlp. 198
Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement of the pump can be infini…p. 198
+The spring reset in the control unit is no safety feature.p. 198
The spring reset in the control unit is no safety feature.p. 198
Internal contamination – like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system components – can cause blockage of the spool valve in the control unit. The flow volume from the variable displacement pump will in this case n…p. 198
+Swash plate principle, pumpp. 199
Swash plate principle, pumpp. 199
Fig. 10p. 199
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. 199
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used in motor mode the hydrostat…p. 199
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor throughput, by simply changing the angle of the swash plate.p. 199
+Description of functionp. 199
Description of functionp. 199
Fig. 11p. 199
+1p. 200
1p. 200
+Drive shaftp. 200
Drive shaftp. 200
+8p. 200
8p. 200
+Through drivep. 200
Through drivep. 200
+2p. 200
2p. 200
+Pistonp. 200
Pistonp. 200
+9p. 200
9p. 200
+Valve platep. 200
Valve platep. 200
+3p. 200
3p. 200
+Piston areap. 200
Piston areap. 200
+10p. 200
10p. 200
+Top dead centre TDCp. 200
Top dead centre TDCp. 200
+4p. 200
4p. 200
+Piston strokep. 200
Piston strokep. 200
+11p. 200
11p. 200
+Bottom dead centre BTCp. 200
Bottom dead centre BTCp. 200
+5p. 200
5p. 200
+Slipping discp. 200
Slipping discp. 200
+12p. 200
12p. 200
+Control slots in suction side of swash plate (for sense of rotation shown)p. 200
Control slots in suction side of swash plate (for sense of rotation shown)p. 200
+6p. 200
6p. 200
+Adjusting anglep. 200
Adjusting anglep. 200
+13p. 200
13p. 200
+Control slot on pressure sidep. 200
Control slot on pressure sidep. 200
+7p. 200
7p. 200
+Cylinderp. 200
Cylinderp. 200
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. 200
13.3 Troubleshooting axial piston pumpsp. 201
+The following table should be of help when performing troubleshooting This table is by no means complete.p. 201
The following table should be of help when performing troubleshooting This table is by no means complete.p. 201
In practice you may encounter problems that have not been listed here.p. 201
+Procedurep. 201
Procedurep. 201
+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. 201
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. 201
l Get an overview over the function of the product in connection with the overall system.p. 201
l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred.p. 201
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver.p. 201
Try to detect changes to the overall system, the product is installed in:p. 201
+l Have conditions or area of application of the product been changed?p. 201
l Have conditions or area of application of the product been changed?p. 201
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. 201
l Has the product or the machine been operated as intended?p. 201
l How does the fault occur?p. 201
+Faultp. 201
Faultp. 201
+Possible causep. 201
Possible causep. 201
+Remedyp. 201
Remedyp. 201
+Unusual noisesp. 201
Unusual noisesp. 201
+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. 201
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. 201
+Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 201
Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 201
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 201
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 201
+Remove foreign bodies from inside the suction line.p. 201
Remove foreign bodies from inside the suction line.p. 201
+Inappropriate fastening of the axial piston unit.p. 201
Inappropriate fastening of the axial piston unit.p. 201
+Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 201
Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 201
+Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 201
Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 201
+Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 201
Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 201
+Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 201
Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 201
+Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 201
Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 201
+Mechanical damage to the axial piston unit.p. 201
Mechanical damage to the axial piston unit.p. 201
+Replace the axial piston unit, consult the service department.p. 201
Replace the axial piston unit, consult the service department.p. 201
+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. 202
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. 202
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 202
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 202
+Remove foreign bodies from inside the suction line.p. 202
Remove foreign bodies from inside the suction line.p. 202
+Pressure fluid not within the optimal viscosity range.p. 202
Pressure fluid not within the optimal viscosity range.p. 202
+Use appropriate pressure fluid.p. 202
Use appropriate pressure fluid.p. 202
+External control and setting facilities defective.p. 202
External control and setting facilities defective.p. 202
+Check the external control.p. 202
Check the external control.p. 202
+Pilot or control pressure too low.p. 202
Pilot or control pressure too low.p. 202
+Check pilot and control pressure, consult the service department.p. 202
Check pilot and control pressure, consult the service department.p. 202
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 202
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 202
+Consult the service department.p. 202
Consult the service department.p. 202
+Wear of the axial piston unit.p. 202
Wear of the axial piston unit.p. 202
+Replace the axial piston unit.p. 202
Replace the axial piston unit.p. 202
+Mechanical damage to the axial piston unit.p. 202
+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. 203
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. 203
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 203
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 203
+Remove foreign bodies from inside the suction line.p. 203
Remove foreign bodies from inside the suction line.p. 203
+Pressure fluid not within the optimal viscosity range.p. 203
Pressure fluid not within the optimal viscosity range.p. 203
+Use appropriate pressure fluid.p. 203
Use appropriate pressure fluid.p. 203
+External control and setting facilities defective.p. 203
External control and setting facilities defective.p. 203
+Check the external control.p. 203
Check the external control.p. 203
+Pilot or control pressure too low.p. 203
Pilot or control pressure too low.p. 203
+Check pilot and control pressure.p. 203
Check pilot and control pressure.p. 203
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 203
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 203
+Consult the service department.p. 203
Consult the service department.p. 203
+Wear of the axial piston unit.p. 203
Wear of the axial piston unit.p. 203
+Replace the axial piston unit.p. 203
Replace the axial piston unit.p. 203
+Mechanical damage to the axial piston unit.p. 203
Mechanical damage to the axial piston unit.p. 203
+Replace the axial piston unit.p. 203
Replace the axial piston unit.p. 203
+Drive unit defective (e.g. hydraulic motor or cylinder).p. 203
Drive unit defective (e.g. hydraulic motor or cylinder).p. 203
+Check the drive unit, replace if necessary.p. 203
Check the drive unit, replace if necessary.p. 203
+Fluctuations in pressure/volumetric flowp. 203
Fluctuations in pressure/volumetric flowp. 203
+Axial piston unit not or insufficiently purged.p. 203
Axial piston unit not or insufficiently purged.p. 203
+Completely purge the axial piston unit.p. 203
Completely purge the axial piston unit.p. 203
+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. 203
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. 203
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 203
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 203
+Remove foreign bodies from inside the suction line.p. 203
Remove foreign bodies from inside the suction line.p. 203
+Pressure fluid too hot.p. 203
Pressure fluid too hot.p. 203
+Excessive input temperature on axial piston unit.p. 203
Excessive input temperature on axial piston unit.p. 203
+Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 203
Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 203
+Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 203
Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 203
+Consult the service department.p. 203
Consult the service department.p. 203
+Malfunction of the flushing valve (not for nominal size 18).p. 203
Malfunction of the flushing valve (not for nominal size 18).p. 203
+Consult the service department.p. 203
Consult the service department.p. 203
+Wear of the axial piston unit.p. 203
Wear of the axial piston unit.p. 203
+Replace the axial piston unit.p. 203
Replace the axial piston unit.p. 203
+13.4 Component overview — hydraulicsp. 204
13.4 Component overview — hydraulicsp. 204
+Tractorp. 204
Tractorp. 204
Fig. 12p. 204
+Pos.p. 204
Pos.p. 204
+Description (if electric connection is available)p. 204
Description (if electric connection is available)p. 204
+1p. 204
1p. 204
+Brake valve (Y04)p. 204
Brake valve (Y04)p. 204
+2p. 204
2p. 204
+Brake releasing valvep. 204
Brake releasing valvep. 204
+3p. 204
3p. 204
+Valve – activation of hydraulic system (Y194)p. 204
Valve – activation of hydraulic system (Y194)p. 204
+4p. 204
4p. 204
+Valve block – screed up/down (Y226/Y227), floating position (Y227), Load Control System (Y229)p. 204
Valve block – screed up/down (Y226/Y227), floating position (Y227), Load Control System (Y229)p. 204
+5p. 204
5p. 204
+Valve block – auger block up/down (Y214/Y215), hopper wings left open/close (Y202/Y203), right open/close (Y204/Y205), screed left up/down (Y220/Y221), right up/down (Y222/Y223)p. 204
Valve block – auger block up/down (Y214/Y215), hopper wings left open/close (Y202/Y203), right open/close (Y204/Y205), screed left up/down (Y220/Y221), right up/down (Y222/Y223)p. 204
+6p. 204
6p. 204
+Valve – conveyor belt right backward/forward (Y208/Y209)p. 204
Valve – conveyor belt right backward/forward (Y208/Y209)p. 204
+7p. 204
7p. 204
+Valve – auger right forward/backward (Y212/Y213)p. 204
Valve – auger right forward/backward (Y212/Y213)p. 204
+8p. 204
8p. 204
+Valve – conveyor belt left backward/forward (Y206/Y207)p. 204
Valve – conveyor belt left backward/forward (Y206/Y207)p. 204
+9p. 204
9p. 204
+Valve – auger left forward/backward (Y210/Y211)p. 204
Valve – auger left forward/backward (Y210/Y211)p. 204
+10p. 204
10p. 204
+Valve – chain tensioner for drive trackp. 204
Valve – chain tensioner for drive trackp. 204
+Screedp. 205
Screedp. 205
Fig. 13p. 205
+Pos.p. 205
Pos.p. 205
+Description (if electric connection is available)p. 205
Description (if electric connection is available)p. 205
+1p. 205
1p. 205
+Valve block vibration (Y225)p. 205
Valve block vibration (Y225)p. 205
+2p. 205
2p. 205
+Valve block tamper (Y224)p. 205
Valve block tamper (Y224)p. 205
+3p. 205
3p. 205
+Valve block extension screed left extend and retract (Y216/Y217), right extend and retract (Y218/Y219)p. 205
Valve block extension screed left extend and retract (Y216/Y217), right extend and retract (Y218/Y219)p. 205
+4p. 205
4p. 205
+Valve block for hydraulic crown adjustment. Screed down (Y232), screed up (Y231).p. 205
Valve block for hydraulic crown adjustment. Screed down (Y232), screed up (Y231).p. 205
+Arrangement of hydraulic pumpsp. 206
Arrangement of hydraulic pumpsp. 206
Fig. 14p. 206
+Pos.p. 206
Pos.p. 206
+Descriptionp. 206
Descriptionp. 206
+1p. 206
1p. 206
+Gear pump – screed rightp. 206
Gear pump – screed rightp. 206
+2p. 206
2p. 206
+Gear pump – tamping and vibrationp. 206
Gear pump – tamping and vibrationp. 206
+3p. 206
3p. 206
+Service pumpp. 206
Service pumpp. 206
+4p. 206
4p. 206
+Gear pump – screed leftp. 206
Gear pump – screed leftp. 206
+5p. 206
5p. 206
+Gear pump – scraper belt rightp. 206
Gear pump – scraper belt rightp. 206
+6p. 206
6p. 206
+Gear pump – scraper belt leftp. 206
Gear pump – scraper belt leftp. 206
+7p. 206
7p. 206
+Travel pump – drive track rightp. 206
Travel pump – drive track rightp. 206
+8p. 206
8p. 206
+Travel pump – drive track leftp. 206
Travel pump – drive track leftp. 206
+13.10 Check the hydraulic oil levelp. 207
Travel circuitp. 207
+Travel systemp. 207
Travel systemp. 207
The travel system consists of a closed hydraulic circuit. The most important components are the travel pump with integrated safety elements and control and the travel motors.p. 207
Fig. 15 Travel system — excerpt from hydraulic diagramp. 207
+1p. 207
1p. 207
+Travel motor, rightp. 207
Travel motor, rightp. 207
+2p. 207
2p. 207
+Travel motor, leftp. 207
Travel motor, leftp. 207
+3p. 207
3p. 207
+Travel pump stage 1p. 207
Travel pump stage 1p. 207
+4p. 207
4p. 207
+Travel pump stage 2p. 207
Travel pump stage 2p. 207
The travel pumps are joined together to a tandem unit and flange mo0unted to the flywheel end of the diesel engine.p. 208
The travel pumps deliver the hydraulic oil for the travel circuit, they also supply the track tensioner and the service brake.p. 208
The hydraulic oil is cleaned by a pressure filter, which is hydraulically arranged directly in front of the travel pumps.p. 208
A charge circuit supplies the closed circuits with cool and filtered hydraulic oil to compensate for leakage and flushing quantities. The hydraulic oil is additionally needed for the travel system control and for releasing the parking brake.p. 208
+Brake controlp. 208
Brake controlp. 208
During operation the closed hydrostatic travel circuit has the function of a service brake.p. 208
When the travel lever is returned towards neutral position, the displacement of the travel pujmp is adjusted towards zero accordingly and the machine is hydraulically braked.p. 208
To avoid creeping movements, the machine is additionally equipped with multi-disc parking brakes which are integrated in the travel gears. These close in neutral position of the travel lever and when the machine is stopped.p. 208
The parking brakes are electrically operated by a micro controller and a 3/2-way solenoid valve. In de-energized state the charge oil supply to the brake pistons is interrupted, allowing the hydraulic oil to return to the tank via the 3/2-way valve. …p. 208
Releasing the brake mechanically, towing the machinep. 208
Fig. 16 Brake releasing valvep. 208
+The pump lever extension can be found on the operator's stand, inside the frame at the right hand side (it also serves the purpose for erecting the wether protection roof hydraulically).p. 208
The pump lever extension can be found on the operator's stand, inside the frame at the right hand side (it also serves the purpose for erecting the wether protection roof hydraulically).p. 208
+l Press the emergency operation button (2)p. 208
+l Press the emergency operation button (2)p. 208
(Fig. 16)p. 208
+l Release the brake by operating the hand pump (1).p. 208
l Release the brake by operating the hand pump (1).p. 208
After towingp. 208
+l Pull the emergency operation button (2) completely up.p. 208
l Pull the emergency operation button (2) completely up.p. 208
+After starting the engine the emergency operation button is pushed out by hydraulic pressure.p. 208
After starting the engine the emergency operation button is pushed out by hydraulic pressure.p. 208
+Travel gearsp. 209
Travel motorsp. 209
The travel motors on the finisher are fixed displacement bent axle axial piston motors.p. 209
Fig. 17 Sectional view of travel motorp. 209
+1p. 209
1p. 209
+Drive shaftp. 209
Drive shaftp. 209
+5p. 209
5p. 209
+Valve platep. 209
Valve platep. 209
+2p. 209
2p. 209
+Control pistonp. 209
Control pistonp. 209
+6p. 209
6p. 209
+Cylinderp. 209
Cylinderp. 209
+3p. 209
3p. 209
+Control pistonp. 209
Control pistonp. 209
+7p. 209
7p. 209
+Pistonp. 209
Pistonp. 209
+4p. 209
4p. 209
+Connecting platep. 209
Connecting platep. 209
+Travel gearsp. 209
Travel gearsp. 209
The travel gears are planetary gears for mobile equipment, which are each driven by a flange mounted travel motor (see section "Travel motors").p. 209
Function and designp. 209
The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor engages directly in the drive shaft. A second flange on the bearing axle side carries a gear, which engages in the crawler track.p. 209
The gearbox transfers the torque generated by the travel motor via the gearing of the gearbox to the gear for the crawler tracks.p. 209
The drive shaft carries an additional hydraulically operated spring accumulator multi-disc parking brake. Pressure is applied to the brake when the brake releasing valve is operated. This pressure works against the discs of the parking brake and rele…p. 209
+13.10 Check the hydraulic oil levelp. 210
+13.6 Vibration and tamper drivep. 210
The vibration and tamper drive has been designed as an open hydraulic circuit.p. 210
The most essential components are:p. 210
+l the hydraulic pumpp. 210
l the hydraulic pumpp. 210
l the valve block for vibration drivep. 210
l the valve block for tamper operationp. 210
l the vibration motorsp. 210
l the tamper motorsp. 210
Fig. 18 Vibration and tamper drive – excerpt from hydraulic diagramp. 210
+1p. 210
1p. 210
+Vibration motors (two for the main screed and one each for the mobile screeds)p. 210
Vibration motors (two for the main screed and one each for the mobile screeds)p. 210
+2p. 210
2p. 210
+Tamper motors (two for the main screed and one each for the mobile screeds)p. 210
Tamper motors (two for the main screed and one each for the mobile screeds)p. 210
+3p. 210
3p. 210
+Valve block for tamper operationp. 210
Valve block for tamper operationp. 210
+4p. 210
4p. 210
+Hydraulic pumpp. 210
Hydraulic pumpp. 210
+5p. 210
5p. 210
+Valve block for vibration drivep. 210
Valve block for vibration drivep. 210
Vibration and tamper pumpp. 211
Fig. 19 Vibration and tamper pumpp. 211
+The vibration and tamper pumpp. 211
(Fig. 19)p. 211
Valve blocksp. 211
+This hydraulic oil supply runs through separate valve blocks for vibration drive (5)p. 211
(Fig. 18)p. 211
(Fig. 18)p. 211
Vibration motorp. 211
The vibration motors each engage directly into a flanged on exciter housing with exciter shaft (eccentric shaft). The eccentric arrangement of the weight of the exciter shaft causes a radial vibration, which works directly on the screed plates of scr…p. 211
+Tamper motorp. 211
Optionp. 211
The tamper motors of screed and mobile screeds each drive a drive shaft which are connected with the corresponding tamper plate by eccentrically mounted connecting rods. This moves the conrods with the attached tamper plates up and down. This up and …p. 211
The vibration and tamper motors of the screed are additionally linked by a universal shaft, to ensure synchronization of amplitudes in vibration and tamping. This makes ure that there will be no undesired resonance vibrations or mutual elimination of…p. 211
+13.10 Check the hydraulic oil levelp. 212
Scraper belt drivep. 212
+Scraper belt drivep. 212
Scraper belt drivep. 212
The scraper belt drive has been designed as an open hydraulic circuit.p. 212
The most essential components are:p. 212
+l the scraper belt pumpsp. 212
l the scraper belt pumpsp. 212
l the scraper belt valve blocksp. 212
l the scraper belt motorsp. 212
Fig. 20 Scraper belt drive – excerpt from hydraulic diagramp. 212
+1p. 212
1p. 212
+Scraper belt motor leftp. 212
Scraper belt motor leftp. 212
+4p. 212
4p. 212
+Valve block for right hand motorp. 212
Valve block for right hand motorp. 212
+2p. 212
2p. 212
+Scraper belt motor rightp. 212
Scraper belt motor rightp. 212
+5p. 212
5p. 212
+Gear pump for scraper belt motor leftp. 212
Gear pump for scraper belt motor leftp. 212
+3p. 212
3p. 212
+Valve block for left hand motorp. 212
Valve block for left hand motorp. 212
+6p. 212
6p. 212
+Gear pump for scraper belt motor rightp. 212
Gear pump for scraper belt motor rightp. 212
Scraper belt pump (gear pump)p. 213
Fig. 21 Gear pump for scraper belt drivep. 213
+The pump for the scraper belt drivep. 213
(Fig. 21)p. 213
Valve blocksp. 213
+The valve blocks for the scraper belt drive (3), (4)p. 213
(Fig. 20)p. 213
The solenoid valve attached to the valve block enables the user to run the scraper belts individually in forward or reverse mode, depending on the requirements when paving.p. 213
Scraper belt motorp. 213
The scraper belt motors both drive the scraper belts via a chain drive. Using an intermediate chain drive increases the torque.p. 213
Paddlep. 213
The end of the scraper belts is equipped with paddles. These touch the material and are thereby moved. If there is too much material on the scraper belt, the paddle sends a signal through an attached sensor, which forces the electronics to stop the c…p. 213
+Ultrasonic sensorp. 213
optionalp. 213
The material flow on the scraper belt is detected by an ultrasonic sensor. If there is too much material on the scraper belt, the ultrasonic sensor will generate a signal through an attached sensor, which forces the electronics to stop the correspond…p. 213
+13.10 Check the hydraulic oil levelp. 214
Auger drivep. 214
+Auger drivep. 214
Auger drivep. 214
The auger drive has been designed as an open hydraulic circuit.p. 214
The most essential components are:p. 214
+l the hydraulic pumpsp. 214
l the hydraulic pumpsp. 214
l the valve blocksp. 214
l the auger motorsp. 214
Fig. 22 Auger drive – excerpt from hydraulic diagramp. 214
+1p. 214
1p. 214
+Auger motor leftp. 214
Auger motor leftp. 214
+4p. 214
4p. 214
+Valve block for right hand motorp. 214
Valve block for right hand motorp. 214
+2p. 214
2p. 214
+Auger motor rightp. 214
Auger motor rightp. 214
+5p. 214
5p. 214
+Gear pump for auger motor leftp. 214
Gear pump for auger motor leftp. 214
+3p. 214
3p. 214
+Valve block for left hand motorp. 214
Valve block for left hand motorp. 214
+6p. 214
6p. 214
+Gear pump for auger motor rightp. 214
Gear pump for auger motor rightp. 214
Pump for auger drive (gear pump)p. 215
Fig. 23 Gear pump for auger drivep. 215
+The auger drive pumpp. 215
(Fig. 23)p. 215
Valve blocksp. 215
+The valve blocks for the auger drive (3), (4)p. 215
(Fig. 22)p. 215
The solenoid valve attached to the valve block enables the user to run the augers individually in forward or reverse mode, depending on the requirements when paving.p. 215
Auger motorp. 215
The auger motors both drive the auger shafts via a chain drive. Using an intermediate chain drive increases the torque.p. 215
+13.10 Check the hydraulic oil levelp. 216
Cylinder functionsp. 216
+Cylinder functionsp. 216
Cylinder functionsp. 216
The cylinder functions can be sub-divided into the following sections:p. 216
+l Hopper functionsp. 216
+l Hopper functionsp. 216
l Hopperp. 216
+l Screed functionsp. 216
l Screedp. 216
+l Auger functionsp. 216
l Augerp. 216
+l Track tensioner functionsp. 216
l Track tensionerp. 216
The cylinders for hopper, screed and auger functions are supplied by the work pump. The track tensioners are supplied by the return flow from the auger motors (further details on the pump: See chapter "Technical data").p. 216
Fig. 24 Work pump – excerpt from hydraulic diagramp. 216
Hopperp. 217
The hopper functions can be sub-divided into two sections:p. 217
+l Open/close left hand hopper wingp. 217
l Open/close left hand hopper wingp. 217
l Open/close right hand hopper wingp. 217
Fig. 25 Hopper functions — excerpt from hydraulic diagramp. 217
+1p. 217
1p. 217
+Open/close left hand wingp. 217
Open/close left hand wingp. 217
+2p. 217
2p. 217
+Open/close right hand wingp. 217
Open/close right hand wingp. 217
+Opening / closing the hopper wingsp. 218
Opening / closing the hopper wingsp. 218
The hopper wings can be adjusted in height. This changes the volume of the material hopper. This adjustment is accomplished by hydraulic cylinders, which are fastened to the outside of the wings. When paving the hopper has to take up the material. Fo…p. 218
Screedp. 219
The screed functions can be sub-divided into the following sections:p. 219
+l Lifting/lowering the left/right hook-in pointp. 219
l Lifting/lowering the left/right hook-in pointp. 219
l Lifting/lowering the complete screedp. 219
l Extending/retracting the extendable screed left/rightp. 219
+Lifting/lowering the screed Load Control System (LCS)p. 219
Lifting/lowering the screed Load Control System (LCS)p. 219
+3p. 219
3p. 219
+Extending/retracting the extendable screedp. 219
Extending/retracting the extendable screedp. 219
+2p. 219
2p. 219
+Lifting / lowering the hook in pointsp. 219
Lifting / lowering the hook in pointsp. 219
+4p. 219
4p. 219
+Crown adjustmentp. 219
Crown adjustmentp. 219
+Lifting/lowering the left/right hook-in pointp. 220
Lifting/lowering the left/right hook-in pointp. 220
With their height the hook-in points directly influence the thickness of the material to be applied. For this reason they are adjustable in height. This is accomplished with hydraulic cylinders (the so-called levelling cylinders) mounted at the front…p. 220
+Lifting/lowering the complete screedp. 220
Lifting/lowering the complete screedp. 220
Lifting/lowering the screed is accomplished by two hydraulic cylinders (the so-called lift-out cylinder) at the rear ends of both side arms. These cylinders lift/lower or release the screed by means of the screed load control system (L.C.S.) interven…p. 220
+Extending/retracting the extendable screed left/rightp. 220
Extending/retracting the extendable screed left/rightp. 220
Extending and retracting the extendable screed is accomplished by two hydraulic cylinders in the centre of the screed. The extendable screeds can thereby by infinitely extended or retracted independently from one another.p. 220
Augersp. 221
The auger functions can be sub-divided into two sections:p. 221
+l Augers upp. 221
l Augers upp. 221
l Augers downp. 221
Fig. 27 Auger functionsp. 221
+1p. 221
1p. 221
+Lifting / lowering the augersp. 221
Lifting / lowering the augersp. 221
+Lifting / lowering the augersp. 221
Lifting / lowering the augersp. 221
The augers can be adjusted in height to make sure that a sufficient amount of material is placed in front of the screed at any time. This adjustment is accomplished by hydraulic cylinders, which are fastened to the auger unit. The Way valve controls …p. 221
Track tensioner – chassisp. 222
Fig. 28 Crawler track tensionerp. 222
+1p. 222
1p. 222
+Tensioning cylinder for crawler tracksp. 222
Tensioning cylinder for crawler tracksp. 222
+2p. 222
2p. 222
+Check valvesp. 222
Check valvesp. 222
+3p. 222
3p. 222
+Valvep. 222
Valvep. 222
+Tensioning the crawler tracksp. 222
Tensioning the crawler tracksp. 222
+The crawler track tensioners are controlled via valve (3)p. 222
(Fig. 28)p. 222
The valves (3) keep the cylinders (1) for the crawler tracks under tension with a uniform pressure level and thus realize a chain tensioning device with automatic readjustment. The so-called "shock limitation" prevents sudden pressure peaks in the hy…p. 222
+13.10 Check the hydraulic oil levelp. 222
13.10 Check the hydraulic oil levelp. 222
+In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer.p. 222
+In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer.p. 222
In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer.p. 222
+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. 222
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. 222
For quality of oil refer to the "table of fuels and lubricants".p. 222
+Risk of overfilling!p. 222
Risk of overfilling!p. 222
+l Fully open the hopper.p. 222
l Fully open the hopper.p. 222
l Fully retract the mobile screed.p. 222
l Raise the screed to half height.p. 222
Fig. 29p. 223
+l Check the hydraulic oil level in the inspection glassp. 223
+l Check the hydraulic oil level in the inspection glassp. 223
(Fig. 29)p. 223
Normal level:p. 223
approx. 3 cm below the top edge of the inspection glass.p. 223
Minimum level:p. 223
Middle of inspection glass.p. 223
Fig. 30p. 223
+l If necessary fill in hydraulic oil through the filler neckp. 223
+l If necessary fill in hydraulic oil through the filler neckp. 223
(Fig. 30)p. 223
+13.11 Changing hydraulic oil and filterp. 223
13.11 Changing hydraulic oil and filterp. 223
+See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 223
+See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 223
See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 223
+Danger of scalding!p. 223
Danger of scalding!p. 223
When draining off hot hydraulic oil!p. 223
+The hydraulic oil must also be changed after major repairs in the hydraulic system.p. 223
The hydraulic oil must also be changed after major repairs in the hydraulic system.p. 223
Perform the oil change when the hydraulic oil is warm.p. 223
Replace the hydraulic oil filter elements with every hydraulic oil change.p. 223
Change the filter only after the hydraulic oil change and after the test run.p. 223
Clean the area round hydraulic oil tank, filler opening and breather filter.p. 223
Do not start the engine after draining the hydraulic oil.p. 223
Do not use any detergents to clean the system.p. 223
Use only lint-free cleaning cloths.p. 223
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 223
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. 223
+Any hydraulic oil must be caught and disposed of in an environmentally friendly manner.p. 223
Any hydraulic oil must be caught and disposed of in an environmentally friendly manner.p. 223
Fig. 31p. 224
+l Unscrew the plugp. 224
+l Unscrew the plugp. 224
(Fig. 31)p. 224
l Turn the plug tightly back in.p. 224
+l Remove the filler cap.p. 224
l Remove the filler cap.p. 224
l Fill in new hydraulic oil through the screen.p. 224
+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. 224
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. 224
Fig. 32p. 224
+l Check the oil level in the inspection glassp. 224
+l Check the oil level in the inspection glassp. 224
(Fig. 32)p. 224
Nominal value:p. 224
approx. 3 cm below the upper edge of the inspection glassp. 224
+The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap.p. 224
The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap.p. 224
+l Close the tank with a new cover.p. 224
l Close the tank with a new cover.p. 224
+l Open the hopper wings and remove the cover to the engine compartment.p. 224
l Open the hopper wings and remove the cover to the engine compartment.p. 224
Fig. 33p. 224
+l Unscrew spigot nut (4)p. 224
+l Unscrew spigot nut (4)p. 224
(Fig. 33)p. 224
l Examine the surface of the filter element thoroughly for any visible dirt.p. 224
+Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to…p. 224
Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to…p. 224
Do not clean or reuse the filter element.p. 224
+l Take out the old filter element (3), clean filter bowl and thread.p. 224
l Take out the old filter element (3), clean filter bowl and thread.p. 224
l Reassemble the filter bowl with a new filter element and new O-rings (1, 2).p. 224
l After a short test run check the filter for leaks.p. 224
+14 Tests and adjustmentsp. 225
14 Tests and adjustmentsp. 225
+14.2 Checking and adjusting the vibrationp. 226
14.1 Special tools, tests and adjustmentsp. 226
+Fig. 1p. 226
Fig. 1p. 226
+1. Vibration reed frequency meterp. 226
1. Vibration reed frequency meterp. 226
+1000 – 4.000 rpmp. 226
1000 – 4.000 rpmp. 226
+17 – 67 Hzp. 226
17 – 67 Hzp. 226
+BOMAG part-no.: 300 120 80p. 226
BOMAG part-no.: 300 120 80p. 226
+Fig. 2p. 226
Fig. 2p. 226
+2. Frequency counterp. 226
2. Frequency counterp. 226
The frequency counter is used for testing the pre- tension of drive belts by frequency measurement.p. 226
+10 – 600 Hzp. 226
10 – 600 Hzp. 226
+BOMAG part-no.: 079 901 74p. 226
BOMAG part-no.: 079 901 74p. 226
+Fig. 3p. 226
Fig. 3p. 226
+3. Sirometer (frequency meter)p. 226
3. Sirometer (frequency meter)p. 226
+800 – 50.000 rpmp. 226
800 – 50.000 rpmp. 226
+14 – 750 Hzp. 226
14 – 750 Hzp. 226
+BOMAG part-no.: 059 710 02p. 226
BOMAG part-no.: 059 710 02p. 226
+Fig. 4p. 226
Fig. 4p. 226
+4. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Plastic, temperature range: down to -40 °Cp. 226
4. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Plastic, temperature range: down to -40 °Cp. 226
BOMAG part-no.: 050 100 75p. 226
+Fig. 5p. 227
Fig. 5p. 227
+5. Digital rpm-meter for petrol enginesp. 227
5. Digital rpm-meter for petrol enginesp. 227
BOMAG part-no.: 079 948 99p. 227
+Fig. 6p. 227
Fig. 6p. 227
+6. Digital rpm-meter for petrol enginesp. 227
6. Digital rpm-meter for petrol enginesp. 227
BOMAG part-no.: 059 711 12p. 227
+Fig. 7p. 227
Fig. 7p. 227
+7. Digital rpm-meter, optical/mechanical, universal usep. 227
7. Digital rpm-meter, optical/mechanical, universal usep. 227
BOMAG part-no.: 079 948 98p. 227
+Fig. 8p. 227
Fig. 8p. 227
+8. Infrared hand-held thermometer, -18 to 275°Cp. 227
8. Infrared hand-held thermometer, -18 to 275°Cp. 227
BOMAG part-no.: 057 668 06p. 227
+Fig. 9p. 228
Fig. 9p. 228
+9. Hydraulic test case, largep. 228
9. Hydraulic test case, largep. 228
BOMAG part-no.: 007 610 03p. 228
+4 X 600 bar pressure gaugesp. 228
4 X 600 bar pressure gaugesp. 228
4 X 60 bar pressure gaugesp. 228
8 pressure test hosesp. 228
+Fig. 10p. 228
Fig. 10p. 228
+10. Hydraulic test case, smallp. 228
10. Hydraulic test case, smallp. 228
BOMAG part-no.: 079 930 01p. 228
+2X 60 bar pressure gaugesp. 228
2X 60 bar pressure gaugesp. 228
2X 600 bar pressure gaugesp. 228
4 pressure test hosesp. 228
+Fig. 11p. 228
Fig. 11p. 228
+11. Pressure test hosesp. 228
11. Pressure test hosesp. 228
+1000 mm BOMAG part-no.: 079 930 02p. 228
1000 mm BOMAG part-no.: 079 930 02p. 228
+2500 mm BOMAG part-no.: 079 930 03p. 228
2500 mm BOMAG part-no.: 079 930 03p. 228
+Fig. 12p. 228
Fig. 12p. 228
+12. Pressure gaugep. 228
12. Pressure gaugep. 228
+60 bar BOMAG part-no.: 059 721 07p. 228
60 bar BOMAG part-no.: 059 721 07p. 228
+600 bar BOMAG part-no.: 059 721 04p. 228
600 bar BOMAG part-no.: 059 721 04p. 228
+Fig. 13p. 229
Fig. 13p. 229
+13. Adapter for pressure test hosep. 229
13. Adapter for pressure test hosep. 229
BOMAG part-no.: 055 439 02p. 229
+Fig. 14p. 229
Fig. 14p. 229
+14. Gear pump testing devicep. 229
14. Gear pump testing devicep. 229
BOMAG part-no.: 007 610 05p. 229
+Fig. 15p. 229
Fig. 15p. 229
+15. Vacuum pump for hydraulic oil tankp. 229
15. Vacuum pump for hydraulic oil tankp. 229
+BOMAG part-no.: 007 610 04 (12 Volt)p. 229
BOMAG part-no.: 007 610 04 (12 Volt)p. 229
+BOMAG part-no.: 007 610 24 (24 Volt)p. 229
BOMAG part-no.: 007 610 24 (24 Volt)p. 229
+14.2 Checking and adjusting the vibrationp. 230
14.2 Checking and adjusting the vibrationp. 230
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 230
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 230
+The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 237
The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 237
All test steps must be performed one after the other!p. 237
+Fig. 1p. 237
Fig. 1p. 237
+1. Raise and lock the screedp. 237
+1. Raise and lock the screedp. 237
(Fig. 1)p. 237
+2. Fully extend right and left hand screeds.p. 237
2. Fully extend right and left hand screeds.p. 237
+3. Shut down the engine.p. 237
3. Shut down the engine.p. 237
+Fig. 2p. 237
Fig. 2p. 237
+Danger of injury!p. 237
Danger of injury!p. 237
Before connecting the pressure gauge make sure that the engine has been shut down!p. 237
+4. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 237
+4. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 237
(Fig. 2)p. 237
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 237
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 237
+Fig. 3p. 238
Fig. 3p. 238
+The pressure relief valve (PRV) is located at the underside of the solenoid valve, which in turn is mounted to the main screedp. 238
+The pressure relief valve (PRV) is located at the underside of the solenoid valve, which in turn is mounted to the main screedp. 238
(Fig. 3)p. 238
+Write down the number of revolutions when turning in the setscrew. This turning in must be reversed later during this procedure.p. 238
Write down the number of revolutions when turning in the setscrew. This turning in must be reversed later during this procedure.p. 238
+5. On the pressure relief valve loosen the counter nut (1) and turn the setscrew (2) completely inp. 238
+5. On the pressure relief valve loosen the counter nut (1) and turn the setscrew (2) completely inp. 238
(Fig. 3)p. 238
+Fig. 4p. 238
Fig. 4p. 238
+6. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a prybar)p. 238
+6. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a prybar)p. 238
(Fig. 4)p. 238
+Rest the prybar against the screed frame so that it will not hit the frame when tamper operation is switched on!p. 238
Rest the prybar against the screed frame so that it will not hit the frame when tamper operation is switched on!p. 238
+Fig. 5p. 238
Fig. 5p. 238
+7. Start the engine and set the switch to position "MAX"p. 238
+7. Start the engine and set the switch to position "MAX"p. 238
(Fig. 5)p. 238
+Fig. 6p. 238
Fig. 6p. 238
+8. Activate the hydraulic systemp. 238
+8. Activate the hydraulic systemp. 238
(Fig. 6)p. 238
+Fig. 7p. 239
Fig. 7p. 239
+9. Activate the parking brakep. 239
+9. Activate the parking brakep. 239
(Fig. 7)p. 239
+Fig. 8p. 239
Fig. 8p. 239
+10. Select "Work"-modep. 239
+10. Select "Work"-modep. 239
(Fig. 8)p. 239
+Fig. 9p. 239
Fig. 9p. 239
+Run the following pressure test only for max. 5 seconds.p. 239
Run the following pressure test only for max. 5 seconds.p. 239
+11. Switch on the tamperp. 239
+11. Switch on the tamperp. 239
(Fig. 9)p. 239
+Fig. 10p. 239
Fig. 10p. 239
+12. Shift the travel lever to "forward" positionp. 239
+12. Shift the travel lever to "forward" positionp. 239
(Fig. 10)p. 239
+13. Read the hydraulic oil pressure in the pressure gauge.p. 239
13. Read the hydraulic oil pressure in the pressure gauge.p. 239
+14. Shift the travel lever to "Neutral" position .p. 239
14. Shift the travel lever to "Neutral" position .p. 239
+Fig. 11p. 240
Fig. 11p. 240
+15. Switch of the tamperp. 240
+15. Switch of the tamperp. 240
(Fig. 11)p. 240
+Fig. 12p. 240
Fig. 12p. 240
+Nominal valuep. 240
Nominal valuep. 240
See chapter "Technical Data".p. 240
+If the nominal pressure of the pressure relief valve is not reached:p. 240
If the nominal pressure of the pressure relief valve is not reached:p. 240
Adjust the PRV on the tamper motor.p. 240
+16. Loosen the counter nut and turn the setscrew in or out, until the nominal value is reachedp. 240
+16. Loosen the counter nut and turn the setscrew in or out, until the nominal value is reachedp. 240
(Fig. 12)p. 240
+Turning clockwisep. 240
+Turning clockwisep. 240
increasesp. 240
reducesp. 240
+17. Check the pressure once again (see above).p. 240
17. Check the pressure once again (see above).p. 240
+18. Retighten the counter nut.p. 240
18. Retighten the counter nut.p. 240
+Fig. 13p. 240
Fig. 13p. 240
+19. Turn the switch to position "MIN" and shut down the enginep. 240
+19. Turn the switch to position "MIN" and shut down the enginep. 240
(Fig. 13)p. 240
+Danger of injury!p. 240
Danger of injury!p. 240
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 240
+20. Disconnect the pressure gauge.p. 240
20. Disconnect the pressure gauge.p. 240
+21. Remove the blockage (prybar) from the shaft.p. 240
21. Remove the blockage (prybar) from the shaft.p. 240
test 2/3 tamper extension screedp. 241
+The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 241
The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 241
+Fig. 14p. 241
Fig. 14p. 241
+Danger of injury!p. 241
Danger of injury!p. 241
Before connecting the pressure gauge make sure that the engine has been shut down!p. 241
+1. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 241
+1. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 241
(Fig. 14)p. 241
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 241
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 241
+Fig. 15p. 241
Fig. 15p. 241
+2. Pressure relief valvep. 241
+2. Pressure relief valvep. 241
(Fig. 15)p. 241
+Fig. 16p. 241
Fig. 16p. 241
+3. Loosen the counter nut (1) and back out the setscrew (2) by the same amount of turns that you turned it in before (see your own notes)p. 241
+3. Loosen the counter nut (1) and back out the setscrew (2) by the same amount of turns that you turned it in before (see your own notes)p. 241
(Fig. 16)p. 241
+Fig. 17p. 242
Fig. 17p. 242
+4. Remove the front covering plate (safeguarding) of the extension screed (see chapter: "Vibrating screed repair" section: "Disassembling the tamper blades").p. 242
4. Remove the front covering plate (safeguarding) of the extension screed (see chapter: "Vibrating screed repair" section: "Disassembling the tamper blades").p. 242
+5. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a timber block)p. 242
+5. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a timber block)p. 242
(Fig. 17)p. 242
+Fig. 18p. 242
Fig. 18p. 242
+6. Start the engine and set the switch to position "MAX"p. 242
+6. Start the engine and set the switch to position "MAX"p. 242
(Fig. 18)p. 242
+Fig. 19p. 242
Fig. 19p. 242
+7. Activate the hydraulic systemp. 242
+7. Activate the hydraulic systemp. 242
(Fig. 19)p. 242
+Fig. 20p. 242
Fig. 20p. 242
+8. Activate the parking brakep. 242
+8. Activate the parking brakep. 242
(Fig. 20)p. 242
+Fig. 21p. 243
Fig. 21p. 243
+9. Select "Work"-modep. 243
+9. Select "Work"-modep. 243
(Fig. 21)p. 243
+Fig. 22p. 243
Fig. 22p. 243
+Run the following pressure test only for max. 5 seconds.p. 243
Run the following pressure test only for max. 5 seconds.p. 243
+10. Switch on the tamperp. 243
+10. Switch on the tamperp. 243
(Fig. 22)p. 243
+Fig. 23p. 243
Fig. 23p. 243
+11. Shift the travel lever to "forward" positionp. 243
+11. Shift the travel lever to "forward" positionp. 243
(Fig. 23)p. 243
+12. Read the hydraulic oil pressure in the pressure gauge.p. 243
12. Read the hydraulic oil pressure in the pressure gauge.p. 243
+13. Shift the travel lever to "Neutral" position .p. 243
13. Shift the travel lever to "Neutral" position .p. 243
+Fig. 24p. 243
Fig. 24p. 243
+14. Switch of the tamperp. 243
+14. Switch of the tamperp. 243
(Fig. 24)p. 243
+Fig. 25p. 244
Fig. 25p. 244
+Nominal valuep. 244
Nominal valuep. 244
See chapter "Technical Data".p. 244
+If the nominal pressure of the pressure relief valve is not reached:p. 244
If the nominal pressure of the pressure relief valve is not reached:p. 244
+Adjust the PRV on the tamper motorp. 244
(Fig. 25)p. 244
+15. Loosen the counter nut and turn the setscrew in or out, until the nominal value is reached.p. 244
15. Loosen the counter nut and turn the setscrew in or out, until the nominal value is reached.p. 244
+Turning clockwisep. 244
+Turning clockwisep. 244
increasesp. 244
reducesp. 244
+16. Check the pressure once again (see above).p. 244
16. Check the pressure once again (see above).p. 244
+17. Retighten the counter nut.p. 244
17. Retighten the counter nut.p. 244
+Fig. 26p. 244
Fig. 26p. 244
+18. Turn the switch to position "MIN" and shut down the enginep. 244
+18. Turn the switch to position "MIN" and shut down the enginep. 244
(Fig. 26)p. 244
+Danger of injury!p. 244
Danger of injury!p. 244
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 244
+19. Disconnect the pressure gauge.p. 244
19. Disconnect the pressure gauge.p. 244
+20. Remove the blockage (wooden block) from the shaft.p. 244
20. Remove the blockage (wooden block) from the shaft.p. 244
+21. Reassemble the safeguarding /see chapter: "Vibrating screed repair", section "Installing the tamper blades)p. 244
21. Reassemble the safeguarding /see chapter: "Vibrating screed repair", section "Installing the tamper blades)p. 244
Pressure test 3/3 tamper main protection (200 bar)p. 245
+The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 245
The correct order of the test steps is mandatory, because otherwise incorrect measuring values may be obtained!p. 245
+Fig. 27p. 245
Fig. 27p. 245
+Danger of injury!p. 245
Danger of injury!p. 245
Before connecting the pressure gauge make sure that the engine has been shut down!p. 245
+1. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 245
+1. Connect a high pressure gauge (600 bar) to pressure test port "M" on the pumpp. 245
(Fig. 27)p. 245
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 245
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 245
+Fig. 28p. 245
Fig. 28p. 245
+2. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a prybar)p. 245
+2. Block the propshaft (1) of the tamper motors with a suitable object (e.g. a prybar)p. 245
(Fig. 28)p. 245
+Rest the prybar against the screed frame so that it will not hit the frame when tamper operation is switched on!p. 245
Rest the prybar against the screed frame so that it will not hit the frame when tamper operation is switched on!p. 245
+Fig. 29p. 245
Fig. 29p. 245
+3. Start the engine and set the switch to position "MAX"p. 245
+3. Start the engine and set the switch to position "MAX"p. 245
(Fig. 29)p. 245
+Fig. 30p. 246
Fig. 30p. 246
+4. Activate the hydraulic systemp. 246
+4. Activate the hydraulic systemp. 246
(Fig. 30)p. 246
+Fig. 31p. 246
Fig. 31p. 246
+5. Activate the parking brakep. 246
+5. Activate the parking brakep. 246
(Fig. 31)p. 246
+Fig. 32p. 246
Fig. 32p. 246
+6. Fully extend right and left hand screedsp. 246
+6. Fully extend right and left hand screedsp. 246
(Fig. 32)p. 246
+Fig. 33p. 246
Fig. 33p. 246
+7. Select "Work"-modep. 246
+7. Select "Work"-modep. 246
(Fig. 33)p. 246
+Fig. 34p. 247
Fig. 34p. 247
+Run the following pressure test only for max. 5 seconds.p. 247
Run the following pressure test only for max. 5 seconds.p. 247
+8. Switch on the tamperp. 247
+8. Switch on the tamperp. 247
(Fig. 34)p. 247
+Fig. 35p. 247
Fig. 35p. 247
+9. Shift the travel lever to "forward" positionp. 247
+9. Shift the travel lever to "forward" positionp. 247
(Fig. 35)p. 247
+10. Read the hydraulic oil pressure in the pressure gauge.p. 247
10. Read the hydraulic oil pressure in the pressure gauge.p. 247
+11. Shift the travel lever to "Neutral" position .p. 247
11. Shift the travel lever to "Neutral" position .p. 247
+Fig. 36p. 247
Fig. 36p. 247
+12. Switch of the tamperp. 247
+12. Switch of the tamperp. 247
(Fig. 36)p. 247
+Fig. 37p. 247
Fig. 37p. 247
+Nominal valuep. 247
Nominal valuep. 247
See chapter "Technical Data".p. 247
+If the nominal pressure of the pressure relief valve is not reached:p. 247
If the nominal pressure of the pressure relief valve is not reached:p. 247
+Adjust the PRV on the "tamper" valve blockp. 247
(Fig. 37)p. 247
+13. Loosen the counter nut (4) and turn the setscrew (3) in or out, until the nominal value is reached.p. 247
13. Loosen the counter nut (4) and turn the setscrew (3) in or out, until the nominal value is reached.p. 247
+Turning clockwisep. 248
+Turning clockwisep. 248
increasesp. 248
reducesp. 248
+14. Check the pressure once again (see above).p. 248
14. Check the pressure once again (see above).p. 248
+15. Retighten the counter nut (1).p. 248
15. Retighten the counter nut (1).p. 248
+Fig. 38p. 248
Fig. 38p. 248
+16. Turn the switch to position "MIN" and shut down the enginep. 248
+16. Turn the switch to position "MIN" and shut down the enginep. 248
(Fig. 38)p. 248
+Danger of injury!p. 248
Danger of injury!p. 248
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 248
+17. Disconnect the pressure gauge.p. 248
17. Disconnect the pressure gauge.p. 248
+18. Remove the blockage (prybar) from the shaft.p. 248
18. Remove the blockage (prybar) from the shaft.p. 248
Tamper speed measurementp. 249
+Fig. 39p. 249
Fig. 39p. 249
+1. Raise and lock the screedp. 249
+1. Raise and lock the screedp. 249
(Fig. 39)p. 249
+2. Fully extend right and left hand screeds.p. 249
2. Fully extend right and left hand screeds.p. 249
+3. Shut down the engine.p. 249
3. Shut down the engine.p. 249
+Fig. 40p. 249
Fig. 40p. 249
+1. Fasten a reflex mark (2) on the shaft (1)p. 249
+1. Fasten a reflex mark (2) on the shaft (1)p. 249
(Fig. 40)p. 249
+Fig. 41p. 249
Fig. 41p. 249
+2. Completely close the hand wheel for tamper speedp. 249
+2. Completely close the hand wheel for tamper speedp. 249
(Fig. 41)p. 249
+Fig. 42p. 249
Fig. 42p. 249
+3. Start the engine and set the switch to position "MAX"p. 249
+3. Start the engine and set the switch to position "MAX"p. 249
(Fig. 42)p. 249
+Fig. 43p. 250
Fig. 43p. 250
+4. Activate the hydraulic systemp. 250
+4. Activate the hydraulic systemp. 250
(Fig. 43)p. 250
+Fig. 44p. 250
Fig. 44p. 250
+5. Activate the parking brakep. 250
+5. Activate the parking brakep. 250
(Fig. 44)p. 250
+Fig. 45p. 250
Fig. 45p. 250
+6. Select "Work"-modep. 250
+6. Select "Work"-modep. 250
(Fig. 45)p. 250
+Fig. 46p. 250
Fig. 46p. 250
+7. Switch on the tamperp. 250
+7. Switch on the tamperp. 250
(Fig. 46)p. 250
+Fig. 47p. 251
Fig. 47p. 251
+8. Shift the travel lever to "forward" positionp. 251
+8. Shift the travel lever to "forward" positionp. 251
(Fig. 47)p. 251
+9. Read the shaft speed.p. 251
9. Read the shaft speed.p. 251
+Nominal valuep. 251
Nominal valuep. 251
See chapter "Technical Data".p. 251
+10. Shift the travel lever to "Neutral" position.p. 251
10. Shift the travel lever to "Neutral" position.p. 251
+Fig. 48p. 251
Fig. 48p. 251
+11. Switch of the tamperp. 251
+11. Switch of the tamperp. 251
(Fig. 48)p. 251
+If the nominal value is not reached, you must:p. 251
If the nominal value is not reached, you must:p. 251
1. check the tamper pumpp. 251
2. the tamper motorsp. 251
.p. 251
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 251
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 251
+Fig. 49p. 251
Fig. 49p. 251
+12. Turn the switch to position "MIN" and shut down the enginep. 251
+12. Turn the switch to position "MIN" and shut down the enginep. 251
(Fig. 49)p. 251
+14.4 Checking/adjusting the scraper beltsp. 252
14.4 Checking/adjusting the scraper beltsp. 252
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 252
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 252
+The following section describes the test for thep. 258
+The following section describes the test for thep. 258
leftp. 258
+Fig. 1p. 258
Fig. 1p. 258
+Danger of injury!p. 258
Danger of injury!p. 258
Before connecting the pressure gauge make sure that the engine has been shut down!p. 258
+1. Connect a high pressure gauge (600 bar) to pressure test port (1) on the pumpp. 258
+1. Connect a high pressure gauge (600 bar) to pressure test port (1) on the pumpp. 258
(Fig. 1)p. 258
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 258
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 258
+2. Block the auger with suitable means.p. 258
2. Block the auger with suitable means.p. 258
+Fig. 2p. 258
Fig. 2p. 258
+3. Start the engine and set the switch to position "MAX"p. 258
+3. Start the engine and set the switch to position "MAX"p. 258
(Fig. 2)p. 258
+Fig. 3p. 259
Fig. 3p. 259
+4. Activate the hydraulic systemp. 259
+4. Activate the hydraulic systemp. 259
(Fig. 3)p. 259
+Fig. 4p. 259
Fig. 4p. 259
+5. Activate the parking brakep. 259
+5. Activate the parking brakep. 259
(Fig. 4)p. 259
+Fig. 5p. 259
Fig. 5p. 259
+6. Select "Work"-modep. 259
+6. Select "Work"-modep. 259
(Fig. 5)p. 259
+Fig. 6p. 259
Fig. 6p. 259
+Run the following pressure test only for max. 5 seconds.p. 259
Run the following pressure test only for max. 5 seconds.p. 259
+7. Set the switch “b” (right auger : “c”) downwards.p. 259
+7. Set the switch “b” (right auger : “c”) downwards.p. 259
(Fig. 6)p. 259
+8. Read the hydraulic oil pressure in the pressure gauge.p. 259
8. Read the hydraulic oil pressure in the pressure gauge.p. 259
+9. Turn switch "b" ("c") to position "0".p. 259
9. Turn switch "b" ("c") to position "0".p. 259
+Fig. 7p. 260
Fig. 7p. 260
+Nominal valuep. 260
Nominal valuep. 260
See chapter "Technical Data".p. 260
+If the nominal pressure of the pressure relief valve is not reached:p. 260
If the nominal pressure of the pressure relief valve is not reached:p. 260
1. Adjust the pressure relief valve (PRV) on the "Auger drive" valve block (see next step).p. 260
2. Solenoid valve (Y210, Y211 (right auger: Y212, Y213)) – check electrical control and mechanical function.p. 260
3. Check the gear pump ("defect?").p. 260
4. Check the auger motor ("defect?").p. 260
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 260
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 260
+10. Remove the cap from the PRVp. 260
+10. Remove the cap from the PRVp. 260
(Fig. 7)p. 260
+11. Loosen the counter nut (1) and turn the setscrew (2) in or out, until the nominal value is reached.p. 260
11. Loosen the counter nut (1) and turn the setscrew (2) in or out, until the nominal value is reached.p. 260
+Turning clockwisep. 260
+Turning clockwisep. 260
increasesp. 260
reducesp. 260
+12. Check the pressure once again (see above).p. 260
12. Check the pressure once again (see above).p. 260
+13. Retighten the counter nut (1) and replace the cap.p. 260
13. Retighten the counter nut (1) and replace the cap.p. 260
+Fig. 8p. 260
Fig. 8p. 260
+14. Turn the switch to position "MIN" and shut down the enginep. 260
+14. Turn the switch to position "MIN" and shut down the enginep. 260
(Fig. 8)p. 260
+Danger of injury!p. 260
Danger of injury!p. 260
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 260
+15. Disconnect the pressure gauge.p. 260
15. Disconnect the pressure gauge.p. 260
+16. Remove the blockage from the auger.p. 260
16. Remove the blockage from the auger.p. 260
Rotary speed test augerp. 261
+The following section describes the test for one side. The other side must be checked accordingly.p. 261
The following section describes the test for one side. The other side must be checked accordingly.p. 261
+Fig. 9p. 261
Fig. 9p. 261
+1. Fasten a reflex mark (2) on the auger (1)p. 261
+1. Fasten a reflex mark (2) on the auger (1)p. 261
(Fig. 9)p. 261
+Fig. 10p. 261
Fig. 10p. 261
+2. Start the engine and set the switch to position "MAX"p. 261
+2. Start the engine and set the switch to position "MAX"p. 261
(Fig. 10)p. 261
+Fig. 11p. 261
Fig. 11p. 261
+3. Activate the hydraulic systemp. 261
+3. Activate the hydraulic systemp. 261
(Fig. 11)p. 261
+Fig. 12p. 262
Fig. 12p. 262
+4. Activate the parking brakep. 262
+4. Activate the parking brakep. 262
(Fig. 12)p. 262
+Fig. 13p. 262
Fig. 13p. 262
+5. Select "Work"-modep. 262
+5. Select "Work"-modep. 262
(Fig. 13)p. 262
+Fig. 14p. 262
Fig. 14p. 262
+6. Set the switch “b” (right auger : “c”) downwards.p. 262
+6. Set the switch “b” (right auger : “c”) downwards.p. 262
(Fig. 14)p. 262
+Fig. 15p. 262
Fig. 15p. 262
+7. Shift the travel lever to "forward" positionp. 262
+7. Shift the travel lever to "forward" positionp. 262
(Fig. 15)p. 262
+8. Read the shaft speed.p. 262
8. Read the shaft speed.p. 262
+Nominal valuep. 262
Nominal valuep. 262
See chapter "Technical Data".p. 262
+9. Shift the travel lever to "Neutral" position.p. 262
9. Shift the travel lever to "Neutral" position.p. 262
+10. Turn switch "b" ("c") to position "0".p. 262
10. Turn switch "b" ("c") to position "0".p. 262
+If the nominal pressure of the pressure relief valve is not reached:p. 262
If the nominal pressure of the pressure relief valve is not reached:p. 262
1. Check the PRV ("defect?").p. 262
2. Solenoid valve (Y210, Y211 (right auger: Y212, Y213)) – check electrical control and mechanical function.p. 263
3. Check the gear pump ("defect?").p. 263
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 263
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 263
+Fig. 16p. 263
Fig. 16p. 263
+11. Turn the switch to position "MIN" and shut down the enginep. 263
+11. Turn the switch to position "MIN" and shut down the enginep. 263
(Fig. 16)p. 263
+14.6 Checking/adjusting the main screedp. 264
14.6 Checking/adjusting the main screedp. 264
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 264
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 264
+Special toolsp. 264
Special toolsp. 264
+Hydraulic test casep. 264
[BOMAG Part-No.: 079 930 01]p. 264
Pressure limitation main screedsp. 264
+Fig. 1p. 264
Fig. 1p. 264
+Danger of injury!p. 264
Danger of injury!p. 264
Before connecting the pressure gauge make sure that the engine has been shut down!p. 264
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 264
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 264
(Fig. 1)p. 264
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 264
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 264
+Fig. 2p. 264
Fig. 2p. 264
+2. Start the engine and set the switch to position "MAX"p. 264
+2. Start the engine and set the switch to position "MAX"p. 264
(Fig. 2)p. 264
+Fig. 3p. 264
Fig. 3p. 264
+3. Activate the hydraulic systemp. 264
+3. Activate the hydraulic systemp. 264
(Fig. 3)p. 264
+Fig. 4p. 265
Fig. 4p. 265
+4. Select "Work"-modep. 265
+4. Select "Work"-modep. 265
(Fig. 4)p. 265
+Fig. 5p. 265
Fig. 5p. 265
+For the following pressure test drive the screed max. 5 seconds against block.p. 265
For the following pressure test drive the screed max. 5 seconds against block.p. 265
+5. Lift the screed completely and read the pressure gaugep. 265
+5. Lift the screed completely and read the pressure gaugep. 265
(Fig. 5)p. 265
+Nominal valuep. 265
Nominal valuep. 265
See chapter "Technical Data".p. 265
+Fig. 6p. 265
Fig. 6p. 265
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 265
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 265
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 265
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 265
(Fig. 6)p. 265
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 265
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 265
+Fig. 7p. 265
Fig. 7p. 265
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 265
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 265
(Fig. 7)p. 265
+Turning clockwisep. 265
+Turning clockwisep. 265
increasesp. 265
reducesp. 265
+7. Check the pressure once again (see above).p. 265
7. Check the pressure once again (see above).p. 265
+8. Retighten the counter nut (2).p. 265
8. Retighten the counter nut (2).p. 265
+Fig. 8p. 266
Fig. 8p. 266
+9. Deactivate the hydraulic systemp. 266
+9. Deactivate the hydraulic systemp. 266
(Fig. 8)p. 266
+Fig. 9p. 266
Fig. 9p. 266
+10. Turn the switch to position "MIN" and shut down the enginep. 266
+10. Turn the switch to position "MIN" and shut down the enginep. 266
(Fig. 9)p. 266
+Danger of injury!p. 266
Danger of injury!p. 266
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 266
+11. Disconnect the pressure gauge.p. 266
11. Disconnect the pressure gauge.p. 266
Time measurement for lifting and lowering the main screedp. 267
+Fig. 10p. 267
Fig. 10p. 267
+1. Start the engine and set the switch to position "MAX"p. 267
+1. Start the engine and set the switch to position "MAX"p. 267
(Fig. 10)p. 267
+Fig. 11p. 267
Fig. 11p. 267
+2. Activate the hydraulic systemp. 267
+2. Activate the hydraulic systemp. 267
(Fig. 11)p. 267
+Fig. 12p. 267
Fig. 12p. 267
+3. Select "Work"-modep. 267
+3. Select "Work"-modep. 267
(Fig. 12)p. 267
+Fig. 13p. 268
Fig. 13p. 268
+4. If necessary lower the screed (1) completelyp. 268
+4. If necessary lower the screed (1) completelyp. 268
(Fig. 13)p. 268
+5. Lift the screed completely and measure the required time.p. 268
+5. Lift the screed completely and measure the required time.p. 268
5. Liftp. 268
+Nominal valuep. 268
Nominal valuep. 268
+3-5 secondsp. 268
3-5 secondsp. 268
+6. Lower the screed completely and measure the required time.p. 268
+6. Lower the screed completely and measure the required time.p. 268
6. Lowerp. 268
+Nominal valuep. 268
Nominal valuep. 268
+3-5 secondsp. 268
3-5 secondsp. 268
+If the nominal value is not reached, this may have one of the following causes:p. 268
If the nominal value is not reached, this may have one of the following causes:p. 268
– Throttle (see hydraulic diagram) dirty –> cleanp. 268
– Valves Y226, Y237, Y228 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 268
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 268
– Flow volume from service pump too low –> check the pumpp. 268
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 268
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 268
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 268
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 268
+– Bigger throttle: The screed movesp. 268
fasterp. 268
+– Smaller throttle: The screed movesp. 268
slowerp. 268
+Fig. 14p. 268
Fig. 14p. 268
+7. Deactivate the hydraulic systemp. 268
+7. Deactivate the hydraulic systemp. 268
(Fig. 14)p. 268
+Fig. 15p. 269
Fig. 15p. 269
+8. Turn the switch to position "MIN" and shut down the enginep. 269
+8. Turn the switch to position "MIN" and shut down the enginep. 269
(Fig. 15)p. 269
+14.7 Checking/adjusting the screed levellingp. 270
14.7 Checking/adjusting the screed levellingp. 270
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 270
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 270
+Special toolsp. 270
Special toolsp. 270
+Hydraulic test casep. 270
[BOMAG Part-No.: 079 930 01]p. 270
Pressure test screed levellingp. 270
+Fig. 1p. 270
Fig. 1p. 270
+Danger of injury!p. 270
Danger of injury!p. 270
Before connecting the pressure gauge make sure that the engine has been shut down!p. 270
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 270
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 270
(Fig. 1)p. 270
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 270
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 270
+Fig. 2p. 270
Fig. 2p. 270
+2. Start the engine and set the switch to position "MAX"p. 270
+2. Start the engine and set the switch to position "MAX"p. 270
(Fig. 2)p. 270
+Fig. 3p. 270
Fig. 3p. 270
+3. Activate the hydraulic systemp. 270
+3. Activate the hydraulic systemp. 270
(Fig. 3)p. 270
+Fig. 4p. 271
Fig. 4p. 271
+4. Select "Work"-modep. 271
+4. Select "Work"-modep. 271
(Fig. 4)p. 271
+Fig. 5p. 271
Fig. 5p. 271
+For the following pressure test move the screed levelling max. 5 seconds against block.p. 271
For the following pressure test move the screed levelling max. 5 seconds against block.p. 271
+5. Lift the screed levelling completely and read the pressure gaugep. 271
+5. Lift the screed levelling completely and read the pressure gaugep. 271
(Fig. 5)p. 271
+Nominal valuep. 271
Nominal valuep. 271
See chapter "Technical Data".p. 271
+Fig. 6p. 271
Fig. 6p. 271
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 271
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 271
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 271
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 271
(Fig. 6)p. 271
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 271
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 271
+Fig. 7p. 271
Fig. 7p. 271
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 271
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 271
(Fig. 7)p. 271
+Turning clockwisep. 271
+Turning clockwisep. 271
increasesp. 271
reducesp. 271
+7. Check the pressure once again (see above).p. 271
7. Check the pressure once again (see above).p. 271
+8. Retighten the counter nut (2).p. 271
8. Retighten the counter nut (2).p. 271
+Fig. 8p. 272
Fig. 8p. 272
+9. Deactivate the hydraulic systemp. 272
+9. Deactivate the hydraulic systemp. 272
(Fig. 8)p. 272
+Fig. 9p. 272
Fig. 9p. 272
+10. Turn the switch to position "MIN" and shut down the enginep. 272
+10. Turn the switch to position "MIN" and shut down the enginep. 272
(Fig. 9)p. 272
+Danger of injury!p. 272
Danger of injury!p. 272
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 272
+11. Disconnect the pressure gauge.p. 272
11. Disconnect the pressure gauge.p. 272
Time measurement screed levellingp. 273
+Fig. 10p. 273
Fig. 10p. 273
+1. Start the engine and set the switch to position "MAX"p. 273
+1. Start the engine and set the switch to position "MAX"p. 273
(Fig. 10)p. 273
+Fig. 11p. 273
Fig. 11p. 273
+2. Activate the hydraulic systemp. 273
+2. Activate the hydraulic systemp. 273
(Fig. 11)p. 273
+Fig. 12p. 273
Fig. 12p. 273
+3. Select "Work"-modep. 273
+3. Select "Work"-modep. 273
(Fig. 12)p. 273
+Fig. 13p. 273
Fig. 13p. 273
+4. If necessary lower the drawing arms completelyp. 273
+4. If necessary lower the drawing arms completelyp. 273
(Fig. 13)p. 273
+5. Lift the drawing arms completely and measure the required time.p. 273
+5. Lift the drawing arms completely and measure the required time.p. 273
5. Liftp. 273
+Nominal valuep. 273
Nominal valuep. 273
+27-29 secondsp. 273
27-29 secondsp. 273
+6. Lower the drawing arms completely and measure the required time.p. 273
+6. Lower the drawing arms completely and measure the required time.p. 273
6. Lowerp. 273
+Nominal valuep. 273
Nominal valuep. 273
+23-25 secondsp. 273
23-25 secondsp. 273
+If the nominal value is not reached, this may have one of the following causes:p. 274
If the nominal value is not reached, this may have one of the following causes:p. 274
– Throttle (see hydraulic diagram) dirty –> cleanp. 274
– Valves Y220, Y221, Y222, Y223 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 274
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 274
– Flow volume from service pump too low –> check the pumpp. 274
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 274
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 274
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 274
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 274
+– Bigger throttle: The levelling cylinder movesp. 274
fasterp. 274
+– Smaller throttle: The levelling cylinder movesp. 274
slowerp. 274
+Fig. 14p. 274
Fig. 14p. 274
+7. Deactivate the hydraulic systemp. 274
+7. Deactivate the hydraulic systemp. 274
(Fig. 14)p. 274
+Fig. 15p. 275
Fig. 15p. 275
+8. Turn the switch to position "MIN" and shut down the enginep. 275
+8. Turn the switch to position "MIN" and shut down the enginep. 275
(Fig. 15)p. 275
+14.8 Checking/adjusting the hopper wingsp. 276
14.8 Checking/adjusting the hopper wingsp. 276
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 276
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 276
+Special toolsp. 276
Special toolsp. 276
+Hydraulic test casep. 276
[BOMAG Part-No.: 079 930 01]p. 276
Pressure test for hopper wingsp. 276
+Fig. 1p. 276
Fig. 1p. 276
+Danger of injury!p. 276
Danger of injury!p. 276
Before connecting the pressure gauge make sure that the engine has been shut down!p. 276
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 276
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 276
(Fig. 1)p. 276
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 276
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 276
+Fig. 2p. 276
Fig. 2p. 276
+2. Start the engine and set the switch to position "MAX"p. 276
+2. Start the engine and set the switch to position "MAX"p. 276
(Fig. 2)p. 276
+Fig. 3p. 276
Fig. 3p. 276
+3. Activate the hydraulic systemp. 276
+3. Activate the hydraulic systemp. 276
(Fig. 3)p. 276
+Fig. 4p. 277
Fig. 4p. 277
+4. Select "Work"-modep. 277
+4. Select "Work"-modep. 277
(Fig. 4)p. 277
+Fig. 5p. 277
Fig. 5p. 277
+For the following pressure test move the hopper wings max. 5 seconds against block.p. 277
For the following pressure test move the hopper wings max. 5 seconds against block.p. 277
+5. Close the hopper wings completely and read the pressure gaugep. 277
+5. Close the hopper wings completely and read the pressure gaugep. 277
(Fig. 5)p. 277
+Nominal valuep. 277
Nominal valuep. 277
See chapter "Technical Data".p. 277
+Fig. 6p. 277
Fig. 6p. 277
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 277
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 277
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 277
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 277
(Fig. 6)p. 277
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 277
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 277
+Fig. 7p. 277
Fig. 7p. 277
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 277
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 277
(Fig. 7)p. 277
+Turning clockwisep. 277
+Turning clockwisep. 277
increasesp. 277
reducesp. 277
+7. Check the pressure once again (see above).p. 277
7. Check the pressure once again (see above).p. 277
+8. Retighten the counter nut (2).p. 277
8. Retighten the counter nut (2).p. 277
+Fig. 8p. 278
Fig. 8p. 278
+9. Deactivate the hydraulic systemp. 278
+9. Deactivate the hydraulic systemp. 278
(Fig. 8)p. 278
+Fig. 9p. 278
Fig. 9p. 278
+10. Turn the switch to position "MIN" and shut down the enginep. 278
+10. Turn the switch to position "MIN" and shut down the enginep. 278
(Fig. 9)p. 278
+Danger of injury!p. 278
Danger of injury!p. 278
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 278
+11. Disconnect the pressure gauge.p. 278
11. Disconnect the pressure gauge.p. 278
Testing the hopper wing movement timep. 279
+Fig. 10p. 279
Fig. 10p. 279
+1. Start the engine and set the switch to position "MAX"p. 279
+1. Start the engine and set the switch to position "MAX"p. 279
(Fig. 10)p. 279
+Fig. 11p. 279
Fig. 11p. 279
+2. Activate the hydraulic systemp. 279
+2. Activate the hydraulic systemp. 279
(Fig. 11)p. 279
+Fig. 12p. 279
Fig. 12p. 279
+3. Select "Work"-modep. 279
+3. Select "Work"-modep. 279
(Fig. 12)p. 279
+Fig. 13p. 280
Fig. 13p. 280
+4. If necessary open the hopper wings completelyp. 280
+4. If necessary open the hopper wings completelyp. 280
(Fig. 13)p. 280
+5. Close the hopper wing completely and measure the required time.p. 280
+5. Close the hopper wing completely and measure the required time.p. 280
5. Closep. 280
+Nominal valuep. 280
Nominal valuep. 280
+4-5 secondsp. 280
4-5 secondsp. 280
+6. Open the hopper wing completely and measure the required time.p. 280
+6. Open the hopper wing completely and measure the required time.p. 280
6. Openp. 280
+Nominal valuep. 280
Nominal valuep. 280
+5-6 secondsp. 280
5-6 secondsp. 280
+If the nominal value is not reached, this may have one of the following causes:p. 280
If the nominal value is not reached, this may have one of the following causes:p. 280
– Throttles (see hydraulic diagram) dirty –> cleanp. 280
– Valves Y202, Y203, Y204, Y205 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 280
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 280
– Flow volume from service pump too low –> check the pumpp. 280
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 280
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 280
+If the nominal value is still not reached despite these measures you may change the size of the throttles:p. 280
If the nominal value is still not reached despite these measures you may change the size of the throttles:p. 280
+– Bigger throttle: The hopper wings movep. 280
fasterp. 280
+– Smaller throttle: The hopper wings movep. 280
slowerp. 280
+Fig. 14p. 280
Fig. 14p. 280
+7. Deactivate the hydraulic systemp. 280
+7. Deactivate the hydraulic systemp. 280
(Fig. 14)p. 280
+Fig. 15p. 281
Fig. 15p. 281
+8. Turn the switch to position "MIN" and shut down the enginep. 281
+8. Turn the switch to position "MIN" and shut down the enginep. 281
(Fig. 15)p. 281
+14.9 Checking/adjusting the mobile screedp. 282
14.9 Checking/adjusting the mobile screedp. 282
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 282
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 282
+Special toolsp. 282
Special toolsp. 282
+Hydraulic test casep. 282
[BOMAG Part-No.: 079 930 01]p. 282
Pressure limitation mobile screedsp. 282
+Fig. 1p. 282
Fig. 1p. 282
+Danger of injury!p. 282
Danger of injury!p. 282
Before connecting the pressure gauge make sure that the engine has been shut down!p. 282
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 282
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 282
(Fig. 1)p. 282
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 282
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 282
+Fig. 2p. 282
Fig. 2p. 282
+2. Start the engine and set the switch to position "MAX"p. 282
+2. Start the engine and set the switch to position "MAX"p. 282
(Fig. 2)p. 282
+Fig. 3p. 282
Fig. 3p. 282
+3. Activate the hydraulic systemp. 282
+3. Activate the hydraulic systemp. 282
(Fig. 3)p. 282
+Fig. 4p. 283
Fig. 4p. 283
+4. Select "Work"-modep. 283
+4. Select "Work"-modep. 283
(Fig. 4)p. 283
+Fig. 5p. 283
Fig. 5p. 283
+For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 283
For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 283
+Perform the pressure test by RETRACTING the mobile screed. In this case the bending forces acting on the screed are lower!p. 283
Perform the pressure test by RETRACTING the mobile screed. In this case the bending forces acting on the screed are lower!p. 283
+5. Completelyp. 283
+5. Completelyp. 283
retractp. 283
(Fig. 5)p. 283
+Nominal valuep. 283
Nominal valuep. 283
See chapter "Technical Data".p. 283
+Fig. 6p. 283
Fig. 6p. 283
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 283
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 283
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 283
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 283
(Fig. 6)p. 283
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 283
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 283
+Fig. 7p. 284
Fig. 7p. 284
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 284
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 284
(Fig. 7)p. 284
+Turning clockwisep. 284
+Turning clockwisep. 284
increasesp. 284
reducesp. 284
+7. Check the pressure once again (see above).p. 284
7. Check the pressure once again (see above).p. 284
+8. Retighten the counter nut (2).p. 284
8. Retighten the counter nut (2).p. 284
+Fig. 8p. 284
Fig. 8p. 284
+9. Deactivate the hydraulic systemp. 284
+9. Deactivate the hydraulic systemp. 284
(Fig. 8)p. 284
+Fig. 9p. 284
Fig. 9p. 284
+10. Turn the switch to position "MIN" and shut down the enginep. 284
+10. Turn the switch to position "MIN" and shut down the enginep. 284
(Fig. 9)p. 284
+Danger of injury!p. 284
Danger of injury!p. 284
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 284
+11. Disconnect the pressure gauge.p. 284
11. Disconnect the pressure gauge.p. 284
Time measurement for extension and retraction of mobile screedsp. 285
+Fig. 10p. 285
Fig. 10p. 285
+1. Start the engine and set the switch to position "MAX"p. 285
+1. Start the engine and set the switch to position "MAX"p. 285
(Fig. 10)p. 285
+Fig. 11p. 285
Fig. 11p. 285
+2. Activate the hydraulic systemp. 285
+2. Activate the hydraulic systemp. 285
(Fig. 11)p. 285
+Fig. 12p. 285
Fig. 12p. 285
+3. Select "Work"-modep. 285
+3. Select "Work"-modep. 285
(Fig. 12)p. 285
+Fig. 13p. 286
Fig. 13p. 286
+4. If necessary retract the mobile screed completelyp. 286
+4. If necessary retract the mobile screed completelyp. 286
(Fig. 13)p. 286
+5. Fullyp. 286
+5. Fullyp. 286
extendp. 286
+Nominal valuep. 286
Nominal valuep. 286
+15-17 secondsp. 286
15-17 secondsp. 286
+6. Fullyp. 286
+6. Fullyp. 286
retractp. 286
+Nominal valuep. 286
Nominal valuep. 286
+12-14 secondsp. 286
12-14 secondsp. 286
+If the nominal value is not reached, this may have one of the following causes:p. 286
If the nominal value is not reached, this may have one of the following causes:p. 286
– Throttle (see hydraulic diagram) dirty –> cleanp. 286
– Valves Y216, Y217, Y218, Y219 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 286
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 286
– Flow volume from service pump too low –> check the pumpp. 286
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 286
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 286
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 286
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 286
+– Bigger throttle: The mobile screed movesp. 286
fasterp. 286
+– Smaller throttle: The mobile screed movesp. 286
slowerp. 286
+Fig. 14p. 286
Fig. 14p. 286
+7. Deactivate the hydraulic systemp. 286
+7. Deactivate the hydraulic systemp. 286
(Fig. 14)p. 286
+Fig. 15p. 287
Fig. 15p. 287
+8. Turn the switch to position "MIN" and shut down the enginep. 287
+8. Turn the switch to position "MIN" and shut down the enginep. 287
(Fig. 15)p. 287
+15 Central lubrication systemp. 289
+15 Central lubrication systemp. 289
Filling the lubricant containerp. 290
Fig. 1 Filler couplingp. 290
+(Fig. 1) Through filler coupling.p. 290
(Fig. 1)p. 290
Fig. 2 Grease gunp. 290
+(Fig. 2) With grease gunp. 290
(Fig. 2)p. 290
Fig. 3 Grease nipplep. 290
+(Fig. 3) Through grease nipple with hand-operated or pneumatic grease gunp. 290
(Fig. 3)p. 290
15.2 Electric pumpp. 291
+Electric pump EP-1p. 291
Electric pump EP-1p. 291
+The central lubrication grease pump is electrically driven. With a working pressure of max. 280 bar (setting of high pressure relief valve) this pump is suitable for pumping conventional greases up to NLGI-Kl. 2.p. 291
The central lubrication grease pump is electrically driven. With a working pressure of max. 280 bar (setting of high pressure relief valve) this pump is suitable for pumping conventional greases up to NLGI-Kl. 2.p. 291
Fig. 4 EP-1 with 4 kg container and integrated electronic controlp. 291
Technical dadap. 291
Motor:p. 291
+Operating voltagep. 291
Operating voltagep. 291
12/24 V DCp. 291
Rated speedp. 291
15 rpmp. 291
Power consumption at idle speedp. 291
0.4 Ap. 291
Power consumption at full load speedp. 291
1.1 Ap. 291
Fusep. 291
3 Ap. 291
Pump:p. 291
+Max. operating pressurep. 291
Max. operating pressurep. 291
280 barp. 291
Permissible operating temperaturep. 291
-35°C to +80°Cp. 291
Container capacityp. 291
1.9 kg, 2.5 kg, 4 kg or 8 kgp. 291
Rotation of agitatorp. 291
counter-clockwisep. 291
Installation positionp. 291
Container vertically uprightp. 291
Protection classp. 291
IP5K9K acc. to DIN 40050p. 291
Working principlep. 292
Fig. 5p. 292
+A DC-motor 10p. 292
(Fig. 5)p. 292
The agitator (2) forces the lubricant out of the provision container (1) through a screen plate (4 to the suction area in the pump housing (3), whereby air bubbles are eliminated A scraper on the agitator (2) enables visual inspection of the still av…p. 292
The pressure relief valve (9) is factory set to 280 bar.p. 292
Fig. 6 Pump element drawing in greasep. 292
Fig. 7 Pump element pumpingp. 292
Pump element PE-120Vp. 293
+Max. flow capacityp. 293
Max. flow capacityp. 293
+l Pump element factory set to full strokep. 293
l Pump element factory set to full strokep. 293
l max. flow capacity 0.12 cm with full strokep. 293
l Reduction of 0.013 cm per detent = 1/2 revolutionp. 293
Flow capacity regulation:p. 293
+l Unscrew the plug 2p. 293
+l Unscrew the plug 2p. 293
(Fig. 8)p. 293
l The setscrew (3) is then regulated with a screwdriverp. 293
l Turning clockwise reduces the flow capacityp. 293
l Turn anti-clockwise increases the flow capacityp. 293
l Max. stroke of setscrew is 2.4 mm = 6 detents.p. 293
l 1 turn of the setscrew is 0.8 mm = 2 detentsp. 293
l Tighten the plug (2) with the seal ring.p. 293
Technical data:p. 293
+Max. flow capacityp. 293
Max. flow capacityp. 293
+0.04 to 0.12 cmp. 293
3p. 293
Flow capacity regulationp. 293
6 detents per 1/2 turnp. 293
Reductionp. 293
+0.013 cmp. 293
3p. 293
Piston returnp. 293
forcedp. 293
Fig. 8p. 293
Fig. 9p. 293
Installation of pump elementp. 294
+l Installation and removal only with the pump stopped.p. 294
l Installation and removal only with the pump stopped.p. 294
+l Assembly of the pump element with the piston (4) partly pulled out, insert upwards under a slanted angle into the housing borep. 294
(Fig. 10)p. 294
+l Once the piston head touches the pressing ring – move the element to horizontal positionp. 294
(Fig. 11)p. 294
l The piston head must run in the groove of the guide ring.p. 294
l Tighten the pump element.p. 294
l Disassemble in reverse order.p. 294
+When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 294
When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 294
Fig. 10p. 294
Fig. 11p. 294
15.3 Integrated electronic controlp. 295
+The control unit is equipped with a data memory which logs the following values:p. 295
The control unit is equipped with a data memory which logs the following values:p. 295
+l Control typep. 295
l Control typep. 295
l Version of control serial numberp. 295
l Manufacturing datep. 295
l Type of operation (time or speed control)p. 295
l Settings (setting ranges).p. 295
+Functional sequencep. 295
Functional sequencep. 295
After switching on the ignition the green and red LEDs light up for 1.5 seconds to indicate readiness for operation (switch-on control), irrespective of the set program.p. 295
+Each initial connection of the control triggers a lubrication process, the green LED 2p. 295
(Fig. 12)p. 295
The integrated electronic control unit BEKA-troniX1 is equipped with a data log. This, among other, serves the purpose of logging expired times. If the ignition is interrupted during a lubrication process or within a pause period, this time is stoppe…p. 295
With the ignition switched on intermediate lubrication can be triggered at any time by pressing the push button (1) on the side of the motor housing, this function also serve the purpose of function testing. The pump in this case immediately starts a…p. 295
Fig. 12p. 295
+1 Push button to trigger intermediate lubricationp. 295
1 Push button to trigger intermediate lubricationp. 295
2 Green LED to indicate functionp. 295
3 Red LED to indicate faultsp. 295
Technical data:p. 295
+Supply voltagep. 295
Supply voltagep. 295
10 to 60 V DCp. 295
Current load max.p. 295
6.0 Ap. 295
Fuse (not contained in the unit)p. 295
6.3 Ap. 295
Output for signal lampp. 295
0.4 Ap. 295
Temperature rangep. 295
-35°C to +75°Cp. 295
Protection classp. 295
IP 65p. 295
+Summary of signal displaysp. 296
Modes of operationp. 296
+A) Timer controlp. 296
A) Timer controlp. 296
With time dependent control of a central lubrication system both the cycle time and the lubrication time can be adjusted. Cycle time means the time span between beginning of a lubrication process to the beginning of the next lubrication process.p. 296
Fig. 13p. 296
+B) RPM-controlp. 296
B) RPM-controlp. 296
With the integrated electronic control unit one can, e.g. in case of speed fluctuations caused by low temperatures or high torques, also determine the lubrication period on the basis of the number of revolutions of the pump motor.p. 296
A sliding contact connects the pump motor with the control. Each pump revolution sends a signal to the control, which in turn counts the number of arriving signals.p. 296
If no signals are received from the pump motor over an adjustable monitoring time (standard 30 sec.) after the beginning of the lubrication process, the control will indicate a fault.p. 296
The red LED in the inspection window in the bottom motor shell of the pump or an externally installed signal lamp (option) will start to flash.p. 296
+Summary of signal displaysp. 296
Setting parametersp. 296
The cycle or lubrication times can be set with the help of maintained-contact switches in the inspection window of the control.p. 296
Fig. 14p. 296
+For setting the time disassemble the red frame from the motor protection housing of the pump using a flat screwdriverp. 296
(Fig. 14)p. 296
The cycle or lubrication time can be set with a flat screwdriver.p. 296
+The cycle time must not be changed.p. 296
The cycle time must not be changed.p. 296
In case of improper closing of the cover water will seep into the control and cause damage. In this case any warranty will become null and void.p. 296
Fig. 15p. 296
+1 Connection of system diagnosep. 296
1 Connection of system diagnosep. 296
2 Maintained-contact switch to set the lubrication timep. 296
3 Maintained-contact switch to set the cycle timep. 296
Lubrication times:p. 297
1 to 16 min. (16 contacts for 1 min. each)p. 297
2 to 32 min. (16 contacts for 2 min. each)p. 297
2 to 32 sec. (16 contacts for 2 sec. each)p. 297
Cycle times:p. 297
0.5 to 8 h (16 contacts for 0.5 h each)p. 297
2 to 32 min. (16 contacts for 2 min. each)p. 297
2 to 32 h (16 contacts for 2 h each)p. 297
Pump revolutions:p. 297
1 to 16 revolutions (16 contacts for 1 revolution each)p. 297
10 to 160 revolutions (16 contacts for 10 revolution each)p. 297
170 to 320 revolutions (16 contacts for 10 revolution each)p. 297
+Summary of signal displaysp. 297
Summary of signal displaysp. 297
+Two control LEDs (green/red) in the inspection window of the motor shell show the functions of the pump, whereby the red LED always indicates a fault in the program sequence.p. 297
Two control LEDs (green/red) in the inspection window of the motor shell show the functions of the pump, whereby the red LED always indicates a fault in the program sequence.p. 297
Fig. 1 Indication of functional readinessp. 297
+1 Red LED to indicate faultsp. 297
1 Red LED to indicate faultsp. 297
2 Green LED to indicate functionp. 297
+a) Functional readinessp. 297
a) Functional readinessp. 297
Fig. 2 Indication of functional readinessp. 297
+b) Lubrication activep. 297
b) Lubrication activep. 297
Fig. 3 Lubrication sequencep. 297
+c) Rotary speed faultp. 297
c) Rotary speed faultp. 297
Fig. 4 Rotary speed fault on pump motorp. 297
+d) Fault CPU/memoryp. 297
d) Fault CPU/memoryp. 297
Fig. 5 Fault CPU/memoryp. 297
+e) Test lubrication (permanent lubrication)p. 297
e) Test lubrication (permanent lubrication)p. 297
Fig. 6 Test lubricationp. 297
+In order to be able to trigger permanent lubrication for service purposes in "Timer controlled" mode, the lubrication time must be set to a value that is higher than the cycle time.p. 297
In order to be able to trigger permanent lubrication for service purposes in "Timer controlled" mode, the lubrication time must be set to a value that is higher than the cycle time.p. 297
+Terminal diagramp. 298
Terminal diagramp. 298
Fig. 7p. 298
+(No. …) = Cable no. for mono-colour cablep. 298
(No. …) = Cable no. for mono-colour cablep. 298
15.4 Progressive distributorp. 299
+The progressive distributor can be employed as main or a secondary distributor.p. 299
The progressive distributor can be employed as main or a secondary distributor.p. 299
Progressive piston distributors are distributor units with a hydraulic sequence control the pistons of which are controlled by the fed lubricant in such a way that the lubricant is forced successively to the individual outlets. In case of disturbance…p. 299
The progressive distributors are manufactured in a variable disc design. This has the advantage that the distributor can be extended or shortened, depending on the number of lubrication points. This disc design also provides the possibility to custom…p. 299
The different displacements per piston stroke are achieved by different piston diameters.p. 299
For correct functioning a progressive distributor requires at least three pistons, i.e. at lest three pumping elements.p. 299
Technical data:p. 299
+Operating pressure at inletp. 299
Operating pressure at inletp. 299
max. 300 barp. 299
Temperature rangep. 299
-35°C to + 80°Cp. 299
Number of elementsp. 299
Min. 3 piston elements, Max. 12 piston elementsp. 299
Fig. 8 Example: 4 piston elements and 8 outletsp. 299
In detail the progressive distributor consists of a start element (without piston), a middle element ME and an end element EE, which are held together as distributor blocks by tie rods (socket head cap screws) with serrated washers. The individual el…p. 299
+Element designationp. 299
Element designationp. 299
+Max. flow capacityp. 299
Max. flow capacityp. 299
+Pistonp. 299
Pistonp. 299
+Æp. 299
Æp. 299
+per outletp. 299
per outletp. 299
+per elementp. 299
per elementp. 299
+MX- F25p. 299
MX- F25p. 299
+25 mm3p. 299
+25 mmp. 299
3p. 299
+50 mm3p. 299
+50 mmp. 299
3p. 299
+3 mmp. 299
3 mmp. 299
+MX- F45p. 299
MX- F45p. 299
+45 mm3p. 299
+45 mmp. 299
3p. 299
+90 mm3p. 299
+90 mmp. 299
3p. 299
+4 mmp. 299
4 mmp. 299
+MX- F75p. 299
MX- F75p. 299
+75 mm3p. 299
+75 mmp. 299
3p. 299
+150 mm3p. 299
+150 mmp. 299
3p. 299
+5 mmp. 299
5 mmp. 299
+MX- F105p. 299
MX- F105p. 299
+105 mm3p. 299
+105 mmp. 299
3p. 299
+210 mm3p. 299
+210 mmp. 299
3p. 299
+6 mmp. 299
6 mmp. 299
Description of functionp. 300
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 300
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 300
(Fig. 1)p. 300
(Fig. 2)p. 300
+Then the metering pistons (II) and (III) are displaced in succession and lubricant is delivered to outlets 2 and 3. After displacing piston (III) lubricant is delivered to the left side of pumping piston (I)p. 300
(Fig. 3)p. 300
Then the metering pistons (II) and (III) are displaced in succession and lubricant is pressed to outlets 5 and 6.p. 300
+After the displacement of pumping piston (III) the lubricant is once again guided to the right side of the pumping pistonp. 300
(Fig. 1)p. 300
Fig. 1p. 300
Fig. 2p. 300
Fig. 3p. 300
Connection of 2 outletsp. 301
For large lubrication points it may be necessary to join two or more outlets on the progressive distributor together.p. 301
The individual discs of the progressive distributor have two outlets.p. 301
When connecting two outlets on the progressive distributor, both outlets of one disc are joined together. For this purpose the sealing screw, which separates both sides, is removed and a plug is screwed into the side to be closed. The metered quantit…p. 301
+2 outlets per distributor elementp. 301
+2 outlets per distributor elementp. 301
(Fig. 4)p. 301
Fig. 4 2 outletsp. 301
+1 Sealing screwp. 301
1 Sealing screwp. 301
+1 outlet per distributor elementp. 301
+1 outlet per distributor elementp. 301
(Fig. 5)p. 301
Fig. 5 1 outletp. 301
+1 Plugp. 301
1 Plugp. 301
For connecting outlets, plugs are required.p. 301
Connection of several outletsp. 301
+Connection of outlets with bridging pipes without outletp. 301
Connection of outlets with bridging pipes without outletp. 301
+Should the total metering quantity exceed the capacity of the outlets connected in one disc of the progressive distributor, e.g. for extremely big lubrication points or for main distributors, there is a possibility to join the outlets of several dist…p. 301
(Fig. 6)p. 301
Fig. 6 Bridging pipep. 301
+3 outlets joined togetherp. 301
(Fig. 7)p. 301
+In this case two distributor discs are connected with a bridging pipe or a distributor bridge without outlet, as described hereunder. Depending on the element from which the sealing screw 1p. 301
(Fig. 7)p. 301
The metered quantity is calculated on the basis of the metering parameters for all joined piston sides.p. 301
Fig. 7 3 outletsp. 301
+1 Sealing screwp. 301
1 Sealing screwp. 301
+4 outlets joined togetherp. 301
(Fig. 8)p. 301
With the help of a bridging pipe or a distributor bridge without outlet you can even join four outlets. For this purpose the sealing screws must be removed from both distributor discs and one of the two outlets opposite the bridging pipe or the distr…p. 301
Fig. 8 4 outletsp. 302
Distributor bridge without outletp. 302
+Distributor bridge without check valvep. 302
+Distributor bridge without check valvep. 302
(Fig. 9)p. 302
Fig. 9 without check valvep. 302
+Distributor bridge with integrated check valvep. 302
Distributor bridge with integrated check valvep. 302
+In order to ensure proper functioning of a progressive distributor with three delivering elements but only two outletsp. 302
(Fig. 10)p. 302
(Fig. 11)p. 302
Fig. 10p. 302
Fig. 11 with check valvep. 302
Connection of outlets with distributor bridges with outletp. 303
Fig. 12 Distributor bridge with outletp. 303
+2 outlets joined togetherp. 303
+2 outlets joined togetherp. 303
(Fig. 13)p. 303
If two outlets (on different, adjacent distributor discs) are to be joined together, the sealing screws must not be unscrewed from any of the affected distributor discs. The delivery from both outlets in this case emerges from the outlet on the distr…p. 303
Fig. 13 2 outletsp. 303
+3 outlets joined togetherp. 303
+3 outlets joined togetherp. 303
(Fig. 14)p. 303
If three outlets are to be joined together, the sealing screw must be unscrewed from one of the two affected distributor discs and a plug must be screwed into the free outlet on this distributor disc. The delivery from all three outlets in this case …p. 303
Fig. 14 3 outletsp. 303
+4 outlets joined togetherp. 303
+4 outlets joined togetherp. 303
(Fig. 15)p. 303
If four outlets are to be joined together, the sealing screws must be unscrewed from both distributor discs the plugs must be screwed into the outlets opposite the distribuitor bridge. The delivery from all four outlets in this case emerges from the …p. 303
Fig. 15 4 outletsp. 303
Check valvesp. 304
The check valves are used in combination with high pressure hoses, e.g. on lubrication points with high counter pressure or in main distributors.p. 304
There are two versions of check valves available, on which the pipe socket is screwed in.p. 304
+Check valve for main distributorp. 304
+Check valve for main distributorp. 304
(Fig. 16)p. 304
Fig. 16p. 304
+1 Cap screwp. 304
1 Cap screwp. 304
2 Duplex ringp. 304
+Check valve for secondary distributorp. 304
+Check valve for secondary distributorp. 304
(Fig. 17)p. 304
Fig. 17p. 304
+1 Cap nut and cutting ringp. 304
1 Cap nut and cutting ringp. 304
15.5 Fault – Cause – Remedyp. 305
+Faultp. 305
Faultp. 305
+Causep. 305
Causep. 305
+Remedyp. 305
Remedyp. 305
+Pump does not workp. 305
Pump does not workp. 305
+Integrated electronic control defectivep. 305
Integrated electronic control defectivep. 305
+Replace the lower part of the motor protection housingp. 305
Replace the lower part of the motor protection housingp. 305
+Electric line interruptedp. 305
Electric line interruptedp. 305
+Replace the electric linep. 305
Replace the electric linep. 305
+Pump defectivep. 305
Pump defectivep. 305
+Replace the pumpp. 305
Replace the pumpp. 305
+Pump works, but does not deliverp. 305
Pump works, but does not deliverp. 305
+Air cushion in pumping pistonp. 305
Air cushion in pumping pistonp. 305
+Vent the pumpp. 305
Vent the pumpp. 305
+Min. filling level fallen short ofp. 305
Min. filling level fallen short ofp. 305
+Fill up the provision containerp. 305
Fill up the provision containerp. 305
+Pump element defectivep. 305
Pump element defectivep. 305
+Replace the pump elementp. 305
Replace the pump elementp. 305
+No grease collar at the lubrication pointsp. 305
No grease collar at the lubrication pointsp. 305
+Pump does not workp. 305
Pump does not workp. 305
+See "Pump does not work"p. 305
See "Pump does not work"p. 305
+Pause time too long or lubrication period too shortp. 305
Pause time too long or lubrication period too shortp. 305
+Reduce pause time or extend lubrication timep. 305
Reduce pause time or extend lubrication timep. 305
+System blockedp. 305
System blockedp. 305
+See "Grease emerging from pressure relief valve"p. 305
See "Grease emerging from pressure relief valve"p. 305
+No grease collars at various lubrication pointsp. 305
No grease collars at various lubrication pointsp. 305
+Supply line to secondary distributor burst or leakingp. 305
Supply line to secondary distributor burst or leakingp. 305
+Replace the linep. 305
Replace the linep. 305
+Screw fittings leakingp. 305
Screw fittings leakingp. 305
+Retighten or replace screw fittingp. 305
Retighten or replace screw fittingp. 305
+No grease collar on one lubrication pointp. 305
No grease collar on one lubrication pointp. 305
+Corresponding grease line burst or leakingp. 305
Corresponding grease line burst or leakingp. 305
+Replace the linep. 305
Replace the linep. 305
+Screw fitting leakingp. 305
Screw fitting leakingp. 305
+Retighten or replace screw fittingp. 305
Retighten or replace screw fittingp. 305
+Pump speed too lowp. 305
Pump speed too lowp. 305
+High system pressure or low ambient temperaturep. 305
High system pressure or low ambient temperaturep. 305
+Check system / bearing pointp. 305
Check system / bearing pointp. 305
No damage (perform 1 or 2 intermediate lubrication cycles)p. 305
+Grease emerging from pressure relief valvep. 305
Grease emerging from pressure relief valvep. 305
+System pressure too highp. 305
System pressure too highp. 305
+Check systemp. 305
Check systemp. 305
+Progressive distributor blockedp. 305
Progressive distributor blockedp. 305
+Replace the distributorp. 305
Replace the distributorp. 305
+System blockedp. 305
System blockedp. 305
+Repair blocked / seized bearing pointsp. 305
Repair blocked / seized bearing pointsp. 305
+Valve spring defectivep. 305
Valve spring defectivep. 305
+Replace the pressure relief valvep. 305
Replace the pressure relief valvep. 305
+LED-displayp. 305
LED-displayp. 305
+The LED of the control flashes or is permanently onp. 305
The LED of the control flashes or is permanently onp. 305
+See "Summary of signal displays"p. 305
See "Summary of signal displays"p. 305
+Cause for a blockage in the systemp. 305
Cause for a blockage in the systemp. 305
+l A crushed or blocked lubricant linep. 305
l A crushed or blocked lubricant linep. 305
l A bearing overfilled with lubricant or blockedp. 305
l An unsuitable lubricant for central lubrication systemsp. 305
l A blocked distributor outletp. 305
l A blocked distributorp. 305
Indication of a blockagep. 305
+l Grease emerging from pressure relief valvep. 305
l Grease emerging from pressure relief valvep. 305
Identify the location of the blockagep. 306
+All repair work must be carried out with utmost cleanliness.p. 306
All repair work must be carried out with utmost cleanliness.p. 306
Fig. 18p. 306
+l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 306
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 306
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. 306
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication point.p. 306
Fig. 19 KIT to check central lubrication systemsp. 306
Repair of a blocked distributorp. 307
+Repair of a blocked distributorp. 307
Repair of a blocked distributorp. 307
+All repair work must be carried out with utmost cleanliness.p. 307
All repair work must be carried out with utmost cleanliness.p. 307
Fig. 20 Examplep. 307
Remove the distributor from the system. .p. 307
+l Note the sequence of distributor discs.p. 307
l Note the sequence of distributor discs.p. 307
+l Remove the draw bars 1p. 307
(Fig. 20)p. 307
l Take off the distributor disc(s).p. 307
+Pistons are not exchangeable among each other .p. 307
Pistons are not exchangeable among each other .p. 307
If piston and bores in the distributor disc show deposits of hardened grease, these deposits must be removed by washing or blowing out. The bores in the distributor disc must be free of grease residues.p. 307
+Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 307
Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 307
+l Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 307
l Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 307
l Screw the plugs back in.p. 307
l Check the next distributor disc, until the blocked piston is found.p. 307
l the piston of the blocked distributor disc out and check the bore in the distributor disc and the surface of the piston for scratches and damage.p. 307
+In case of severe damage replace the distributor disc.p. 307
In case of severe damage replace the distributor disc.p. 307
+l Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 307
l Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 307
l To prevent jamming of the pistons tighten the draw bars with 12 Nm.p. 307
l Check function of the distributor.p. 307
+16 Circuit diagramsp. 309
16 Circuit diagramsp. 309
2p. 310
+2p. 311
2p. 311
16.1 Hydraulic diagramp. 311
+2p. 323
2p. 323
16.2 Electric circuit diagramsp. 323
Service and repair work this manual supports
Setting valve clearance and checking injection timing on the Kubota V3307 T engine
Replacing engine oil and filter, fuel filter, water separator and air filter
Checking and adjusting the thermostat, coolant concentration and radiator hoses
Calibrating travel system currents automatically or manually after pump or control replacement
Teaching the E-throttle function and the Load Control System
Reading, saving and deleting fault codes through the input code menu
Checking and adjusting vibration, tamping, scraper belts, augers, main screed, screed levelling, hopper wings and mobile screed
Testing hydraulic pressures at the test ports and adjusting pressure relief valves
Servicing the central lubrication system, including repairing a blocked progressive distributor
Troubleshooting axial piston pumps using the fault tables
Why the correct procedure matters on a BF 300 C
The BF 300 C is a hydrostatic machine with a CAN-linked electronic control system. Travel, steering, screed functions and material feed all pass through the ESX control and its sensors. A travel pump fitted without calibrating the start currents will not respond consistently, and an E-throttle actuator fitted without teaching its end positions will not track engine speed correctly. The input code chapter in this manual covers every one of those teach procedures in sequence. The hydraulic chapter gives the actual pressure relief settings and test port locations so you can confirm a valve is doing what it should instead of assuming it. Working from the BOMAG BF 300 C Road Finisher Service Training Manual keeps the machine inside the settings BOMAG specified and keeps the paving result consistent.
How the file is delivered
The BOMAG BF 300 C Road Finisher Service Training Manual is supplied as an instant PDF download after payment. There is no shipping and no waiting for a physical book. The file opens on any device, laptop, tablet or phone, and the pages can be printed if you prefer a paper copy in the workshop. Keep it on a tablet next to the machine, or print the chapter you need for the job in front of you.
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