BOMAG BF 600 C Road Finisher Service Manual 008 916 41 – HCE/HCG, HSG/HSE, E/G
This 770-page service manual is a detailed repair, maintenance, diagnostic and technical reference for the BOMAG BF 600 C road finisher variants shown on the cover: BF 600 C – HCE/HCG, BF 600 C – HSG/HSE and BF 600 C – E/G. It is written for professionally qualified personnel and after-sales service work, with procedures covering disassembly, dismantling, assembly, installation and repair of components and assemblies. Alongside machine service information, the manual includes technical data, maintenance schedules, electrical fundamentals, engine electronics, Deutz engine material, extensive hydraulic service training, pressure tests and adjustments, central lubrication information, supplier component documentation, and hydraulic and wiring diagrams.
File Details
Manual type: Service Manual
Brand: BOMAG
Model: BF 600 C Road Finisher
Covered variants: BF 600 C – HCE/HCG; BF 600 C – HSG/HSE; BF 600 C – E/G
Catalogue number: 008 916 41
Date: 09/2010
Language: English
Page count: 770 pages
File format: PDF
Machine, Engine and Service Data
The BOMAG BF 600 C road finisher service manual brings the machine specifications and service systems together in one reference. The technical-data section identifies a water-cooled Deutz TCD 2013 L04 2V four-cylinder diesel engine rated at 120 kW (160 HP) at 2300 rpm. It records a 24 V electrical system with two 100 Ah batteries, along with filling capacities of 215 litres for diesel fuel, 20 litres for coolant, 160 litres for hydraulic oil and 15 litres for engine oil. The manual also gives variant-specific operating weights and screed data, working and transport speeds, dimensions, track data, frequency ranges for tamper and vibration functions, and detailed hydraulic component specifications.
Hydraulic component data includes the Sauer Danfoss travel pump and travel motors, vibration and tamper pumps and motors, scraper belt and conveyor screw pumps and motors, the service pump, fan motor data and the Bonfiglioli travel gear. This makes the manual useful not only for routine servicing but also when a repair requires identification of the correct system, pressure circuit, drive component or adjustment point before work begins.
Engine Electronics and Diagnostic Coverage
A major part of this manual is devoted to engine electrics and the EMR3 system. It covers the engine control unit and its installation location, EDC16/EMR3 pin assignments, camshaft and crankshaft speed sensors, rail pressure and fuel pressure sensors, the fuel control unit, injectors, oil pressure monitoring, combined charge-air pressure and temperature sensing, coolant temperature sensing, glow plugs, water-in-fuel sensing, air-filter vacuum monitoring and coolant-level sensing. Removal, installation and checking procedures are illustrated through the section, with tightening values and cleanliness requirements where they are specified.
Diagnostic material includes the diagnostic interface, CAN-bus diagnosis, Deutz SERDIA diagnosis and a substantial EMR3 fault-code section. The manual explains how the fault display presents engine warnings and hexadecimal codes, and the SERDIA material covers reading, deleting and saving the error log, viewing fault location and fault type, examining operating data recorded at the time of a fault, function testing and checking current input/output assignments. For electrical troubleshooting beyond the engine control system, there is also a large fundamentals section covering wiring-diagram reading, circuit symbols, grounds, PWM control, resistance, series and parallel circuits, Ohm’s law, metrology, relays, fuses, proximity switches, plug connectors, Deutsch DT/DTM connectors, batteries and machine fuse locations.
Hydraulic Service Training, Testing and Adjustment
The hydraulics portion is especially extensive. Prepared for the BF 600 C road finisher series, it describes the hydrostatic systems used for travel, adjustment functions, vibration and tamper operation, scraper-chain and conveyor-screw drives, and fan drive. The travel-system section explains the closed hydraulic circuit between travel pumps and motors, brake release, crawler-track tensioning, two-speed travel motors and travel gears. The actuator-drive material covers functions such as hopper side walls, screed locking, screw height, draw-point adjustment and screed up/down. Separate sections explain scraper-chain and conveyor-screw circuits, vibration and tamper drive, and fan drive using diagrams, component views, test ports and system descriptions.
IMAGES PREVIEW
The following test-and-adjustment chapter turns that system description into practical workshop procedures. It includes vibration pressure testing, tamping pressure limitation checks, travel-pump charge/high-pressure relief and pressure-override checks, mobile-screed extension and retraction timing and pressure checks, and maximum fan-motor speed measurement. The procedures identify test equipment, test-port locations, operating-temperature requirements, sequence of controls and evaluation steps. This is valuable when the job is not simply replacing a part but verifying that a repaired system reaches the specified operating condition afterward.
Maintenance, Lubricants and Central Lubrication
Routine service information starts with fuels and lubricants, running-in instructions and a maintenance chart. The chart organizes work across daily checks and service intervals including 250, 500, 1000, 2000, 3000 and 6000 operating hours, plus as-required operations. Tasks include engine oil and filter service, fuel-system work, conveyor belt and auger chain checks, lubrication, cooler cleaning, battery maintenance, track-drive checks, valve-clearance and control-piston adjustments, coolant and hydraulic-oil service, air-filter service, injector testing and other machine checks.
The lubricant section specifies approved engine-oil quality classes, viscosity guidance, coolant protection, diesel-fuel requirements, HLP-D 46 (ISO VG 46) hydraulic oil, SAE 80W/90 API GL5 crawler-track gear oil and lithium-saponified NLGI 3 grease. A dedicated central-lubrication chapter covers BF 600 C configurations with HC screed and 32 or 34 lubrication points, filling the lubricant container, the electric pump, integrated electronic control, progressive distributors, fault-cause-remedy information and repair of a blocked distributor.
Chapters Covered
1. General: Introduction; safety regulations; general repair instructions; tightening torques.
3. Maintenance: General maintenance notes; fuels and lubricants; fuel and lubricant table; running-in instructions; maintenance chart.
4. Fundamental electrics: Wiring-diagram interpretation; circuit symbols; battery and analog ground; processor signals; current and voltage; PWM; resistance; series/parallel circuits; Ohm’s law; electrical energy; formula diagram; metrology; diodes, relays and fuses; proximity switches; connectors; batteries; jump starting; main battery switch; machine fuses; heating-element replacement.
5. Engine electrics: Engine control unit; EMR3 system; EDC16/EMR3 pin assignments; engine sensors and actuators; fuel control and injectors; CAN-bus and SERDIA diagnosis; engine fault-code indication and EMR3 diagnostic trouble codes; generator; electric starter.
6. Engine: Diesel-engine description; TCD 2013 engine systems; lubrication, coolant and fuel circuits; Deutz Common Rail injection; exhaust gas recirculation; charge-pressure control; engine problems; oil, fuel, coolant and air-filter service; valve clearance; control piston play; cooling; mounts; crankcase ventilation; injector test; conservation; belts; special tools.
7. Service Training Hydraulics: General system description; travel system; actuator drive; scraper-chain drive; vibration and tamper drive; fan drive.
8. Tests and adjustments: Vibration checks; tamping pressure limitation; travel-pump charge/high-pressure relief and pressure override; mobile-screed adjustment times and pressure limitations; fan-motor speed measurement.
9. Central lubrication system: HC screed lubrication-point layouts; lubricant-container filling; electric pump; integrated electronic control; progressive distributor; fault-cause-remedy diagnosis; blocked-distributor repair.
The complete bookmarks in the “BOMAG BF 600 C Road Finisher Service Manual 008 916 41 – HCE/HCG, HSG/HSE, E/G” are as follows:
+BF 600 C – HCE/HCGp. 1
+BF 600 C – HCE/HCGp. 1
BF 600 C – HCE/HCGp. 1
BF 600 C – HSG/HSEp. 1
BF 600 C – E/Gp. 1
+S/N 821 837 45 …. 821 837 46 ….p. 1
S/N 821 837 45 …. 821 837 46 ….p. 1
S/N 821 837 47 …. 821 837 48 ….p. 1
S/N 821 837 53 …. 821 837 61 ….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 addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 8
This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts…p. 8
+Documentationp. 8
Documentationp. 8
For the BOMAG machines described in this manual the following documentation is additionally available:p. 8
+1 Operating and maintenance instructionsp. 8
1 Operating and maintenance instructionsp. 8
2 Spare parts cataloguep. 8
3 Wiring diagram*p. 8
4 Hydraulic diagram*p. 8
5 Service Informationp. 8
Use only genuine BOMAG spare parts.p. 8
Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.p. 8
These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins".p. 8
In case of a new release all necessary changes will be included.p. 8
In the course of technical development we reserve the right for technical modifications without prior notification.p. 8
Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.p. 8
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 8
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 8
BOMAG GmbHp. 8
Printed in Germanyp. 8
Copyright by BOMAGp. 8
* The applicable documents valid at the date of printing are part of this manual.p. 8
+Generalp. 9
Safety regulationsp. 9
+Important notesp. 9
Important notesp. 9
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 9
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 9
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 9
Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obv…p. 9
This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment.p. 9
+Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for persons.p. 9
Paragraphs marked like this highlight possible dangers for persons.p. 9
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Observe the regulations for the protection of the environment.p. 9
+Generalp. 9
Generalp. 9
+For repair and maintenance work move the machine on a firm base and shut it down.p. 9
For repair and maintenance work move the machine on a firm base and shut it down.p. 9
Always secure the machine against unintended rolling.p. 9
Secure the engine reliably against unintentional starting.p. 9
Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard.p. 9
Block the articulated joint with the articulation lock.p. 9
Use protective clothes like hard hat, safety boots and gloves.p. 9
Keep unauthorized persons away from the machine during repair work.p. 9
Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.p. 9
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
Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.p. 9
Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank.p. 9
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
+Follow the operating instructions of the manufacturer when working with cranes.p. 9
Follow the operating instructions of the manufacturer when working with cranes.p. 9
+Follow the operating instructions of the operator when working with cranes.p. 9
Follow the operating instructions of the operator when working with cranes.p. 9
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
+Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 9
Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 9
Ensure good conductivity between ground cable and workpiece, avoid joints and bearings.p. 9
Start the extraction fan before starting work and guide with the progressing work as required.p. 10
Always isolate the burner when laying it down (remove possible electrode residues).p. 10
Protect cables from being damaged, use cables with insulated couplings.p. 10
Ensure sufficient fire protection, keep a fire extinguisher at hand.p. 10
Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission.p. 10
Remove any combustible materials from the welding area or cover such items appropriately.p. 10
Name a fire watch during and after welding work.p. 10
Place welding rod holders and inert gas welding guns only on properly insulated bases.p. 10
Place the inert gas bottles in a safe place and secure them against falling over.p. 10
Use a protective screen or hand shield with welding filter, wear welding gloves and clothes.p. 10
Switch the welding unit off before connecting welding cables.p. 10
Check electrode holders and electric cables at regular intervals.p. 10
Behaviour in case of faultsp. 10
+In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 10
In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 10
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
+Replace damaged insulating jaws and welding rod holders immediately.p. 10
Replace damaged insulating jaws and welding rod holders immediately.p. 10
Replace the welding wire reels only in de-energized state.p. 10
What to do in case of accidents; First Aidp. 10
+Keep calm.p. 10
Keep calm.p. 10
Call first air helpers.p. 10
Report the accident.p. 10
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
+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
+Wear protective clothes and safety gloves, if possible.p. 10
Wear protective clothes and safety gloves, if possible.p. 10
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
Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately.p. 10
Apply protective cream before starting work, so that oil can be easier removed from the skin.p. 10
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
Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin.p. 10
Do not put oil soaked cloths into your pockets.p. 10
Avoid clothes getting soiled by oil.p. 10
Overalls must be washed at regular intervals. Dispose of non-washable clothes environmentally.p. 10
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. 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. 10
+Hydraulicsp. 10
Hydraulicsp. 10
+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. 10
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. 10
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. 10
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 ma…p. 10
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. 10
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
+Fire extinguishers charged with FOAM, COp. 11
+Fire extinguishers charged with FOAM, COp. 11
2p. 11
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
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 fuelp. 11
+Hot fuelsp. 11
Hot fuelsp. 11
Please apply the following measures before draining of fuel to prepare for repair work:p. 11
+Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 11
Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 11
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
+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
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
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. 11
Enginep. 11
+Do not work on the fuel system while the engine is running. (Danger to life!)p. 11
Do not work on the fuel system while the engine is running. (Danger to life!)p. 11
Once the engine has stopped wait approx. 5 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!)p. 11
Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!)p. 11
When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!)p. 11
+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, attac…p. 11
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, attac…p. 11
Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/- 0105 Electric precautions against dangerous contact voltages).p. 11
Cover all electric components properly before wet cleaning.p. 12
+Batteryp. 12
Batteryp. 12
+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
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
Work only well ventilated rooms (formation of oxyhydrogen gas).p. 12
Do not lean over the battery while it is under load, being charged or tested (danger of explosion).p. 12
Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the batteryp. 12
Use battery chargers etc. only in strict compliance with the operating instructions.p. 12
After an accident with acid flush the skin with a sufficient amount of water and seek medical advice.p. 12
Do not allow children access to batteries.p. 12
When mixing battery fluid always pour acid into water, never vice-versa.p. 12
+Special safety regulationsp. 12
Special safety regulationsp. 12
+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
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
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 explicitl…p. 12
Unauthorized changes to the machine are prohibited for safety reasons.p. 12
Do not perform any cleaning work while the engine is running.p. 12
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
If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!).p. 12
Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous!p. 12
Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.p. 12
Always ensure an adequate supply of fresh air when refuelling in closed rooms.p. 12
Dispose of used filters in accordance with applicable environmental regulations.p. 12
When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations.p. 12
Do not heat up oils higher than 160 °C because they may ignite.p. 12
Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations.p. 12
Dispose of old batteries according to applicable environmental regulations.p. 12
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
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
+Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 13
Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 13
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
+In approx. 10 % of the examined cases the problems were caused by control units.p. 13
In approx. 10 % of the examined cases the problems were caused by control units.p. 13
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
+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 w…p. 13
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 w…p. 13
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
Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately.p. 13
Do not disconnect or connect battery or generator while the engine is running.p. 13
Do not operate the main battery switch under load.p. 13
Do not use jump leads after the battery has been removed.p. 13
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
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
Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!p. 13
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
Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions.p. 14
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
+Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 14
Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 14
Isolate the generator and all control units from the electric circuit.p. 14
Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.p. 14
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
+Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 16
Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 16
Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 16
During repair work keep all openings closed with clean plastic plugs and caps.p. 16
Never run pumps, motors and engines without oil or hydraulic oil.p. 16
When cleaning hydraulic components take care not to damage any fine machine surfaces.p. 16
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
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
Avoid the formation of rust on fine machined caused by hand sweat.p. 16
Use new O-rings or seal rings for reassembly.p. 16
Use only hydraulic oil as sliding agent when reassembling. Do not use any grease!p. 16
Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.p. 16
Check the hydraulic oil level before and after the work.p. 16
Fill in only clean oil as specified in the maintenance instructions.p. 16
Check the hydraulic system for leaks, if necessary find and rectify the cause.p. 16
Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions.p. 16
After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system.p. 16
Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).p. 16
After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.p. 16
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, danger…p. 16
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
+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
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
After changing a component flush the hydraulic system as described in the flushing instructions.p. 16
+Taking into operationp. 16
Taking into operationp. 16
+Bleed the hydraulic circuits.p. 16
Bleed the hydraulic circuits.p. 16
Start up the hydraulic system without load.p. 16
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
+Check fittings and flanges for leaks.p. 16
Check fittings and flanges for leaks.p. 16
After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary.p. 16
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
Notes on cleanliness for Common Rail enginesp. 17
Special requirements with respect to cleanliness in the fuel system do apply for commissioning, maintenance and repair work, particularly for TEIRIII engines with the DEUTZ Common Rail System. Contamination like dirt, welding residues or similar can …p. 17
Fig. 1p. 17
+Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 17
Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 17
+When parts are unpacked any connections must be closed with suitable plugs or caps, in order to preventp. 17
(Fig. 1)p. 17
+Notes and measures to be applied before starting work in the fuel systemp. 17
Notes and measures to be applied before starting work in the fuel systemp. 17
+The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 17
The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 17
Before starting work in the fuel system clean the complete engine and the engine compartment with the system still closed.p. 17
The engine should be dry before work is started in the fuel system.p. 17
Blow drying with compressed air is only permitted while the fuel system is still closed.p. 17
When using steam cleaning equipment cover control unit, cable plugs, all other electrical connections and the generator beforehand and do not expose these items to the direct steam jet.p. 17
Electrical plug connections must be plugged in during jet cleaning.p. 17
Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 17
Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 17
Perform work on the fuel system only in a clean environment (no dust, no grinding or welding work). Avoid draughts (dust). The workshop floor must be cleaned at regular intervals. No brake or power test stand should be present or operated in the same…p. 17
Air movements, which could swirl up dust, such as brake repairs or starting of engines, must be strictly avoided.p. 17
For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle rep…p. 17
No general machine tools should be operated in this room.p. 17
Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 17
Engine compartment area where dirt particles could come loose, should be covered with new, clean foil.p. 17
Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 17
+Notes and measures to be applied during work in the fuel systemp. 17
Notes and measures to be applied during work in the fuel systemp. 17
+Wear clean working clothes.p. 17
Wear clean working clothes.p. 17
Use only lint-free cleaning cloths for work in the fuel system.p. 17
Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction. Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 17
Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 17
Do not use any previously used cleaning or testing fluids for cleaning.p. 18
Compressed air should never be used for cleaning when the fuel system is open.p. 18
Work on disassembled components must only be carried out at a specially furnished work place.p. 18
When disassembling or assembling components you should not use any materials from which particles or fibres could flake off (cardboard, wood, towels).p. 18
Dismantled parts must only be wiped off with clean, lint-free cloths if required. No dirt particles must be wiped into the components.p. 18
Close openings on components and engine immediately with suitable plugs/caps.p. 18
Plugs/caps must only be removed just before the installation.p. 18
Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use.p. 18
Take new parts out of their original packaging just before installation.p. 18
Disassembled components must be stored in new, sealable bags or – if available – in the packaging material of the new components.p. 18
Always use the original packaging material of the new part to return the disassembled old component.p. 18
+Notes and measures concerning the workshop areap. 18
Notes and measures concerning the workshop areap. 18
+For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle rep…p. 18
For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle rep…p. 18
The workshop floor must be sealed or tiled.p. 18
No welding equipment, grinding machines, general machine tools, brake or power test benches must be operated in this room.p. 18
Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 18
+Notes and measures for work place and tools in the workshopp. 18
Notes and measures for work place and tools in the workshopp. 18
+A special work place must be set up for work on disassembled components.p. 18
A special work place must be set up for work on disassembled components.p. 18
Clean disassembly and assembly tools at regular intervals and keep these in a closed tool cabinet.p. 18
Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 18
Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 18
+The values specified in the table apply for screws:p. 19
Fuel hosesp. 19
Fig. 2p. 19
+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. 19
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. 19
+The values specified in the table apply for screws:p. 19
Gaskets and mating surfacesp. 19
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 19
+Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 19
Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 19
Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 19
Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 19
If necessary remove any old sealing compound before assembling. For this purpose do not use any tools that could damage the sealing surfaces.p. 19
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. 19
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. 19
Blow out lines, ducts and gaps with compressed air, replace any O-rings and seals that have been dislodged by the compressed air.p. 19
Assembly of radial sealsp. 19
Fig. 3p. 19
+Lubricate the sealing lips (2)p. 19
+Lubricate the sealing lips (2)p. 19
(Fig. 3)p. 19
Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 19
+If possible, use an assembly sleeve (1p. 19
+If possible, use an assembly sleeve (1p. 19
(Fig. 3)p. 19
to protect the lip from being damaged by sharp edges, threads or splines.p. 19
+Lubricate the outer rim (arrow 3p. 20
+Lubricate the outer rim (arrow 3p. 20
(Fig. 3)p. 20
Fig. 4p. 20
+Press or knock the seal into the housing, until it is flush with the housing surface.p. 20
Press or knock the seal into the housing, until it is flush with the housing surface.p. 20
+If possible, use a "bell" (1p. 20
+If possible, use a "bell" (1p. 20
(Fig. 4)p. 20
that the seal will not skew.p. 20
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. 20
+The values specified in the table apply for screws:p. 20
Feather keys and keywaysp. 20
+Feather keys may only be reused if they are free of damage.p. 20
Feather keys may only be reused if they are free of damage.p. 20
Fig. 5p. 20
+Clean and thoroughly examine the feather key.p. 20
Clean and thoroughly examine the feather key.p. 20
Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 20
+The values specified in the table apply for screws:p. 21
Ball and roller bearingsp. 21
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 21
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 21
Fig. 6p. 21
+If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 21
If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 21
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. 21
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. 21
Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 21
Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 21
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. 21
Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 21
Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 21
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 ins…p. 21
Fig. 7p. 21
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 21
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 21
(Fig. 7)p. 21
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 21
+The values specified in the table apply for screws:p. 22
Screws and nutsp. 22
Tightening torquep. 22
+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. 22
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. 22
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. 22
Self-locking nuts must generally be replaced after disassembly.p. 22
The use of screws with too high strength can cause damage!p. 22
+Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 22
Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 22
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. 22
+Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 22
The same applies for self-locking nuts.p. 22
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. 22
Strength classes, metric screwsp. 22
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. 22
Fig. 8 Identification of screwsp. 22
Example: A screw is identified with 12.9.p. 22
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 22
2p. 22
+The nominal tensile strength is 12 X 100 N/mmp. 22
+The nominal tensile strength is 12 X 100 N/mmp. 22
2p. 22
2p. 22
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 22
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 22
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 22
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 22
+The lower tensile strength is 9/10 X 1200 N/mmp. 22
+The lower tensile strength is 9/10 X 1200 N/mmp. 22
2p. 22
2p. 22
+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. 22
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. 22
Strength classes of metric nutsp. 23
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. 23
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 23
Fig. 9 Identification of nutsp. 23
+In a connection with a screw, these nuts 1p. 23
(Fig. 9)p. 23
Nut height above 0.8 d (d = nominal dimension).p. 23
+Strength class of nutp. 23
Strength class of nutp. 23
+Strength class of associated screwp. 23
Strength class of associated screwp. 23
+4p. 23
4p. 23
+3.6, 4.6, 4.8p. 23
3.6, 4.6, 4.8p. 23
+5p. 23
5p. 23
+3.6, 4.6, 4.8p. 23
3.6, 4.6, 4.8p. 23
5.6, 5.8p. 23
+6p. 23
6p. 23
+6.8p. 23
6.8p. 23
+8p. 23
8p. 23
+8.8p. 23
8.8p. 23
+9p. 23
9p. 23
+9.8p. 23
9.8p. 23
+10p. 23
10p. 23
+10.8p. 23
10.8p. 23
+12p. 23
12p. 23
+12.8p. 23
12.8p. 23
Nuts for screw joints with limited load factor (04, 05)p. 23
+The preceding "0" indicates that, due to their low height, nuts 2p. 23
(Fig. 9)p. 23
Nut height below 0,8 d (d = nominal dimension).p. 23
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 23
+This standard contains strength classes (hardness classes) for nuts 3p. 23
(Fig. 9)p. 23
Nut height below 0,5 d (d = nominal dimension).p. 23
Identification in clock systemp. 23
Fig. 10 Identification of nuts in clock systemp. 23
+For small nutsp. 23
(Fig. 10)p. 23
+The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 23
The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 23
The strength class is identified by a dash (b).p. 23
Identification of UNF-threadsp. 24
Fig. 11p. 24
Screwsp. 24
+The screw head is marked with a stamped in, round cavity 3p. 24
(Fig. 11)p. 24
Nutsp. 24
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 24
Studs and brake rodsp. 24
At the outmost end a short end of the component is reduced to its core diameter (1).p. 24
Cotter pinsp. 24
Fig. 12p. 24
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 24
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 24
+The values specified in the table apply for screws:p. 25
Tightening torquesp. 25
+The values specified in the table apply for screws:p. 25
The values specified in the table apply for screws:p. 25
+black oiledp. 25
black oiledp. 25
with surface protection A4Cp. 25
with surface protection DACROMETp. 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
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 metric unified threadp. 25
+Tightening torques for screws with metric unified threadp. 25
+Tightening torques for screws with metric unified threadp. 25
+Coefficient of friction m tot. = 0,14p. 25
mp. 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
+M4p. 25
M4p. 25
+3p. 25
3p. 25
+5p. 25
5p. 25
+5p. 25
5p. 25
+M5p. 25
M5p. 25
+6p. 25
6p. 25
+9p. 25
9p. 25
+10p. 25
10p. 25
+M6p. 25
M6p. 25
+10p. 25
10p. 25
+15p. 25
15p. 25
+18p. 25
18p. 25
+M8p. 25
M8p. 25
+25p. 25
25p. 25
+35p. 25
35p. 25
+45p. 25
45p. 25
+M10p. 25
M10p. 25
+50p. 25
50p. 25
+75p. 25
75p. 25
+83p. 25
83p. 25
+M12p. 25
M12p. 25
+88p. 25
88p. 25
+123p. 25
123p. 25
+147p. 25
147p. 25
+M14p. 25
M14p. 25
+137p. 25
137p. 25
+196p. 25
196p. 25
+235p. 25
235p. 25
+M16p. 25
M16p. 25
+211p. 25
211p. 25
+300p. 25
300p. 25
+358p. 25
358p. 25
+M18p. 25
M18p. 25
+290p. 25
290p. 25
+412p. 25
412p. 25
+490p. 25
490p. 25
+M20p. 25
M20p. 25
+412p. 25
412p. 25
+578p. 25
578p. 25
+696p. 25
696p. 25
+M22p. 25
M22p. 25
+560p. 25
560p. 25
+785p. 25
785p. 25
+942p. 25
942p. 25
+M24p. 25
M24p. 25
+711p. 25
711p. 25
+1000p. 25
1000p. 25
+1200p. 25
1200p. 25
+M27p. 25
M27p. 25
+1050p. 25
1050p. 25
+1480p. 25
1480p. 25
+1774p. 25
1774p. 25
+M30p. 25
M30p. 25
+1420p. 25
1420p. 25
+2010p. 25
2010p. 25
+2400p. 25
2400p. 25
+Tightening torques for screws with metric unified fine threadp. 25
+Tightening torques for screws with metric unified fine threadp. 25
+Tightening torques for screws with metric unified fine threadp. 25
+Coefficient of friction m tot. = 0,14p. 25
mp. 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
+M8 x 1p. 25
M8 x 1p. 25
+26p. 25
26p. 25
+37p. 25
37p. 25
+48p. 25
48p. 25
+M10 x 1.25p. 25
M10 x 1.25p. 25
+52p. 25
52p. 25
+76p. 25
76p. 25
+88p. 25
88p. 25
+M12 x 1,25p. 25
M12 x 1,25p. 25
+98p. 25
98p. 25
+137p. 25
137p. 25
+126p. 25
126p. 25
+M12 x 1.5p. 25
M12 x 1.5p. 25
+93p. 25
93p. 25
+127p. 25
127p. 25
+152p. 25
152p. 25
+M14 x 1.5p. 25
M14 x 1.5p. 25
+152p. 25
152p. 25
+216p. 25
216p. 25
+255p. 25
255p. 25
+M16 x 1.5p. 25
M16 x 1.5p. 25
+225p. 25
225p. 25
+318p. 25
318p. 25
+383p. 25
383p. 25
+M18 x 1.5p. 25
M18 x 1.5p. 25
+324p. 25
324p. 25
+466p. 25
466p. 25
+554p. 25
554p. 25
+M20 x 1.5p. 25
M20 x 1.5p. 25
+461p. 25
461p. 25
+628p. 25
628p. 25
+775p. 25
775p. 25
+M22 x 1.5p. 25
M22 x 1.5p. 25
+618p. 25
618p. 25
+863p. 25
863p. 25
+1058p. 25
1058p. 25
+M24 x 2p. 25
M24 x 2p. 25
+780p. 25
780p. 25
+1098p. 25
1098p. 25
+1294p. 25
1294p. 25
+M27 x2p. 25
M27 x2p. 25
+1147p. 25
1147p. 25
+1578p. 25
1578p. 25
+1920p. 25
1920p. 25
+M30 x 2p. 25
M30 x 2p. 25
+1568p. 25
1568p. 25
+2254p. 25
2254p. 25
+2695p. 25
2695p. 25
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 26
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 26
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 26
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. 26
+Screw dimensionp. 26
Screw dimensionp. 26
+Tightening torques Nmp. 26
Tightening torques Nmp. 26
+8.8p. 26
8.8p. 26
+10.9p. 26
10.9p. 26
+12.9p. 26
12.9p. 26
+M16p. 26
M16p. 26
+169p. 26
169p. 26
+240p. 26
240p. 26
+287p. 26
287p. 26
+M16 x 1.5p. 26
M16 x 1.5p. 26
+180p. 26
180p. 26
+255p. 26
255p. 26
+307p. 26
307p. 26
+M18p. 26
M18p. 26
+232p. 26
232p. 26
+330p. 26
330p. 26
+392p. 26
392p. 26
+M18 x 1.5p. 26
M18 x 1.5p. 26
+260p. 26
260p. 26
+373p. 26
373p. 26
+444p. 26
444p. 26
+M20p. 26
M20p. 26
+330p. 26
330p. 26
+463p. 26
463p. 26
+557p. 26
557p. 26
+M20 x 1.5p. 26
M20 x 1.5p. 26
+369p. 26
369p. 26
+502p. 26
502p. 26
+620p. 26
620p. 26
+M22p. 26
M22p. 26
+448p. 26
448p. 26
+628p. 26
628p. 26
+754p. 26
754p. 26
+M22 x 1.5p. 26
M22 x 1.5p. 26
+495p. 26
495p. 26
+691p. 26
691p. 26
+847p. 26
847p. 26
+M24p. 26
M24p. 26
+569p. 26
569p. 26
+800p. 26
800p. 26
+960p. 26
960p. 26
+M24 x 2p. 26
M24 x 2p. 26
+624p. 26
624p. 26
+879p. 26
879p. 26
+1036p. 26
1036p. 26
+M27p. 26
M27p. 26
+840p. 26
840p. 26
+1184p. 26
1184p. 26
+1520p. 26
1520p. 26
+M27 X 2p. 26
M27 X 2p. 26
+918p. 26
918p. 26
+1263p. 26
1263p. 26
+1536p. 26
1536p. 26
+M30p. 26
M30p. 26
+1136p. 26
1136p. 26
+1608p. 26
1608p. 26
+1920p. 26
1920p. 26
+M30 x 2p. 26
M30 x 2p. 26
+1255p. 26
1255p. 26
+1804p. 26
1804p. 26
+2156p. 26
2156p. 26
+3/4“ – 10 UNCp. 26
3/4“ – 10 UNCp. 26
+276p. 26
276p. 26
+388p. 26
388p. 26
+464p. 26
464p. 26
+3/4“ – 16 UNCp. 26
3/4“ – 16 UNCp. 26
+308p. 26
308p. 26
+432p. 26
432p. 26
+520p. 26
520p. 26
+Tightening torques for wheel nuts (fine thread)p. 26
+Tightening torques for wheel nuts (fine thread)p. 26
+Tightening torques for wheel nuts (fine thread)p. 26
+Coefficient of friction m tot. = 0,14p. 26
mp. 26
These values result in a 90% utilization of the yield pointp. 26
+Thread diameterp. 26
Thread diameterp. 26
+Tightening torques Nmp. 26
Tightening torques Nmp. 26
+10.9p. 26
10.9p. 26
+M12x1.5p. 26
M12x1.5p. 26
+100p. 26
100p. 26
+M14x1.5p. 26
M14x1.5p. 26
+150p. 26
150p. 26
+M18x1.5p. 26
M18x1.5p. 26
+300 – 350p. 26
300 – 350p. 26
+M20x1.5p. 26
M20x1.5p. 26
+400 – 500p. 26
400 – 500p. 26
+M22x1.5p. 26
M22x1.5p. 26
+500 – 600p. 26
500 – 600p. 26
The values specified in the table apply for screws:p. 27
+black oiledp. 27
black oiledp. 27
with surface protection A4Cp. 27
with surface protection DACROMETp. 27
+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. 27
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. 27
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. 27
+Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 27
+Tightening torques for screws with UNC thread,p. 27
+Tightening torques for screws with UNC thread,p. 27
+Coefficient of friction m tot. = 0,14p. 27
mp. 27
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 27
+Screw dimensionp. 27
Screw dimensionp. 27
+Tightening torques Nmp. 27
Tightening torques Nmp. 27
+8.8p. 27
8.8p. 27
+10.9p. 27
10.9p. 27
+12.9p. 27
12.9p. 27
+1/4“ – 20p. 27
1/4“ – 20p. 27
+11p. 27
11p. 27
+15p. 27
15p. 27
+19p. 27
19p. 27
+5/16“ – 18p. 27
5/16“ – 18p. 27
+23p. 27
23p. 27
+32p. 27
32p. 27
+39p. 27
39p. 27
+3/8“ – 16p. 27
3/8“ – 16p. 27
+39p. 27
39p. 27
+55p. 27
55p. 27
+66p. 27
66p. 27
+7/16“ – 14p. 27
7/16“ – 14p. 27
+62p. 27
62p. 27
+87p. 27
87p. 27
+105p. 27
105p. 27
+1/2“ – 13p. 27
1/2“ – 13p. 27
+96p. 27
96p. 27
+135p. 27
135p. 27
+160p. 27
160p. 27
+9/16“ – 12p. 27
9/16“ – 12p. 27
+140p. 27
140p. 27
+200p. 27
200p. 27
+235p. 27
235p. 27
+5/8“ – 11p. 27
5/8“ – 11p. 27
+195p. 27
195p. 27
+275p. 27
275p. 27
+330p. 27
330p. 27
+3/4“ – 10p. 27
3/4“ – 10p. 27
+345p. 27
345p. 27
+485p. 27
485p. 27
+580p. 27
580p. 27
+7/8“ – 9p. 27
7/8“ – 9p. 27
+560p. 27
560p. 27
+770p. 27
770p. 27
+940p. 27
940p. 27
+1“ – 8p. 27
1“ – 8p. 27
+850p. 27
850p. 27
+1200p. 27
1200p. 27
+1450p. 27
1450p. 27
+1 1/8“ – 7p. 27
1 1/8“ – 7p. 27
+1200p. 27
1200p. 27
+1700p. 27
1700p. 27
+2000p. 27
2000p. 27
+1 1/4“ – 7p. 27
1 1/4“ – 7p. 27
+1700p. 27
1700p. 27
+2400p. 27
2400p. 27
+2900p. 27
2900p. 27
+1 3/8“ – 6p. 27
1 3/8“ – 6p. 27
+2200p. 27
2200p. 27
+3100p. 27
3100p. 27
+3700p. 27
3700p. 27
+1 1/2“ – 6p. 27
1 1/2“ – 6p. 27
+3000p. 27
3000p. 27
+4200p. 27
4200p. 27
+5100p. 27
5100p. 27
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 27
+Tightening torques for screws with UNF thread,p. 27
+Tightening torques for screws with UNF thread,p. 27
+Coefficient of friction m tot. = 0,14p. 28
mp. 28
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 27
+Screw dimensionp. 27
Screw dimensionp. 27
+Tightening torques Nmp. 27
Tightening torques Nmp. 27
+8.8p. 27
8.8p. 27
+10.9p. 27
10.9p. 27
+12.9p. 27
12.9p. 27
+1/4“ – 28p. 27
1/4“ – 28p. 27
+13p. 27
13p. 27
+18p. 27
18p. 27
+22p. 27
22p. 27
+5/16“ – 24p. 27
5/16“ – 24p. 27
+25p. 27
25p. 27
+35p. 27
35p. 27
+42p. 27
42p. 27
+3/8“ – 24p. 27
3/8“ – 24p. 27
+45p. 27
45p. 27
+63p. 27
63p. 27
+76p. 27
76p. 27
+7/16“ – 20p. 27
7/16“ – 20p. 27
+70p. 27
70p. 27
+100p. 27
100p. 27
+120p. 27
120p. 27
+1/2“ – 20p. 27
1/2“ – 20p. 27
+110p. 27
110p. 27
+155p. 27
155p. 27
+185p. 27
185p. 27
+9/16“ – 18p. 27
9/16“ – 18p. 27
+155p. 27
155p. 27
+220p. 27
220p. 27
+260p. 27
260p. 27
+5/8“ – 18p. 27
5/8“ – 18p. 27
+220p. 27
220p. 27
+310p. 27
310p. 27
+370p. 27
370p. 27
+3/4“ – 16p. 27
3/4“ – 16p. 27
+385p. 27
385p. 27
+540p. 27
540p. 27
+650p. 27
650p. 27
+7/8“ -14p. 27
7/8“ -14p. 27
+620p. 27
620p. 27
+870p. 27
870p. 27
+1050p. 27
1050p. 27
+1“ – 12p. 28
1“ – 12p. 28
+930p. 28
930p. 28
+1300p. 28
1300p. 28
+1600p. 28
1600p. 28
+1 1/8“ – 12p. 28
1 1/8“ – 12p. 28
+1350p. 28
1350p. 28
+1900p. 28
1900p. 28
+2300p. 28
2300p. 28
+1 1/4“ – 12p. 28
1 1/4“ – 12p. 28
+1900p. 28
1900p. 28
+2700p. 28
2700p. 28
+3200p. 28
3200p. 28
+1 3/8“ – 12p. 28
1 3/8“ – 12p. 28
+2600p. 28
2600p. 28
+3700p. 28
3700p. 28
+4400p. 28
4400p. 28
+1 1/2“ – 12p. 28
1 1/2“ – 12p. 28
+3300p. 28
3300p. 28
+4600p. 28
4600p. 28
+5600p. 28
5600p. 28
+2 Technical datap. 29
2 Technical datap. 29
Technical datap. 30
Fig. 13p. 30
+Dimensions in mmp. 30
Dimensions in mmp. 30
+Ap. 30
Ap. 30
+Bp. 30
Bp. 30
+Cp. 30
Cp. 30
+Dp. 30
Dp. 30
+Ep. 30
Ep. 30
+Fp. 30
Fp. 30
+Gp. 30
Gp. 30
+Hp. 30
Hp. 30
+Ip. 30
Ip. 30
+BF 600 Cp. 30
BF 600 Cp. 30
+875p. 30
875p. 30
+2700p. 30
2700p. 30
+300p. 30
300p. 30
+755p. 30
755p. 30
+4330p. 30
4330p. 30
+440p. 30
440p. 30
+3360p. 30
3360p. 30
+3635p. 30
3635p. 30
+1800p. 30
1800p. 30
+Lp. 30
Lp. 30
+Mp. 30
Mp. 30
+Np. 30
Np. 30
+Op. 30
Op. 30
+Pp. 30
Pp. 30
+Qp. 30
Qp. 30
+Rp. 30
Rp. 30
+Sp. 30
Sp. 30
+Zp. 30
Zp. 30
+560p. 30
560p. 30
+2100p. 30
2100p. 30
+2655p. 30
2655p. 30
+180p. 30
180p. 30
+2550p. 30
2550p. 30
+1960p. 30
1960p. 30
+2830p. 30
2830p. 30
+180p. 30
180p. 30
+1645p. 30
1645p. 30
+The right for technical modifications remains reservedp. 30
The right for technical modifications remains reservedp. 31
+BF 600 C -HSE/HSGp. 30
BF 600 C -HSE/HSGp. 30
+Weightsp. 30
Weightsp. 30
+Operating weight (CECE)p. 30
Operating weight (CECE)p. 30
+kgp. 30
kgp. 30
+17840p. 30
17840p. 30
+Weight of basic screedp. 30
Weight of basic screedp. 30
+kgp. 30
kgp. 30
+4200p. 30
4200p. 30
+Screedp. 30
Screedp. 30
+Basic mat widthp. 30
Basic mat widthp. 30
+mmp. 30
mmp. 30
+2550p. 30
2550p. 30
+Max. mat width without extensionp. 30
Max. mat width without extensionp. 30
+mmp. 30
mmp. 30
+5000p. 30
5000p. 30
+Max. mat width with extensionp. 30
Max. mat width with extensionp. 30
+mmp. 30
mmp. 30
+7500p. 30
7500p. 30
+Min. mat width (standard)p. 30
Min. mat width (standard)p. 30
+mmp. 30
mmp. 30
+1900p. 30
1900p. 30
+Min. mat width with optional reducing platesp. 30
+Vibration motor screed, Vibration motor Extension left/rightp. 34
Vibration motor screed, Vibration motor Extension left/rightp. 34
+Manufacturerp. 34
Manufacturerp. 34
+Sauer Danfossp. 34
Sauer Danfossp. 34
+Typep. 34
Typep. 34
+BF 8 with HS 500p. 34
BF 8 with HS 500p. 34
+Systemp. 34
Systemp. 34
+Gear motorp. 34
Gear motorp. 34
+Quantityp. 34
Quantityp. 34
+4p. 34
4p. 34
+Max. displacement.p. 34
Max. displacement.p. 34
+cm3/rev.p. 34
+cmp. 34
3p. 34
+8.4p. 34
8.4p. 34
+Tamper motor screed, Tamper motor Extension left/rightp. 34
Tamper motor screed, Tamper motor Extension left/rightp. 34
+Manufacturerp. 34
Manufacturerp. 34
+Sauer Danfossp. 34
Sauer Danfossp. 34
+Typep. 34
Typep. 34
+SNM2/17 SC02p. 34
SNM2/17 SC02p. 34
+Systemp. 34
Systemp. 34
+Gear motorp. 34
Gear motorp. 34
+Quantityp. 34
Quantityp. 34
+4p. 34
4p. 34
+Max. displacement.p. 34
Max. displacement.p. 34
+cm3/rev.p. 34
+cmp. 34
3p. 34
+16.8p. 34
16.8p. 34
+Tamper pumpp. 34
Tamper pumpp. 34
+Manufacturerp. 34
Manufacturerp. 34
+Sauer Danfossp. 34
Sauer Danfossp. 34
+TYPEp. 34
TYPEp. 34
+PRRR 26/26 S SC47p. 34
PRRR 26/26 S SC47p. 34
+Systemp. 35
Systemp. 35
+Gear pumpp. 35
Gear pumpp. 35
+MAX. Displacementp. 35
MAX. Displacementp. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+26.2p. 35
26.2p. 35
+Scraper belt pumpp. 35
Scraper belt pumpp. 35
+Manufacturerp. 35
Manufacturerp. 35
+Sauer Danfossp. 35
Sauer Danfossp. 35
+Typep. 35
Typep. 35
+PRRR 38/33 S SC47p. 35
PRRR 38/33 S SC47p. 35
+Systemp. 35
Systemp. 35
+Gear pumpp. 35
Gear pumpp. 35
+Quantityp. 35
Quantityp. 35
+1p. 35
1p. 35
+Max. displacementp. 35
Max. displacementp. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+38p. 35
38p. 35
+High pressure limitationp. 35
High pressure limitationp. 35
+barp. 35
barp. 35
+270p. 35
270p. 35
+Scraper belt motorp. 35
Scraper belt motorp. 35
+Manufacturerp. 35
Manufacturerp. 35
+Sauer Danfossp. 35
Sauer Danfossp. 35
+Typep. 35
Typep. 35
+OMT 400p. 35
OMT 400p. 35
+Systemp. 35
Systemp. 35
+Orbital motorp. 35
Orbital motorp. 35
+Quantityp. 35
Quantityp. 35
+2p. 35
2p. 35
+Max. displacement.p. 35
Max. displacement.p. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+400p. 35
400p. 35
+Conveyor screw pumpp. 35
Conveyor screw pumpp. 35
+Manufacturerp. 35
Manufacturerp. 35
+Sauer Danfossp. 35
Sauer Danfossp. 35
+Typep. 35
Typep. 35
+PRRR 38/33 S SC47p. 35
PRRR 38/33 S SC47p. 35
+Systemp. 35
Systemp. 35
+Gear pumpp. 35
Gear pumpp. 35
+Quantityp. 35
Quantityp. 35
+1p. 35
1p. 35
+Max. displacementp. 35
Max. displacementp. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+38p. 35
38p. 35
+Conveyor screw motorp. 35
Conveyor screw motorp. 35
+Manufacturerp. 35
Manufacturerp. 35
+Sauer Danfossp. 35
Sauer Danfossp. 35
+Typep. 35
Typep. 35
+OMT 500p. 35
OMT 500p. 35
+Systemp. 35
Systemp. 35
+Orbital motorp. 35
Orbital motorp. 35
+Quantityp. 35
Quantityp. 35
+2p. 35
2p. 35
+Max. displacement.p. 35
Max. displacement.p. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+500p. 35
500p. 35
+Service pumpp. 35
Service pumpp. 35
+Manufacturerp. 35
Manufacturerp. 35
+Sauer Danfossp. 35
Sauer Danfossp. 35
+Typep. 35
Typep. 35
+PRRR 38/33 S SC 47p. 35
PRRR 38/33 S SC 47p. 35
+Systemp. 35
Systemp. 35
+Gear pumpp. 35
Gear pumpp. 35
+Quantityp. 35
Quantityp. 35
+1p. 35
1p. 35
+Max. displacementp. 35
Max. displacementp. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+33.1p. 35
33.1p. 35
+Fan motorp. 35
Fan motorp. 35
+Systemp. 35
Systemp. 35
+Gear motorp. 35
Gear motorp. 35
+Quantityp. 35
Quantityp. 35
+1p. 35
1p. 35
+Displacement 1. stepp. 35
Displacement 1. stepp. 35
+cm3/rev.p. 35
+cmp. 35
3p. 35
+14.4p. 35
14.4p. 35
The following noise and vibration data acc. top. 36
– EC Machine Regulation edition 98/37/EC andp. 36
– the noise regulation 2000/14/EG, noise protection guideline 2003/10/ECp. 36
– Vibration Protection Regulation 2002/44/ECp. 36
were determined during conditions typical for this type of equipment and by application of harmonized standards.p. 36
During operation these values may vary because of the existing operating conditions.p. 36
+Noise valuep. 36
Noise valuep. 36
sound pressure level on the operator’s stand:p. 36
+Lp. 36
pAp. 36
Guaranteed sound power level:p. 36
+Lp. 36
WAp. 36
+Wear your personal noise protection means (ear defenders) before starting operation.p. 36
Wear your personal noise protection means (ear defenders) before starting operation.p. 36
+Vibration valuep. 36
Vibration valuep. 36
Vibration of the entire body (driver’s seat)p. 36
+The weighted effective acceleration value determined in accordance with ISO 7096 isp. 36
£p. 36
2p. 36
Hand-arm vibration valuesp. 36
+The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 isp. 36
£p. 36
2p. 36
+3 Maintenancep. 37
3 Maintenancep. 37
+3.1 General notes on maintenancep. 38
3.1 General notes on maintenancep. 38
+Maintenance work must only be carried out by qualified and appropriately trained personnel.p. 38
Maintenance work must only be carried out by qualified and appropriately trained personnel.p. 38
When performing maintenance work always comply with the appropriate safety regulations.p. 38
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. 38
The terms right/left correspond with travel direction forward.p. 38
+Always clean machine and engine thoroughly before starting maintenance work.p. 38
Always clean machine and engine thoroughly before starting maintenance work.p. 38
For maintenance work stand the machine on level ground.p. 38
Perform maintenance work only with the motor switched off.p. 38
Relieve hydraulic pressures before working on hydraulic lines.p. 38
Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 38
When working in the area of the articulated joint attach the articulation lock (transport lock).p. 38
+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, coolant and fuels environmentally.p. 38
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, coolant and fuels environmentally.p. 38
+Notes on the fuel systemp. 38
Notes on the fuel systemp. 38
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 38
+Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 38
Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 38
Drums with inside zinc lining are not suitable to store fuel.p. 38
The fuel drum must rest for a longer period of time before drawing off fuel.p. 38
Do not let the hose stir up the slurry at the bottom of the drum.p. 38
Do not draw off fuel from near the bottom of the drum.p. 38
The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 38
+Notes on the performance of the enginep. 38
Notes on the performance of the enginep. 38
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. 38
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. 38
+Notes on the hydraulic systemp. 38
Notes on the hydraulic systemp. 38
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. 38
+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. 38
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. 38
Seal external leaks immediately. If necessary inform the responsible customer service.p. 38
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. 38
Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.p. 38
Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 38
Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 38
+Notes on the cooling systemp. 38
Notes on the cooling systemp. 38
For water-cooled engines the preparation and inspection of the coolant is of greatest importance, as otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 38
The coolant is prepared by mixing a cooling system protection agent into the coolant.p. 38
The cooling system must be permanently monitored. Besides the inspection of the coolant level this includes also the inspection of the concentration of cooling system protection agent.p. 38
The concentration of cooling system protection agent can be checked by means of commercial testers (glycomat).p. 38
+Health hazard!p. 38
Health hazard!p. 38
The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.p. 38
+Cooling system protection agents must be disposed of environmentally.p. 39
Cooling system protection agents must be disposed of environmentally.p. 39
+3.2 Fuels and lubricantsp. 39
3.2 Fuels and lubricantsp. 39
+Engine oilp. 39
Engine oilp. 39
Qualityp. 39
Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used.p. 39
+Approved engine oilsp. 39
Approved engine oilsp. 39
+Deutzp. 39
Deutzp. 39
+DQC IIp. 39
DQC IIp. 39
+DQC IIIp. 39
DQC IIIp. 39
+ACAEp. 39
ACAEp. 39
+E3/96/E5-02p. 39
E3/96/E5-02p. 39
+E4-99p. 39
E4-99p. 39
+APIp. 39
APIp. 39
+CH-4/CG-4p. 39
CH-4/CG-4p. 39
+–p. 39
–p. 39
+DHDp. 39
DHDp. 39
+DHD-1p. 39
DHD-1p. 39
+–p. 39
–p. 39
The exact assignment of the approved oil qualities and oil change intervals can be taken from the following section "Lubrication oil change intervals".p. 39
Consult your local service station if in doubt.p. 39
Oil viscosityp. 39
Multi-purpose oils should be generally used.p. 39
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. 39
+Optimal operating conditions can be achieved by using the opposite oil viscosity chartp. 39
(Fig. 15)p. 39
Occasionally falling short of the temperature limits will impair the cold starting ability, but will not cause any engine damage. In order to keep the occurring wear as low as possible, occasional exceeding of the limits should not happen over a long…p. 39
Fig. 15p. 40
With their better temperature and oxidation stability synthetic lubrication oils offer quite a few benefits.p. 40
Oil change intervalsp. 40
The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operati…p. 40
+ACEAp. 40
European Engine Oil Sequencesp. 40
+E3-96/E5-02 E4-99p. 40
E3-96/E5-02 E4-99p. 40
250 operating hoursp. 40
+APIp. 40
American Petroleum Institutep. 40
+CG-4/CH-4p. 40
CG-4/CH-4p. 40
250 operating hoursp. 40
+These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C.p. 40
These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C.p. 40
When using fuels with a sulphur content of more than 0.5% to 1% or under ambient temperatures below -10 °C the oil change intervals specified in the table must be halved. For fuels with a sulphur content of more than 1% you should consult the respon…p. 40
+Coolant, anti-freeze agentp. 40
Coolant, anti-freeze agentp. 40
Use only soft tap water (drinking water) to prepare the coolant mix.p. 40
As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.p. 40
The proportion of cooling system protection agent must be between min. 35% and max. 45% to the water.p. 40
+Do not mix different coolants and additives of any other kind.p. 40
Do not mix different coolants and additives of any other kind.p. 40
+Cooling system protection agents must be disposed of environmentally.p. 40
Cooling system protection agents must be disposed of environmentally.p. 40
+Fuelsp. 40
Fuelsp. 40
Qualityp. 40
You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fue…p. 40
When using fuels with a Cetan number < 49 poor starting and white smoke can be expected, in particular in connection with low ambient temperatures.p. 40
The following fuel specifications are permitted: DIN/ EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.p. 40
+DIN/EN 590p. 40
DIN/EN 590p. 40
BS 2869p. 40
ASTM D 975-78: 1-D and 2-D.p. 40
Nato Codes: F-54, F-34, F44 and XF63p. 40
Winter fuelp. 40
+Fire hazard!p. 40
Fire hazard!p. 40
Diesel fuels must never be mixed with gasoline.p. 40
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. 40
In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.p. 40
+Hydraulic oilp. 41
Hydraulic oilp. 41
+The hydraulic system is operated with hydraulic oil HLP-D 46 (ISO VG 46) with a kinematic viscosity of 46 mmp. 41
2p. 41
+Oil for crawler track drive gearp. 41
Oil for crawler track drive gearp. 41
For the gearbox use only multi-purpose transmission oil of API-class GL5 with viscosity class SAE 80W/90.p. 41
The additives in this oil ensure low wear lubrication under all operating conditions.p. 41
+Lubrication greasep. 41
Lubrication greasep. 41
For lubrication use only EP-high pressure grease, lithium saponified (NLGI 3).p. 41
+The following maintenance work must be performed when running in new machines or overhauled engines:p. 43
The following maintenance work must be performed when running in new machines or overhauled engines:p. 43
+Up to approx. 250 operating hours check the engine oil level twice every day.p. 43
Up to approx. 250 operating hours check the engine oil level twice every day.p. 43
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. 43
After a running-in time of 30 minutesp. 43
+Retighten the V-beltp. 43
Retighten the V-beltp. 43
After 50 operating hoursp. 43
+Track pads for tight fitp. 43
Track pads for tight fitp. 43
After 250 operating hoursp. 43
+Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.p. 43
Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.p. 43
Retighten the bolted connections on the machine.p. 43
Oil change diesel engine and engine oil filterp. 43
Track drive wheel hubs, oil changep. 43
3.5 Maintenance chartp. 44
+No.p. 44
No.p. 44
+Maintenance workp. 44
Maintenance workp. 44
+Remarkp. 44
Remarkp. 44
+Running-in instructions after 250 operating hoursp. 44
Running-in instructions after 250 operating hoursp. 44
+every 10 operating hours, dailyp. 44
every 10 operating hours, dailyp. 44
+every 250 operating hoursp. 44
every 250 operating hoursp. 44
+every 500 operating hoursp. 44
every 500 operating hoursp. 44
+every 1000 operating hoursp. 44
every 1000 operating hoursp. 44
+every 2000 operating hoursp. 44
every 2000 operating hoursp. 44
+every 3000 operating hoursp. 44
every 3000 operating hoursp. 44
+every 6000 operating hoursp. 44
every 6000 operating hoursp. 44
+as requiredp. 44
as requiredp. 44
+5.6p. 44
5.6p. 44
+Check the engine oil levelp. 44
Check the engine oil levelp. 44
+Dipstick markp. 44
Dipstick markp. 44
+Xp. 44
Xp. 44
+5.7p. 44
5.7p. 44
+Check the water separatorp. 44
Check the water separatorp. 44
+Xp. 44
Xp. 44
+5.8p. 44
5.8p. 44
+Check the fuel levelp. 44
Check the fuel levelp. 44
+Xp. 44
Xp. 44
+5.9p. 44
5.9p. 44
+Check the hydraulic oil levelp. 44
Check the hydraulic oil levelp. 44
+Inspection glassp. 44
Inspection glassp. 44
+Xp. 44
Xp. 44
+5.10p. 44
5.10p. 44
+Check the coolant levelp. 44
Check the coolant levelp. 44
+Inspection glassp. 44
Inspection glassp. 44
+Xp. 44
Xp. 44
+5.11p. 44
5.11p. 44
+Lubricate the machinep. 44
Lubricate the machinep. 44
+Xp. 44
Xp. 44
+5.12p. 44
5.12p. 44
+Change engine oil and oil filter cartridgep. 44
+Change engine oil and oil filter cartridgep. 44
Oil change intervals depend on quality of oil and fuel (sulphur content)p. 46
+min. 1x per yearp. 44
min. 1x per yearp. 44
+Xp. 44
Xp. 44
+5.13p. 44
5.13p. 44
+Change the fuel filter cartridgep. 44
Change the fuel filter cartridgep. 44
+Xp. 44
Xp. 44
+5.14p. 44
5.14p. 44
+Checking / adjusting the conveyor belt chain tensionp. 44
Checking / adjusting the conveyor belt chain tensionp. 44
+Xp. 44
Xp. 44
+5.15p. 44
5.15p. 44
+Grease the conveyor belt chainp. 44
Grease the conveyor belt chainp. 44
+Xp. 44
Xp. 44
+5.16p. 44
5.16p. 44
+Check the tension/adjustment of the conveyor belt drive chainp. 44
Check the tension/adjustment of the conveyor belt drive chainp. 44
+Xp. 44
Xp. 44
+5.17p. 44
5.17p. 44
+Check the tension/adjustment of the auger drive chainp. 44
Check the tension/adjustment of the auger drive chainp. 44
+Xp. 44
Xp. 44
+5.18p. 44
5.18p. 44
+Grease the sliding surfaces of the auger height adjustmentp. 44
Grease the sliding surfaces of the auger height adjustmentp. 44
+Xp. 44
Xp. 44
+5.19p. 44
5.19p. 44
+Grease the conveyor belt drive chainp. 44
Grease the conveyor belt drive chainp. 44
+Xp. 44
Xp. 44
+5.20p. 44
5.20p. 44
+Lubricate the machinep. 44
Lubricate the machinep. 44
+Xp. 44
Xp. 44
+5.21p. 44
5.21p. 44
+Grease the screed extension sliding surfacep. 44
Grease the screed extension sliding surfacep. 44
+Xp. 44
Xp. 44
+5.22p. 44
5.22p. 44
+Clean the cooling fins on engine and hydraulic oil coolerp. 44
Clean the cooling fins on engine and hydraulic oil coolerp. 44
+Xp. 44
Xp. 44
+5.23p. 44
5.23p. 44
+Checking the oil level in the chain drive wheel hubsp. 44
Checking the oil level in the chain drive wheel hubsp. 44
+Xp. 44
Xp. 44
+5.24p. 44
5.24p. 44
+Battery maintenancep. 44
Battery maintenancep. 44
+Pole greasep. 44
Pole greasep. 44
+Xp. 44
Xp. 44
+5.25p. 44
5.25p. 44
+Checking/replacing the heating generator tooth beltp. 44
Checking/replacing the heating generator tooth beltp. 44
+Xp. 44
Xp. 44
+5.26p. 44
5.26p. 44
+Check, tension, replace the V-beltp. 44
Check, tension, replace the V-beltp. 44
+Xp. 44
Xp. 44
+5.27p. 45
5.27p. 45
+Drain the sludge from the fuel tankp. 45
Drain the sludge from the fuel tankp. 45
+Xp. 45
Xp. 45
+5.28p. 45
5.28p. 45
+Change the fuel pre-filter cartridgep. 45
Change the fuel pre-filter cartridgep. 45
+Xp. 45
Xp. 45
+5.29p. 45
5.29p. 45
+Check the state of the conveyor belt chainp. 45
Check the state of the conveyor belt chainp. 45
+Xp. 45
Xp. 45
+5.30p. 45
5.30p. 45
+Check the state of the conveyor belt surfacep. 45
Check the state of the conveyor belt surfacep. 45
+Xp. 45
Xp. 45
+5.31p. 45
5.31p. 45
+Check the state of the augerp. 45
Check the state of the augerp. 45
+Xp. 45
Xp. 45
+5.32p. 45
5.32p. 45
+Auger, check state of bearing guardp. 45
Auger, check state of bearing guardp. 45
+Xp. 45
Xp. 45
+5.33p. 45
5.33p. 45
+Check, adjust tamper bar and floor platesp. 45
Check, adjust tamper bar and floor platesp. 45
+Xp. 45
Xp. 45
+5.34p. 45
5.34p. 45
+Checking the track drivep. 45
Checking the track drivep. 45
+Xp. 45
Xp. 45
+5.35p. 45
5.35p. 45
+Check, adjust the valve clearancep. 45
Check, adjust the valve clearancep. 45
+Intake = 90° (0,4 mm)p. 45
Intake = 90° (0,4 mm)p. 45
Exhaust = 150° (0,6 mm)p. 45
+Xp. 45
Xp. 45
+5.36p. 45
5.36p. 45
+Adjust the control piston playp. 45
Adjust the control piston playp. 45
+Xp. 45
Xp. 45
+5.37p. 45
5.37p. 45
+Check the engine mountsp. 45
Check the engine mountsp. 45
+Xp. 45
Xp. 45
+5.38p. 45
5.38p. 45
+Change the coolantp. 45
Change the coolantp. 45
+at least every 2 yearsp. 45
at least every 2 yearsp. 45
+Xp. 45
Xp. 45
+5.39p. 45
5.39p. 45
+Change hydraulic oil and hydraulic oil filterp. 45
+Change hydraulic oil and hydraulic oil filterp. 45
Also in case of repair in the hydraulic system.p. 46
+at least every 2 yearsp. 45
at least every 2 yearsp. 45
+Xp. 45
Xp. 45
+5.40p. 45
5.40p. 45
+Track drive wheel hubs, oil changep. 45
Track drive wheel hubs, oil changep. 45
+min. 1x per yearp. 45
min. 1x per yearp. 45
+Xp. 45
Xp. 45
+Xp. 45
Xp. 45
+5.41p. 45
5.41p. 45
+Grease the auger drive chainp. 45
Grease the auger drive chainp. 45
+Xp. 45
Xp. 45
+5.42p. 45
5.42p. 45
+Hopper, check scrapers and rubber apronp. 45
Hopper, check scrapers and rubber apronp. 45
+Xp. 45
Xp. 45
+5.43p. 45
5.43p. 45
+Replace the crank case ventilation valvep. 45
Replace the crank case ventilation valvep. 45
+Xp. 45
Xp. 45
+5.44p. 45
5.44p. 45
+Electronic injector test EMRp. 45
Electronic injector test EMRp. 45
+Xp. 45
Xp. 45
+5.45p. 45
5.45p. 45
+Combustion air filter servicep. 45
Combustion air filter servicep. 45
+min. 1x per year, safety cartridge at least every 2 yearsp. 45
min. 1x per year, safety cartridge at least every 2 yearsp. 45
+Xp. 45
Xp. 45
+5.46p. 45
5.46p. 45
+Replace heating elementsp. 45
Replace heating elementsp. 45
+Xp. 45
Xp. 45
+5.47p. 46
5.47p. 46
+Tightening torquesp. 46
Tightening torquesp. 46
+Xp. 46
Xp. 46
+5.48p. 46
5.48p. 46
+Engine conservationp. 46
Engine conservationp. 46
+Xp. 46
Xp. 46
+4 Fundamental electricsp. 47
+4 Fundamental electricsp. 47
4.1 Understanding wiring diagramsp. 48
+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. 48
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. 48
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 48
+Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 48
Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 48
The sequence in which current flows through the individual elements in the electric circuit.p. 48
Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.p. 48
Pin assignment of plug-and-socket connections.p. 48
+Structurep. 48
Structurep. 48
+Table of contentsp. 48
+Table of contentsp. 48
(Fig. 16)p. 48
+Current pathsp. 48
(Fig. 17)p. 48
+Function groupsp. 48
(Fig. 18)p. 48
+Potential cross referencesp. 48
(Fig. 18)p. 48
+Relay cross referencesp. 48
(Fig. 19)p. 48
+List of componentsp. 48
(Fig. 20)p. 48
+Current pathsp. 49
+Table of contentsp. 49
(Fig. 16)p. 49
The table of contents lists all function groups.p. 49
Fig. 16 Table of contentsp. 49
Example:p. 49
The function group "ENGINE SENSORS/MOTORE SENSORI" can be found on sheet no. 10.1 (PAGINA/ PAGE).p. 49
+Current pathsp. 49
+Current pathsp. 49
(Fig. 17)p. 49
+The pages of a circuit diagram are sub-divided into current pathsp. 49
(Fig. 17)p. 49
Fig. 17 Current pathsp. 49
+Potential cross referencesp. 50
Function groupsp. 50
On the individual pages the electric circuits are combined to function groups.p. 50
Arrangement of current pathsp. 50
The individual current paths must be read as follows:p. 50
+From top (plus potential) to bottom (minus potential),p. 50
From top (plus potential) to bottom (minus potential),p. 50
from left to right,p. 50
From function group to function group andp. 50
via cross references for potentials and relays.p. 50
+Potential cross referencesp. 50
+Potential cross referencesp. 50
(Fig. 18)p. 50
+Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 50
Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 50
Example:p. 50
Potential "GEN-ON /80.4.2" on sheet no. 80.3 is continued on sheet no. 80.4 in current path "2" (see arrow).p. 50
Fig. 18 Potential cross referencep. 50
+Relay cross referencesp. 50
+Relay cross referencesp. 50
(Fig. 19)p. 50
+Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 50
Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 50
Apart from this there is a contact plan under each contactor coil providing information about the contact types of a relay and where these appear in the wiring diagram.p. 50
Example:p. 50
The coil of relay (E1) is located on page no. 7 in current path "8".p. 50
The contact pictogram under coil (E1) that a normally open contact with terminals 30 and 87 in current path 8 is triggered.p. 51
Fig. 19 Relay cross-referencep. 51
+Component cross referencesp. 52
+List of componentsp. 52
(Fig. 20)p. 52
This list contains all components used in alphabetical order, related to their component abbreviation (NAME) (AD, AS, BJ,…).p. 52
Fig. 20 List of componentsp. 52
+Component cross referencesp. 52
Component cross referencesp. 52
+Example:p. 52
Example:p. 52
In the circuit diagram the battery (BATTERIA 12V) "LC1-C1" is located on sheet no. 5 in current path 4.p. 52
4.2 Circuit symbols in the circuit diagramp. 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
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. 1 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 Backupp. 53
11 Line connection (fixed)p. 53
12 Line connection (separable)p. 53
4.3 Battery ground and analog groundp. 54
+GND, battery groundp. 54
GND, battery groundp. 54
The term "ground" (abbreviated GND) describes a conductive body which is normally defined with the potential of "Zero" Volt and represents the reference potential for operating voltages.p. 54
The positive pole of the supply voltage (symbol + ) and all other electric voltages and electical signals in an electrical circuitry refer to the ground potential.p. 54
On motor vehicles and also on motorbikes and bicycles the ground potential is represented by the chassis or the frame. As a conductive part, which covers the entire vehicle, it also serves a return conductor for the vehicle wiring system – the consum…p. 54
Terminal designation for GND = terminale 31p. 54
+AGND, analog groundp. 54
AGND, analog groundp. 54
Apart from the "normal" battery ground there is also the analog ground, which is solely reserved for sensors.p. 54
4.4 Processor signalsp. 54
+Signalsp. 54
Signalsp. 54
+Analog signalsp. 54
Analog signalsp. 54
Process states are continuous (analog) when they can be mapped by means of a real number, e.g. temperature = 65.5 °C. The sensor converts a continuous process status into an analog signal. If the control unit needs the numerical value of the analog …p. 54
+Binary signalsp. 54
Binary signalsp. 54
Process states are bivalent (binary) if they have only 2 possible states of truth, such as e.g. button pressed/ not pressed, object present/not present. The two states of truth are mapped by means of defined states of an information carrier, e.g. not…p. 54
4.5 Current and voltagep. 55
+Generalp. 55
Generalp. 55
If one wants to describe electric current, this can most simply be accomplished by means of a comparison:p. 55
One simply compares electric current with water.p. 55
+Voltagep. 55
Voltagep. 55
Fig. 1p. 55
+1 (Fig. 1) Chargep. 55
+1 (Fig. 1) Chargep. 55
1 (Fig. 1)p. 55
2 Voltagep. 55
3 Currentp. 55
+The equalization attempt between different electric charges is referred to as electric voltage.p. 55
The equalization attempt between different electric charges is referred to as electric voltage.p. 55
Voltage sources have two poles of different charge. On the one side we have the plus pole with a lack of electrons, on the opposite side the minus pole with a surplus of electrons. This electric "pressure" is known as electric voltage.p. 55
Fig. 2p. 55
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.p. 55
Plus pole= lack of electronsp. 55
Minus pole = excess of electronsp. 55
The following statements concerning electric voltage can be madep. 55
+electric voltage is the pressure or force applied to free electrons.p. 55
electric voltage is the pressure or force applied to free electrons.p. 55
the electric voltage is the cause of electric currentp. 55
electric voltage is a result of the equalization attempt of electric charges.p. 55
Voltage is measured with a Voltmeter.p. 55
Unit, Voltp. 55
The electric voltage (U) is measured in Volt (V).p. 55
Currentp. 56
+Electric current generally describes the directed movement of charge carriers.p. 56
Electric current generally describes the directed movement of charge carriers.p. 56
+The charge carriers may either be electrons or ions.p. 56
The charge carriers may either be electrons or ions.p. 56
Electric current can only flow if there is a sufficient amount of free moving charge carriers.p. 56
The higher the number of electrons flowing through a conductor per second, the higher the amperage.p. 56
Current is measured with an ammeter.p. 56
Unit, Amperep. 56
The electric amperage (I) is measured in Ampere (A).p. 56
The technical flow direction is specified from PLUS to MINUS.p. 56
+Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 56
Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 56
But since this was only discovered after the poles of a current source had already been designated, the assumption that current flows from plus to minus was maintained for historic reasons.p. 56
+Circuitp. 56
Circuitp. 56
Fig. 3 Circuitp. 56
+A simple circuit consists of a current source 1p. 56
(Fig. 3)p. 56
When the circuit is closed, current can flow.p. 56
The circuit can be interrupted or closed with a switch (2).p. 56
The system is protected by a fuse (4).p. 56
Types of currentp. 56
+Direct current (D.C.)p. 56
Direct current (D.C.)p. 56
Fig. 1 Direct current (D.C.)p. 56
Direct current flows with steady voltage and amperage from the plus to the minus pole.p. 56
Pure D.C.-voltages are only delivered by accumulators or batteries.p. 56
The voltage in the vehicle wiring system is no pure D.C.-voltage. Even without the generator running, but the consumers switched on, the voltage is not constant, but drops gradually according to the battery charge condition.p. 56
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off.p. 56
+Alternating current (A.C.)p. 56
Alternating current (A.C.)p. 56
Fig. 2 Alternating current (A.C.)p. 56
Alternating current not only changes its direction, but also its amperage.p. 56
4.6 Pulse width modulation, PWMp. 57
+Pulse – Width – Modulation, PWMp. 57
Pulse – Width – Modulation, PWMp. 57
PWM is the abbreviation for Pulse Width Modulation, frequently also referred to as "Pulse-Pause-Modulation" (PPM). It is used in controls for mobile and heavy-duty applications, mainly to control proportional valves (PWM-valves).p. 57
The following applies:p. 57
+The signal voltage cannot be measured.p. 57
The signal voltage cannot be measured.p. 57
The current can be measured.p. 57
+PWM-valves must not be interference suppressed with suppressor diodes.p. 57
PWM-valves must not be interference suppressed with suppressor diodes.p. 57
What does a PWM-output do?p. 57
Digital outputs normally deliver a fixed output voltage, as soon as they are switched on. The value of the output voltage can in this case not be changed. In contrast to this, PWM-outputs divide the voltage into a very fast sequence of many square pu…p. 57
Fig. 1p. 57
+(Fig. 1)Course of PWM-voltage U abd coil current I at 10% duty cycle: The effective coil current Ieff also is 10%p. 57
(Fig. 1)p. 57
Fig. 1p. 57
+(Fig. 1) Course of PWM-voltage U abd coil current I at 50% duty cycle: The effective coil current Ieff also is 50%p. 57
(Fig. 1)p. 57
Fig. 1p. 58
+(Fig. 1) Course of PWM-voltage U abd coil current I at 100% duty cycle: The effective coil current Ieff also is 100%p. 58
(Fig. 1)p. 58
+What is a Dither?p. 58
What is a Dither?p. 58
When triggering a proportional hydraulic valve the piston will not move instantaneously and at the beginning not proportionally to the coil current. Due to this "Slip- Stick effect" – some kind of "breakaway torque" – the valve at the beginning requi…p. 58
Engineering tackles this problem by subjecting the valve piston permanently to very small shuttle movements (the dither). The piston permanently vibrates to either side and cannot "stick". Even minor position changes now take place without delay, i.e…p. 58
Advantage: A hydraulic cylinder controlled this way, can be operated more sensitively.p. 58
Disadvantage: With the dither the valve becomes measurably hotter, because the valve coil is permanently in action.p. 58
4.7 Resistancep. 59
+Resistance and voltage dropp. 59
Resistance and voltage dropp. 59
+While current flows through a conductor the current flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.p. 59
While current flows through a conductor the current flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.p. 59
Fig. 1 Various size resistorsp. 59
+Each conductor has its specific resistance, which is characteristic for the corresponding material. A good conductor has a low resistance, a poor conductor has a high resistance.p. 59
Each conductor has its specific resistance, which is characteristic for the corresponding material. A good conductor has a low resistance, a poor conductor has a high resistance.p. 59
The resistance can only be measured with a Multimeter.p. 59
Symbol, Rp. 59
+Unit, Ohmp. 59
Wp. 59
+The electric resistance (R) is measured in Ohmp. 59
Wp. 59
Rule of thumb:p. 59
+The thicker the cable cross-section, the lower the voltage loss.p. 59
The thicker the cable cross-section, the lower the voltage loss.p. 59
The shorter the cable, the better the current.p. 59
The cleaner the contacts, the better the current.p. 59
The quality of the ground cable is of the same importance as the supply line.p. 59
+Unnecessary resistancesp. 59
Unnecessary resistancesp. 59
+Unnecessary resistances are frequently caused by mechanical connections, even clean ones, but mainly soiled and oxidizes terminals, too thin cables, material with poor conductivity or bent open cable lugs.p. 59
Unnecessary resistances are frequently caused by mechanical connections, even clean ones, but mainly soiled and oxidizes terminals, too thin cables, material with poor conductivity or bent open cable lugs.p. 59
Badp. 59
Fig. 1 Screw-type terminalsp. 59
Copper wires are squashed and thus become faulty.p. 59
+Betterp. 59
Betterp. 59
Fig. 2 Spring clampsp. 59
Connecting clamps for flexible conductorsp. 59
BOMAG No. 057 565 72p. 59
Ampacity up to 20 Amp.p. 59
Cable cross-section 0.08 to 2.5 qmmp. 59
Fig. 3p. 60
+In many cases it is better to replace the contact. Soiled or oxidized contacts should be cleaned with Ballistolp. 60
(Fig. 4)p. 60
Copper paste is a heat resistant grease, which has been mixed with copper powder. The paste protects electric contacts against oxidation. Copper paste keeps water away.p. 60
Fig. 4 Balistol oilp. 60
Sometimes the flanks of flat plugs bend open. If these are closed again with the help of pliers the flanks will be excessively strained at the bend and will definitely break sooner or later. It is better to place a small nail under the bottom of the …p. 60
Fig. 5p. 60
Hint for practice:p. 60
A tool you cannot buy. The pliers were converted, the nail is permanently present.p. 60
4.8 Series / parallel connectionp. 61
+Series connectionp. 61
Series connectionp. 61
In a series circuit the resistors (consumers) are lined up one after the other and the same current (I) passes through each of the consumers However, series connection of consumers is not suitable in practice, as each resistance causes a voltage drop…p. 61
Fig. 1 Series connectionp. 61
Currentp. 61
In series connection the current is identical at every point.p. 61
Itotal = I1 = I2 = I3p. 61
Voltagep. 61
The sum of all partial voltages is identical with the total voltage.p. 61
Utotal = U1 + U2 + U3p. 61
Resistancep. 61
The sum of all partial resistances is identical with the total resistance.p. 61
Rtotal = R1 + R2 + R3p. 61
+Series connection of batteriesp. 61
Series connection of batteriesp. 61
Fig. 2p. 61
In order to achieve a vehicle voltage of 24 V two batteries of the same type and capacity must be connected in series mode.p. 61
+In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 61
In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 61
The sum of all individual voltages is applied to the free poles.p. 61
The total capacity (Ah) is identical with the capacity of the individual battery.p. 61
+Parallel connection of batteriesp. 62
Parallel connectionp. 62
In parallel connection all resistances (consumers) are connected between feed and return line.p. 62
+All resistances (consumers) are supplied with the same voltage.p. 62
All resistances (consumers) are supplied with the same voltage.p. 62
Each of the resistances (consumers) draws as much current as required.p. 62
Fig. 3 Parallel connectionp. 62
Currentp. 62
The total current is the sum of all currents.p. 62
Itotal = I1 + I2 + I3p. 62
Voltagep. 62
The voltage values are identical at every resistance (consumer).p. 62
Utotal = U1 = U2 = U3p. 62
Resistancep. 62
The total resistance is less than the lowest individual resistance.p. 62
+Parallel connection of batteriesp. 62
Parallel connection of batteriesp. 62
Fig. 4p. 62
By connecting 2 batteries of same type and capacity in parallel mode the capacity can be doubled, because the individual capacities add up to the total capacity.p. 62
+In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 62
In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 62
Plus and minus poles have the voltage of the single battery applied.p. 62
The total capacity (Ah) is identical with the sum of all battery capacities.p. 62
The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of charging.p. 62
4.9 Ohm's lawp. 63
+In a closed electric circuit voltage, current and resistance must always be considered in close relation. This relation is represented by Ohm's Law.p. 63
In a closed electric circuit voltage, current and resistance must always be considered in close relation. This relation is represented by Ohm's Law.p. 63
Fig. 1p. 63
+According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohmp. 63
Wp. 63
Advicep. 63
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger.p. 63
Voltage U = I multiplied with Rp. 63
Resistance R = U divided by Ip. 63
Amperage I = U divided by Rp. 63
U = Voltage in Voltp. 63
I = Current in Amperep. 63
+R = Resistance in OHMp. 63
Wp. 63
4.10 Electrical energyp. 63
Fig. 1p. 63
In a closed electric circuit current and voltage generate energy.p. 63
If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced.p. 63
Advicep. 63
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger.p. 63
Energy P = I multiplied with Up. 63
Amperage I = P divided by Up. 63
Voltage U = P divided by Ip. 63
U = Voltage in Voltp. 63
I = Current in Amperep. 63
P = Power in Wattp. 63
4.11 Formula diagramp. 64
+Description:p. 64
Description:p. 64
+Select the desired value from the inner circle.p. 64
Select the desired value from the inner circle.p. 64
Determine the formula variables in the quarter circlep. 64
Calculatep. 64
Example:p. 64
P = 150 Wattp. 64
U = 24 Voltp. 64
Sought for = Current in Amperep. 64
I = P : U = 150 W : 24 Volt = 6.25 Amperep. 64
Fig. 1 Formula diagramp. 64
+Resistance, R Ohmp. 64
Wp. 64
Voltage, U Voltp. 64
Current, I Amperep. 64
Power, P Wattp. 64
4.12 Metrologyp. 65
+Test lampsp. 65
Test lampsp. 65
+Test lampp. 65
Test lampp. 65
Fig. 1 Test lampp. 65
+This type of tester must not be used for testing on electronic components. The high power consumption of the test lamp may destroy electronic components in the control units.p. 65
This type of tester must not be used for testing on electronic components. The high power consumption of the test lamp may destroy electronic components in the control units.p. 65
+Diode test lampp. 65
Diode test lampp. 65
This instrument is used for simple voltage measurements. The test lamp consists of two test points. The negative measuring cable is connected to ground and the positive measuring cable to the corresponding measuring location.p. 65
Fig. 2 Diode test lampp. 65
If voltage is present, the corresponding light emitting diode will light up.p. 65
Multimeterp. 65
+This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending on the design it may also be suitable for transistor and frequency.p. 65
This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending on the design it may also be suitable for transistor and frequency.p. 65
Fig. 1 Multimeterp. 65
In order to avoid damage:p. 65
+the range selector switch must be correctly set for the corresponding measurement.p. 65
the range selector switch must be correctly set for the corresponding measurement.p. 65
the test cable must be plugged into the correct socket.p. 65
the voltage type (AC/DC) must be set.p. 65
In case of direct voltage the correct polarity must be assured.p. 65
the measuring range should be chosen higher at the beginning of the test.p. 65
In order to avoid any influence on the circuitry to be measured, the internal resistance of the voltage tester should be as high as possible.p. 65
Resistance and continuity measurement with multimeterp. 66
Fig. 2p. 66
The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points.p. 66
Fig. 3p. 66
The following information should be observed when measuring resistance and continuity:p. 66
+The component to be measured must not be connected to the power supply during the measurement.p. 66
The component to be measured must not be connected to the power supply during the measurement.p. 66
At least one side of the component to be measured must be disconnected from the circuitry, as otherwise the measuring result may be influenced by parallel components.p. 66
Polarity is of no significance.p. 66
Voltage and voltage drop measurement with multimeterp. 66
Fig. 4 Measuring voltagep. 66
+Measurement at the voltage source measures the currently available Voltage.p. 66
Measurement at the voltage source measures the currently available Voltage.p. 66
The meter is always connected parallel to consumer, component or power source.p. 66
Fig. 5 Voltage measurementp. 66
+A measurement at the consumer measures the voltage drop at this component.p. 66
A measurement at the consumer measures the voltage drop at this component.p. 66
Current measurement with the multimeterp. 67
Fig. 6 Measuring currentp. 67
+The meter is connected in series with the consumer.p. 67
The meter is connected in series with the consumer.p. 67
During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened.p. 67
Fig. 7 Current measurementp. 67
Advicep. 67
If the electric circuit is difficult to access and the internal resistance of the consumer is known, the voltage may also be measured at the consumer.p. 67
The current value can then be calculated with the help of Ohm's law.p. 67
Clip-on measuring instrumentp. 67
+The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 67
The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 67
Fig. 1 Clip-on measuring instrumentp. 67
Fig. 2p. 67
+For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 67
For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 67
Magnet testerp. 68
Fig. 1 Magnet testerp. 68
The magnet tester is used to test solenoid valves and magnetic coils.p. 68
The test lamp responds to the magnetic fields of A.C- voltage, D.C.-voltage and permanent magnets.p. 68
+The component to be tested does not need to be removed.p. 68
The component to be tested does not need to be removed.p. 68
The magnetic coil can also be tested under a protective cap.p. 68
Power measurementp. 68
The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage.p. 68
However, there are also pure power meters with 4 connections available. The power meter has a electro- dynamic measuring mechanism. The current circuit must be opened for measuring. Take care when performing power measurements: Voltage or current pat…p. 68
Fig. 2p. 68
4.13 Diodes, relays, fusesp. 69
+Diodesp. 69
Diodesp. 69
Fig. 1p. 69
A diode consists of two different semi-conductors, which are connected by a separating layer. The max. conducting state current must not be exceeded.p. 69
Plus-voltage on diode:p. 69
+At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 69
At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 69
Negative voltage on diode:p. 69
+The diode does not allow current to pass through.p. 69
The diode does not allow current to pass through.p. 69
Fig. 2 Marking of the cathodep. 69
Diodes are used:p. 69
+For rectifying A.C. voltage.p. 69
For rectifying A.C. voltage.p. 69
For absorbing voltage peaks (free-wheeling diode).p. 69
For construction of logical circuits.p. 69
+Diode logics and free-wheeling diodep. 69
Diode logics and free-wheeling diodep. 69
Fig. 3 Diode circuitryp. 69
+The solenoid valve Y48p. 69
+The solenoid valve Y48p. 69
(Fig. 3)p. 69
Solenoid valve Y20 is supplied, if the switch is in position "1".p. 69
Solenoid valve Y21 is supplied, if the switch is in position "2".p. 69
The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.p. 69
+Light emitting diodesp. 70
Light emitting diodesp. 70
Fig. 4 LEDp. 70
The light emitting diode, also referred to as LED, is a semi-conductor diode, which generates (emits) light during operation in forward direction. A semi-conductor crystal thereby emits a light signal, which is converged or scattered by the lenticula…p. 70
Relaysp. 70
Fig. 1 Relaysp. 70
Relays are commonly used to realize switching processes.p. 70
A free-wheeling diode prevents induction voltage from flowing back from the coil into the vehicle wiring system, which would cause interference with electronic components (control units).p. 70
With the possibility of using breaker – maker contacts the effect of an information can be reversed.p. 70
Fig. 2 Relay circuitryp. 70
+The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric currentp. 70
(Fig. 2)p. 70
86 = Positive supply for coilp. 70
85 = Ground supply for coilp. 71
30 = Supply voltagep. 71
87 = Normally open contactp. 71
87a= Normally closed contactp. 71
Fusesp. 71
Fig. 1p. 71
Fuses are used to protect lines and equipment against overloads and short circuit. If the fuse is overloaded the fusible wire heats up with increasing current, until it finally melts.p. 71
+Fuses must not be repaired or bridged.p. 71
Fuses must not be repaired or bridged.p. 71
The melting time at 23 °C is:p. 71
+approx. 1 hour with 1.5 times the rated currentp. 71
approx. 1 hour with 1.5 times the rated currentp. 71
approx. 1 minute with 2.5 times the rated current.p. 71
A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours.p. 71
Yellow = 5 Ap. 71
Brown = 7.5 Ap. 71
White = 8 Ap. 71
Red = 16 Ap. 71
Blue = 25 Ap. 71
4.14 Inductive proximity switchesp. 72
+Generalp. 72
Generalp. 72
In all automated sequences the use of sensors as a source of information for the electronic control is indispensable. The sensors deliver the necessary signals about positions, end positions, filling levels or serve as pulse transducers for counting …p. 72
+Working principlep. 72
Working principlep. 72
Fig. 2p. 72
The working principle is based on the principle of the dampened LC-oscillator. The coil of the oscillation circuit forms a high-frequency magnetic stray field.p. 72
This stray field leaks out from the active area of the proximity switch. If metal or non-ferrous metal enters into the response range energy is absorbed. The oscillator is thus dampened and the resulting change in current consumption is evaluated.p. 72
+PNP circuitryp. 72
PNP circuitryp. 72
Fig. 3 PNP circuitryp. 72
On sensors with PNP-circuitry the output stage contains a PNP-transistor, which switches the load against the positive operating voltage. The load is connected between the output and the negative operating voltage. The switch is designed with a norma…p. 72
+NPN circuitryp. 72
NPN circuitryp. 72
Fig. 4 NPN circuitryp. 72
On sensors with NPN-circuitry the output stage contains a NPN-transistor, which switches the load against the negative operating voltage. The load is connected between the output and the positive operating voltage.p. 72
+Breaking and making contactsp. 72
Breaking and making contactsp. 72
Fig. 5p. 72
Proximity switches are used as breaking or making contacts. Depending on the design the switching distances are 2 or 4 mm. The maximum amperage is 300 mA.p. 72
+The LEDp. 72
(Fig. 5)p. 72
Fig. 6 Circuit diagram, making contactp. 73
+The circuit diagramp. 73
(Fig. 6)p. 73
Brown = voltage supplyp. 73
Blue = ground supplyp. 73
Black = switching outputp. 73
The initiator switches the relay (K05)p. 73
4.15 Plug connectorsp. 73
+Duties and requirementsp. 73
Duties and requirementsp. 73
Electric plug connectors must provide a reliable connection between different system components and thus ensure the safe function of the systems under any operating condition. There design ensures that they will withstand the applied loads throughout…p. 73
+Examples for these loads are:p. 73
Examples for these loads are:p. 73
+Vibration accelerationp. 73
Vibration accelerationp. 73
Temperature fluctuations, high and low temperaturesp. 73
Dampnessp. 73
Micro movements of the contact with resulting friction corrosion.p. 73
These loads may increase the transition resistances of the contacts, up to total interruption. Even the insulation resistances may drop and thus cause short circuits in neighbouring lines. Electric plug connectors must therefore have the following pr…p. 73
+Low transition resistances of the conductive parts.p. 73
Low transition resistances of the conductive parts.p. 73
High insulation strength between conductive parts with different voltage potentials.p. 73
Excellent leak tightness against water and moisture.p. 73
Magnetic coil plugp. 74
+Magnetic coil plug with LED and suppressor diodep. 74
Magnetic coil plug with LED and suppressor diodep. 74
The plug is equipped with a polarized function display and a suppressor diode as protection against overvoltages.p. 74
Fig. 7p. 74
The plug is polarized, it does not matter whether Pin1 or Pin 2 is supplied with current, Pin 3 is not used. The LED lights if voltage is applied to the solenoid valve.p. 74
Fig. 8p. 74
Fig. 9 Switching symbol in circuit diagramp. 74
Magnetic coil plug without LED and without supressor diodep. 74
The plug has no LED and no suppressor diode as protection against overvoltages.p. 74
Assembly of magnetic coil plugsp. 75
These instructions are intended to explain the correct installation of the magnetic coil plug. The objective of the instructions is the correct installation of the plug and to avoid malfunctions in the field caused by moisture and any related corrosi…p. 75
Fig. 10 Solenoid valve plug with pointed cablep. 75
Fig. 11p. 75
+Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 75
Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 75
Fig. 12p. 75
+Fasten the screw with a suitable screwdriver.p. 75
Fasten the screw with a suitable screwdriver.p. 75
Fig. 13p. 75
+Press the plug firmly on again.p. 75
Press the plug firmly on again.p. 75
Fig. 14p. 75
+Retighten the screw.p. 75
Retighten the screw.p. 75
Fig. 15p. 76
+There should be no gap between plug and solenoid coil!p. 76
There should be no gap between plug and solenoid coil!p. 76
Fig. 16 Correctly installed plug without gapp. 76
4.17 Deutsch plug, series DT and DTMp. 76
+Generalp. 76
Generalp. 76
Plug connectors DT and DTM have a wedge to hold the pins and sockets in their position. This wedge can be removed and replaced, without having to cut any leads.p. 76
Fig. 17 Crimp connectionsp. 76
+Do not crimp more than one lead per pin or per socket.p. 76
Do not crimp more than one lead per pin or per socket.p. 76
Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics).p. 76
When connecting sockets and plugs these must engage with a noticeable click when both halves interlock.p. 76
The plug connection should not be separable (without loosening the interlock).p. 76
Pulling testp. 76
This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing.p. 76
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 76
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 76
+DT Seriesp. 77
DT Seriesp. 77
Fig. 1 DT plug connectionp. 77
Fig. 2 DT Seriesp. 77
Fig. 3 Sectional drawingp. 77
Installing DT contactsp. 78
Fig. 4p. 78
+Insert the contacts through the rubber grommet until they click into place.p. 78
Insert the contacts through the rubber grommet until they click into place.p. 78
Insert the orange wedge in direction of arrow.p. 78
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 78
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 78
+Use the same method when assembling the socket.p. 78
Use the same method when assembling the socket.p. 78
Disassembling DT contactsp. 79
Fig. 5p. 79
+Pull the orange wedge out with long nose pliers.p. 79
Pull the orange wedge out with long nose pliers.p. 79
Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 79
Pull the contact out of the socket.p. 79
+Use the same method when assembling the socket.p. 79
Use the same method when assembling the socket.p. 79
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 79
DTM Seriesp. 80
Fig. 1 DTM plug connectionp. 80
Fig. 2 DTM Seriesp. 80
Fig. 3 Sectional drawingp. 80
Installing DTM contactsp. 81
Fig. 4p. 81
+Insert the contacts through the rubber grommet until they click into place.p. 81
Insert the contacts through the rubber grommet until they click into place.p. 81
Insert the orange wedge, until it clicks into place.p. 81
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 81
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 81
+Use the same method when assembling the socket.p. 81
Use the same method when assembling the socket.p. 81
Disassembling DTM contactsp. 82
Fig. 5p. 82
+Pull the orange wedge (interlock) out with long nose pliers.p. 82
Pull the orange wedge (interlock) out with long nose pliers.p. 82
Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 82
Pull the contact out of the socket.p. 82
+Use the same method when assembling the socket.p. 82
Use the same method when assembling the socket.p. 82
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 82
+4.20 Battery maintenancep. 83
4.18 Plugs and terminals in spring clamping technologyp. 83
+Generalp. 83
Generalp. 83
Fig. 1p. 83
+The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 83
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 83
+Spring clamp technologyp. 83
(Fig. 1)p. 83
+Connecting terminal for quick repairsp. 83
Connecting terminal for quick repairsp. 83
Fig. 2 That's how it worksp. 83
BOMAG part-no.: 057 565 72p. 83
+The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mmp. 83
2p. 83
2p. 83
2p. 83
(Fig. 2)p. 83
That's how it worksp. 83
+Strip 9-10 mm of the lead.p. 83
Strip 9-10 mm of the lead.p. 83
Open the actuating lever and insert the strand.p. 83
Return the actuating lever to initial position.p. 83
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 83
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 83
+X-COM plug clampp. 84
Series clampp. 84
Fig. 3 That's how it worksp. 84
That's how it worksp. 84
+Insert a screw driver into the actuating opening until it bottoms.p. 84
Insert a screw driver into the actuating opening until it bottoms.p. 84
Strip 9-10 mm of the lead and insert it into the clamp.p. 84
Pull out the screw driver.p. 84
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 84
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 84
Measuring signalsp. 84
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test adapter is standard in the …p. 84
Fig. 4 Test adapterp. 84
+X-COM plug clampp. 85
X-COM Systemp. 85
The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit for universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus become pluggable.p. 85
+X-COM plug clampp. 85
X-COM plug clampp. 85
Fig. 5 That's how it worksp. 85
That's how it worksp. 85
+Insert a screw driver into the actuating opening until it bottoms.p. 85
Insert a screw driver into the actuating opening until it bottoms.p. 85
Strip 9-10 mm of the lead and insert it into the plug.p. 85
Pull out the screw driver.p. 85
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 85
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 85
Fig. 6 X-COM plug with measuring cablep. 85
+The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 85
The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 85
Measuring signalsp. 86
Fig. 7 X-COM plug plugged onto the series clampp. 86
+4.20 Battery maintenancep. 87
4.19 Batteriesp. 87
+Battery – accumulatorp. 87
Battery – accumulatorp. 87
Fig. 1p. 87
In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries.p. 87
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.p. 87
The basic element of a lead accumulator is the cell. It contains the plate blocks consisting of positive and negative plates. These plates are separated from each other by separators.p. 87
All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.p. 87
Fig. 2p. 87
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.p. 87
Capacityp. 87
is a synonym for the amount of current taken up and discharged by a battery over a specified period of time.p. 87
+Battery maintenancep. 87
Battery maintenancep. 87
+Maintenance free batteries are gaining more and more significance, this freedom from maintenance, however, is only limited to the fact that no water needs to be added.p. 87
Maintenance free batteries are gaining more and more significance, this freedom from maintenance, however, is only limited to the fact that no water needs to be added.p. 87
If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself.p. 87
The accumulator may only be discharged down to a final discharging voltage of 10.5 Volt, as otherwise there is a risk of sulphation, i.e. the generated lead sulphate forms increasingly coarser crystals, which will finally not react at all or only ver…p. 87
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.p. 87
The following therefore applies for longer downtimes:p. 87
+Remove the battery and store it in a cool, dry and frost protected room.p. 87
Remove the battery and store it in a cool, dry and frost protected room.p. 87
Check the open circuit voltage on the battery at regular intervals (at least once every month).p. 87
Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).p. 87
+The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 87
The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 87
+Battery test in generalp. 87
Battery test in generalp. 87
+Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 87
Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 87
Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar.p. 87
+4.20 Battery maintenancep. 88
Batteries with screw plugsp. 88
+Checking the electrolyte levelp. 88
Checking the electrolyte levelp. 88
Fig. 3p. 88
+1 Upper filling level markp. 88
1 Upper filling level markp. 88
2 Lower filling level markp. 88
+If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 88
If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 88
Checking the electrolyte densityp. 88
Fig. 4p. 88
+The cells are filled with diluted sulphuric acid as electrolyte (approx. 25 Vol% sulphuric acid in distilled water), also referred to as accumulator acid, which has a density of 1.285 kg/dmp. 88
3p. 88
3p. 88
With a lead cell the acid density is therefore a measure for the charge condition. This characteristic is used to determine the charge condition of a lead battery. The so-called electrolyte tester (densimeter) is used for this purpose.p. 88
Fig. 5 Checking the electrolyte density:p. 88
1) correctp. 88
2) poorp. 88
3) poorp. 88
+(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 88
(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 88
Do not draw too much electrolyte into the pipe.p. 89
Make sure that the float is not obstructed in its movement and hold the electrolyte tester at eye level.p. 89
The electrolyte tester must be read at the highest electrolyte level.p. 89
+If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 89
+If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 89
(reference)p. 89
Referencep. 89
The specific weight varies slightly with temperature. To be exact, the specific weight drops by 0.0007 per 1 °C temperature increase (by 0.0004 per 1 °F) and increases by 0,0007 per 1 °C temperature reduction (by 0,0004 per 1 °F) . If e.g. a temp…p. 89
+Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 89
Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 89
Specific weight at 68 °F = measuring value + 0,0004 × (electrolyte temperature: 68 °F)p. 89
+Acid density at 27 °C in kg/dmp. 89
3p. 89
+1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 89
1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 89
1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary.p. 89
1.19 and less, open circuit voltage less than 12.3 Volt. Battery is insufficiently charged. The battery needs to be recharged immediately.p. 89
If there is a deviation of the specific weight of more than 0.05 between any of the cells, the battery needs to be replaced.p. 89
If the current consumption during charging is not 1/ 20 of the nominal capacity (example 100 Ah battery: 100Ah x 1/20 = 5 A) or full recharging of the battery results in a final electrolyte density of only 1.24 kg/ dm3 or less, the battery shows norm…p. 89
+4.20 Battery maintenancep. 89
Testing batteries without screw plugsp. 89
On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:p. 89
Fig. 6 Battery and generator testerp. 89
The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) integrated thermal printer.p. 89
+Before testing clean the poles and ensure good connection between clamps and poles.p. 89
Before testing clean the poles and ensure good connection between clamps and poles.p. 89
The test program calculates the text messages "good" or "replace" on the basis of the charge condition (derived from the battery voltage) and the currently available starting power of the battery. A battery with 45% starting power may thus be rated g…p. 89
The starting power can exceed 100%.p. 89
+4.20 Battery maintenancep. 90
Charge condition with hydrometerp. 90
Fig. 7 Charge conditionp. 90
Green = Charge condition >65%p. 90
Dark = Charge conditionp. 90
Light = Electrolyte level too lowp. 90
+Danger of explosion!!! If the electrolyte level is too low, the battery must no longer be charged.p. 90
Danger of explosion!!! If the electrolyte level is too low, the battery must no longer be charged.p. 90
4.20 Battery maintenancep. 90
+4.20 Battery maintenancep. 91
4.20 Battery maintenancep. 91
+Danger of cauterisation ! Danger of explosion!p. 91
+Danger of cauterisation ! Danger of explosion!p. 91
Danger of cauterisation ! Danger of explosion!p. 91
When working on the battery do not use open fire, do not smoke!p. 91
The battery contains acid. Do not let acid come in contact with skin or clothes!p. 91
Wear protective clothing!p. 91
Do not lay any tools on the battery!p. 91
+Dispose of the old battery environmentally.p. 91
Dispose of the old battery environmentally.p. 91
+Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result …p. 91
Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result …p. 91
The following therefore applies for the service life:p. 91
+Switch off all consumers (e.g. ignition, light, inside light, radio).p. 91
Switch off all consumers (e.g. ignition, light, inside light, radio).p. 91
Check open-circuit voltage of the battery at regular intervals. At least once per month.p. 91
Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.p. 91
+Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging.p. 91
Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging.p. 91
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.p. 91
+After each charging process allow the battery to rest for one hour before taking it into service.p. 91
After each charging process allow the battery to rest for one hour before taking it into service.p. 91
For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.p. 91
+Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 91
Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!p. 91
+Open the cover.p. 91
Open the cover.p. 91
Fig. 8p. 91
+Remove the batteryp. 91
+Remove the batteryp. 91
(Fig. 8)p. 91
Clean the outside of the battery.p. 91
Clean battery poles and pole clamps and grease them with pole grease (Vaseline).p. 91
Check the fastening of the battery.p. 91
On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.p. 91
+Charging voltage recommendationp. 91
Charging voltage recommendationp. 91
Fig. 9p. 91
+4.21 Starting with jump wiresp. 92
4.21 Starting with jump wiresp. 92
+When using external starting aid two external batteries (24 V system) are required, one for each on- board battery.p. 92
+When using external starting aid two external batteries (24 V system) are required, one for each on- board battery.p. 92
When using external starting aid two external batteries (24 V system) are required, one for each on- board battery.p. 92
A wrong connection will cause severe damage in the electric system.p. 92
Fig. 10p. 92
+First connect the plus poles with the jump lead.p. 92
First connect the plus poles with the jump lead.p. 92
+Then connect the ground cable first to the minus pole of the current supplying auxiliary battery and then to engine or chassis ground, as far away from the battery as possiblep. 92
+Then connect the ground cable first to the minus pole of the current supplying auxiliary battery and then to engine or chassis ground, as far away from the battery as possiblep. 92
(Fig. 10)p. 92
Start as described under "Starting the engine".p. 92
+Once the engine is running switch on a powerful consumer (working light, etc.).p. 92
Once the engine is running switch on a powerful consumer (working light, etc.).p. 92
+If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.p. 92
If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.p. 92
+After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 92
After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 92
Switch off the consumer.p. 92
4.22 Main battery switchp. 92
Fig. 11p. 92
+No. 1 = Main battery switchp. 92
No. 1 = Main battery switchp. 92
+Position "I"p. 92
Position "I"p. 92
Normal position, operationp. 92
Position "II"p. 92
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. 92
+4.24 Replace heating elementsp. 93
Fusesp. 93
+Fuses, relays and diodes in the dashboardp. 93
+Fuses, relays and diodes in the dashboardp. 93
(Fig. 1)p. 93
Fig. 1 Dashboardp. 93
Fig. 2 BF 600Cp. 93
Fig. 3 BF 600Pp. 94
(D) diodes, (E) relays, (F) fusesp. 94
+Fire hazard!p. 94
Fire hazard!p. 94
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 94
+D1p. 94
D1p. 94
Dashboard lightp. 94
D2p. 94
Dashboard lightp. 94
D3p. 94
Main switch hydraulicsp. 94
D4p. 94
Main switch hydraulicsp. 94
D5p. 94
Warning buzzerp. 94
D6p. 94
Display elementsp. 94
D7p. 94
Automatic functions, travel direction forwardp. 94
D9p. 94
Loading functionsp. 94
D10p. 94
Automatic conveyor beltp. 94
E1p. 94
Ignitionp. 94
E2p. 94
Warning buzzerp. 94
E3p. 94
Hornp. 94
E4p. 94
Rear working lightp. 94
E5p. 94
Working lights, frontp. 94
E6p. 94
Emergency stopp. 94
E7p. 94
Main switch hydraulicsp. 94
E8p. 94
EMRp. 94
E9p. 94
Automatic screw, conveyor beltp. 94
E10p. 94
Brake, PLCp. 94
E13p. 94
2. gearp. 94
E14p. 94
L.C.S.p. 94
E15p. 94
Screw, rightp. 94
E16p. 94
Screw, leftp. 94
E17p. 94
Main switch hydraulicsp. 94
E18p. 94
Automatic functions, bucket screed extensionp. 94
E19p. 94
Transport modep. 94
F1p. 94
25A- Water pumpp. 94
F2p. 94
10A- Flashing beaconp. 94
F3p. 94
10A- Pressure switch brake, warning buzzerp. 94
F4p. 94
10A- Horn, lateral operator standp. 94
F5p. 94
10A- Working lightsp. 94
F6p. 94
25A- Washing pumpp. 94
F7p. 94
10A- Emergency stopp. 94
F8p. 94
10A- ECO modep. 94
F9p. 94
10A- Travel, transport modep. 94
F10p. 94
10A- Voltage converter 24V/12Vp. 94
F11p. 94
10A- Fanp. 94
F13p. 94
15A- EMRp. 94
F14p. 94
25A- Warning horn, dashboardp. 94
F17p. 94
15A- Working lights, frontp. 94
F18p. 94
15A- Working lights, rearp. 94
F19p. 94
10A- Dashboard illuminationp. 94
F20p. 95
10A- Temperature control, heatingp. 95
F21p. 95
10A- Levelling, rightp. 95
F22p. 95
10A- Transport modep. 95
F25p. 95
3A- Brake, PLCp. 95
F26p. 95
10A- 2. gearp. 95
F27p. 95
10A- Screed extension, rightp. 95
F28p. 95
10A- Screed upp. 95
F29p. 95
10A- Compaction control displayp. 95
F30p. 95
15A- Automatic functionsp. 95
F31p. 95
10A- Levelling, leftp. 95
F32p. 95
10A- Screed extension, leftp. 95
F33p. 95
10A- Screw up/downp. 95
F34p. 95
10A- Hopper wingsp. 95
F35p. 95
10A- Screw, rightp. 95
F36p. 95
10A- Screw, leftp. 95
F37p. 95
10A- Conveyor belt, rightp. 95
F38p. 95
10A- Conveyor belt, leftp. 95
F39p. 95
25A- Main switch, hydraulicsp. 95
F40p. 95
7,5A- Preheating systemp. 95
F41p. 95
10A- Screwp. 95
F42p. 95
10A- Conveyor beltp. 95
F43p. 95
+10A- L.C.S. Type 2p. 95
Optional equipmentp. 95
F44p. 95
10A- Tamper, vibrationp. 95
F45p. 95
10A- Water spray boxp. 95
F46p. 95
10A- L.C.S. Type 1p. 95
F47p. 95
10A- Automatic functions, travel direction forwardp. 95
F48p. 95
5A- Travel, reversep. 95
+Fuses under operator's stand, left side (battery box)p. 95
(Fig. 4)p. 95
Fig. 4 Battery boxp. 95
+Fire hazard!p. 95
Fire hazard!p. 95
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 95
+JF 1p. 95
JF 1p. 95
20A- Brake, PLCp. 95
JF 2p. 95
60A- General, ignitionp. 95
JF 3p. 95
+20A- Xenon lightp. 95
Optional equipmentp. 95
JF 4p. 95
20A- Heating control, screedp. 95
JF 5p. 95
100A- Pre-heating systemp. 95
JF 7p. 95
15A- Lights, frontp. 95
JF 8p. 95
15A- Lights, rearp. 95
+Control cabinet for electric heaterp. 96
(Fig. 5)p. 96
On left side of vehicle.p. 96
Fig. 5p. 96
+ap. 96
ap. 96
Ground fault circuit interrupter for electric screed heatingp. 96
+bp. 96
bp. 96
Fuses for electric screed heatingp. 96
+4.24 Replace heating elementsp. 96
4.24 Replace heating elementsp. 96
+Life hazard!p. 96
+Life hazard!p. 96
Life hazard!p. 96
High voltage 400 Voltp. 96
Work on the electric heating system must only be performed by skilled personnel.p. 96
+Defective heating elements are indicated by means of LEDs on the terminal boxp. 96
+Defective heating elements are indicated by means of LEDs on the terminal boxp. 96
(Fig. 7)p. 96
Replacing the heating elements for the base platep. 96
Fig. 6p. 96
+Unscrew fastening screws ap. 96
+Unscrew fastening screws ap. 96
(Fig. 6)p. 96
Fig. 7p. 96
+Pull the plug off the junction boxp. 96
+Pull the plug off the junction boxp. 96
(Fig. 7)p. 96
Disconnect the cable for the defective heating element.p. 96
Fig. 8p. 97
+Unscrew the plugp. 97
+Unscrew the plugp. 97
(Fig. 8)p. 97
Pull the heating element out to the side.p. 97
+Do not overtighten the clamping screws for the heating elements, this may damage the heating elements.p. 97
Do not overtighten the clamping screws for the heating elements, this may damage the heating elements.p. 97
+Push in a new heating element, tighten the clamping screw lightly.p. 97
Push in a new heating element, tighten the clamping screw lightly.p. 97
Connect the heating element.p. 97
Close the junction box, screw in the plug and reassemble the guard.p. 97
Replacing the heating element for the tamperp. 98
Fig. 9p. 98
+Unscrew the fastening screws bp. 98
+Unscrew the fastening screws bp. 98
(Fig. 9)p. 98
Remove the protection plate (c).p. 98
+Disconnect the cable inside the terminal boxp. 98
(Fig. 7)p. 98
Fig. 10p. 98
+Loosen the fastening screws 1p. 98
+Loosen the fastening screws 1p. 98
(Fig. 10)p. 98
Slide in, fasten and connect a new heating element.p. 98
+5 Engine electricsp. 99
5 Engine electricsp. 99
+5.17 Diagnostics interfacep. 100
Installation location for engine control unitp. 100
Fig. 1p. 100
Installation location under the operator's stand on right hand side.p. 100
+Slide the operator's stand to the left and open the floor flap on the right hand side.p. 100
Slide the operator's stand to the left and open the floor flap on the right hand side.p. 100
+5.17 Diagnostics interfacep. 101
5.2 EMR3 system componentsp. 101
+Engine control unitp. 101
Engine control unitp. 101
+It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 101
+It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 101
It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void.p. 101
Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged.p. 101
Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w…p. 101
+The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goalsp. 101
The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goalsp. 101
+excellent exhaust gas characteristics,p. 101
excellent exhaust gas characteristics,p. 101
low fuel consumption,p. 101
smooth running of engine,p. 101
long lifetime of engine,p. 101
efficient servicingp. 101
under all operating conditions. For this purpose the engine control unit uses the recorded measuring values and the parameters stored in its data memory to run a number of calculations, which form the basis or all the available functions. The most im…p. 101
+exact control of the injection process (among others the number, start and duration of injections),p. 101
exact control of the injection process (among others the number, start and duration of injections),p. 101
idle speed regulation,p. 101
regulation of exhaust gas recirculation,p. 101
optimization of smooth running (by means of injection quantity correction),p. 101
engine monitoring,p. 101
system diagnose.p. 101
+Replacing the control unitp. 101
Replacing the control unitp. 101
Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you mu…p. 101
+The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 101
The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 101
Replacing the EMR or DCR componentsp. 101
+On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control unit….p. 101
On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control unit….p. 101
Any other EMR components (sensors etc) must under no circumstances be repaired, but must be replaced if they are defective.p. 101
Fig. 2p. 102
+The EMR3-S (TCD 2012 and TCD 2013)p. 102
(Fig. 2)p. 102
+socket D2.1 to connect the engine wiring loom,p. 102
socket D2.1 to connect the engine wiring loom,p. 102
socket D2.2 to connect the vehicle wiring loom.p. 102
Fig. 3p. 102
+The EMR3-E (TCD 2015)p. 102
(Fig. 3)p. 102
+socket D2.1 to connect the vehicle wiring loom,p. 102
socket D2.1 to connect the vehicle wiring loom,p. 102
socket D2.2 to connect the engine wiring loom for sensors and actuators,p. 102
socket D2.3 to connect the engine wiring loom for fuel metering unit and injection valves.p. 102
EMR-3 system in connection with injection system and electricsp. 103
Fig. 1p. 103
+1 Fuel tankp. 103
1 Fuel tankp. 103
2 Pre-filterp. 103
3 Fuel lift pumpp. 103
4 Fuel filterp. 103
5 High pressure fuel pumpp. 103
6 Fuel control unit FCUp. 103
7 Control unitp. 103
8 High pressure accumulator, Railp. 103
9 Injectorp. 103
10 Rail pressure sensorp. 103
11 Exhaust gas turbochargerp. 103
12 Engine transfer plugp. 103
13 Exhaust gas recirculation, optionp. 103
14 Engine sensorsp. 103
15 Diagnostics lampp. 103
16 Ignition switchp. 103
17 Pedalp. 103
18 Diagnostics buttonp. 103
19 Pressure relief valvep. 103
20 Battery terminal 31 and 30p. 103
21 Connecting line control unit-enginep. 103
22 Wiring loom connecting cablep. 103
23 Engine wiring harnessp. 103
24 Sensor, water in fuelp. 103
Sensors TCD 2012/2013p. 104
Fig. 1p. 104
+1 Fuel control unit FCUp. 104
1 Fuel control unit FCUp. 104
2 Coolant temperature sensorp. 104
3 Sensor for charge air temperature and charge air pressurep. 104
4 Wiring loom connecting cablep. 104
5 Engine control unitp. 104
6 Crankshaft speed sensorp. 104
7 Rail pressure sensorp. 104
8 Oil level sensor, optionp. 104
9 Oil pressure sensorp. 104
10 Fuel pressure sensorp. 104
11 Camshaft speed sensorp. 104
12 Central plugp. 104
Sensors TCD 2015p. 104
Fig. 1p. 104
+1 Oil pressure sensorp. 104
1 Oil pressure sensorp. 104
2 Fuel temperature sensorp. 104
3 Sensor for charge air temperature and charge air pressurep. 104
4 Engine control unitp. 104
5 Coolant temperature sensorp. 104
6 Oil level sensor, optionp. 104
7 Central plugp. 104
8 Crankshaft speed sensorp. 104
9 Camshaft speed sensorp. 104
10 Wiring loom connecting cablep. 104
Shut down the engine.p. 105
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. The injectors are closed immediately, the Rail pressure is discharged in an orderly manner and the counter readings are saved in the non-volatile memo…p. 105
+When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. The injectors are closed immediately, the Rail pressure is discharged in an orderly manner and the counter readings are saved in the non-volatile memo…p. 105
battp. 105
+The main relay serves the purpose of releasing the vehicle energy supply for the EMR3 system.p. 105
The main relay serves the purpose of releasing the vehicle energy supply for the EMR3 system.p. 105
+The EMR3 engine control unit requires an external main relay (relay K41, in single drum rollers and tandem rollers), (relay E8 in road finishers), see machine related circuit diagram.p. 105
The EMR3 engine control unit requires an external main relay (relay K41, in single drum rollers and tandem rollers), (relay E8 in road finishers), see machine related circuit diagram.p. 105
The EMR3-E engine control unit has an internal electronic main relay.p. 105
The following applies for both control units: when terminal 15 is no longer connected to battery (+) (i.e. after the ignition has been switched off), the main relay is switched off after approx. 10 seconds.p. 105
The main relay thereby disconnects the control unit from terminal 30 battery (+), whereby it becomes de- energized.p. 105
On the EMR3-S the fault state of the main relay can be examined directly on Pin72, on the EMR3-E on Pin13.p. 105
+5.17 Diagnostics interfacep. 106
5.3 Pin assignment of engine control EDC16 / EMR3p. 106
+5.17 Diagnostics interfacep. 111
5.4 Camshaft speed sensorp. 111
+Speed sensorp. 111
Speed sensorp. 111
+Inductive sensorp. 111
Inductive sensorp. 111
Determination of TDCp. 111
Limp-home function in case of crankshaft sensor failurep. 111
Fig. 2p. 111
+Disassemble the speed sensorp. 111
Disassemble the speed sensorp. 111
Fig. 3p. 111
+Remove the cable strapp. 111
+Remove the cable strapp. 111
(Fig. 3)p. 111
Disconnect the cable plug.p. 111
Fig. 4p. 111
+Unscrew the screwp. 111
+Unscrew the screwp. 111
(Fig. 4)p. 111
Remove the speed sensor.p. 111
+Assemble the speed sensorp. 111
Assemble the speed sensorp. 111
Fig. 5p. 111
+Clean the sealing surfaces on speed sensor and wheel housing cover.p. 111
Clean the sealing surfaces on speed sensor and wheel housing cover.p. 111
+Assemble the new O-ringp. 111
(Fig. 5)p. 111
Cover the O-ring slightly with oil.p. 111
Fig. 6p. 112
+Assemble the speed sensorp. 112
+Assemble the speed sensorp. 112
(Fig. 6)p. 112
Tighten the screw.p. 112
+Install the screws with screw retention agent.p. 112
Install the screws with screw retention agent.p. 112
Fig. 7p. 112
+Push on the cable plugp. 112
+Push on the cable plugp. 112
(Fig. 7)p. 112
Install the cables.p. 112
Fasten the cables with cable straps.p. 112
+5.17 Diagnostics interfacep. 112
5.5 Crankshaft speed sensorp. 112
+Speed sensorp. 112
Speed sensorp. 112
+Inductive sensorp. 112
Inductive sensorp. 112
Exact determination of engine speedp. 112
Limp-home function in case of camshaft sensor failurep. 112
+RPM-meterp. 112
RPM-meterp. 112
+The rotary speed is detected by the EMR control and passed on to the multi-function displayp. 112
(Fig. 8)p. 112
Fig. 8p. 112
+pp. 112
+pp. 112
pp. 112
Engine rpm-meterp. 112
In case of a fault a fault code is transmitted via the CAN-bus connection to the multi-function display (see chapter "Fault code display engine").p. 112
+Install the speed sensorp. 113
Disassemble the speed sensorp. 113
Fig. 9p. 113
+Disconnect the cable plugp. 113
+Disconnect the cable plugp. 113
(Fig. 9)p. 113
Fig. 10p. 113
+Unscrew both screwsp. 113
+Unscrew both screwsp. 113
(Fig. 10)p. 113
Remove the bracket with the speed sensorp. 113
Fig. 11p. 113
+Unscrew the screwp. 113
+Unscrew the screwp. 113
(Fig. 11)p. 113
Pull the speed sensor out of the bracketp. 113
+Install the speed sensorp. 113
Install the speed sensorp. 113
Fig. 12p. 113
+Press the speed sensor into the bracketp. 113
+Press the speed sensor into the bracketp. 113
(Fig. 12)p. 113
+Clean threads on screw and in bore. Assemble the screws with screw retention agent.p. 113
Clean threads on screw and in bore. Assemble the screws with screw retention agent.p. 113
+Tighten the screw with 9 Nm.p. 113
Tighten the screw with 9 Nm.p. 113
Fig. 13p. 113
+Attach the bracket with the speed sensorp. 113
+Attach the bracket with the speed sensorp. 113
(Fig. 13)p. 113
+Assemble the screws with screw retention agent and check the gap, adjust if necessary.p. 114
Assemble the screws with screw retention agent and check the gap, adjust if necessary.p. 114
Fig. 14p. 114
+Push on the cable plugp. 114
+Push on the cable plugp. 114
(Fig. 14)p. 114
+Adjusting the gap measurementp. 114
Check the gap measurementp. 114
Fig. 15p. 114
+Check the gap measurement with a feeler gaugep. 114
+Check the gap measurement with a feeler gaugep. 114
(Fig. 15)p. 114
+Nominal value: 0,6p. 114
± 0,1p. 114
+The feeler gauge must fit with only little resistance through the gap between toothed disc and speed sensor (crankshaft).p. 114
The feeler gauge must fit with only little resistance through the gap between toothed disc and speed sensor (crankshaft).p. 114
+Adjusting the gap measurementp. 114
Adjusting the gap measurementp. 114
Fig. 16p. 114
+Unscrew both screwsp. 114
+Unscrew both screwsp. 114
(Fig. 16)p. 114
+Install the screws with screw retention agent.p. 114
Install the screws with screw retention agent.p. 114
+Observe the different screw lengths.p. 115
Observe the different screw lengths.p. 115
Fig. 17p. 115
+Slide the feeler gauge through the gap between toothed disc and speed sensor.p. 115
Slide the feeler gauge through the gap between toothed disc and speed sensor.p. 115
Press the speed sensor slightly against the feeler gauge and tighten the screws.p. 115
+Tightening torque: 20Nmp. 115
Tightening torque: 20Nmp. 115
+5.17 Diagnostics interfacep. 115
5.6 Rail pressure sensorp. 115
+Pressure sensorp. 115
Pressure sensorp. 115
+Pressure sensorp. 115
Pressure sensorp. 115
Monitoring the injection pressurep. 115
Fig. 18p. 115
+Disassembling the pressure sensorp. 115
Disassembling the pressure sensorp. 115
+After shutting down the engine wait another 30 seconds before starting work in the fuel system.p. 115
After shutting down the engine wait another 30 seconds before starting work in the fuel system.p. 115
+Ensure absolute cleanliness when working in the fuel system.p. 115
Ensure absolute cleanliness when working in the fuel system.p. 115
Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 115
No foreign objects should enter into the Rail.p. 115
Ensure strict cleanliness. Especially on thread and sealing surface of Rail.p. 115
Follow the safety regulations and country specific regulations concerning the handling of fuel.p. 115
Immediately close all connections and openings with new and clean plugs/caps.p. 115
Only remove plugs/caps just before assembling.p. 115
Do not touch the contact pins of the Rail pressure sensor with bare hands to avoid electrostatic discharging.p. 115
+Catch running out fuel and dispose of environmentally.p. 115
Catch running out fuel and dispose of environmentally.p. 115
Fig. 19p. 116
+Unlock and pull out the cable plugp. 116
+Unlock and pull out the cable plugp. 116
(Fig. 19)p. 116
Unscrew the Rail pressure sensor with a socket spanner.p. 116
Fig. 20p. 116
+Check thread and sealing edge (arrows)p. 116
+Check thread and sealing edge (arrows)p. 116
(Fig. 20)p. 116
+Assembling the pressure sensorp. 116
Assembling the pressure sensorp. 116
Fig. 21p. 116
+Ensure strict cleanliness. Especially on thread and sealing surface of Rail.p. 116
Ensure strict cleanliness. Especially on thread and sealing surface of Rail.p. 116
+Slightly grease thread and sealing edge on Rail pressure sensor with assembly grease.p. 116
Slightly grease thread and sealing edge on Rail pressure sensor with assembly grease.p. 116
+Turn in and tighten the Rail pressure sensor (2)p. 116
(Fig. 21)p. 116
+Tightening torque: 40p. 116
+Tightening torque: 40p. 116
+ 5p. 116
+Plug in the cable plug.p. 116
Plug in the cable plug.p. 116
+5.17 Diagnostics interfacep. 117
5.7 Fuel pressure sensorp. 117
+Pressure sensorp. 117
Pressure sensorp. 117
+Pressure sensorp. 117
Pressure sensorp. 117
Monitoring the inlet pressurep. 117
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 117
Fig. 22p. 117
+Disassembling the pressure sensorp. 117
Disassembling the pressure sensorp. 117
+Ensure absolute cleanliness when working in the fuel system.p. 117
Ensure absolute cleanliness when working in the fuel system.p. 117
Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 117
Follow the safety regulations and country specific regulations concerning the handling of fuel.p. 117
Immediately close all connections and openings with new and clean plugs/caps.p. 117
Only remove plugs/caps just before assembling.p. 117
+Catch running out fuel and dispose of environmentally.p. 117
Catch running out fuel and dispose of environmentally.p. 117
Fig. 23p. 117
+Unscrew the locking ringp. 117
+Unscrew the locking ringp. 117
(Fig. 23)p. 117
Pull off the cable plug.p. 117
Unscrew the fuel pressure sensor with a socket spanner.p. 117
+Installing the pressure sensorp. 117
Installing the pressure sensorp. 117
Fig. 24p. 117
+Insert the fuel pressure sensor with a new seal ring and tightenp. 117
+Insert the fuel pressure sensor with a new seal ring and tightenp. 117
(Fig. 24)p. 117
+Tightening torque: 30p. 117
+Tightening torque: 30p. 117
± 5p. 117
Fig. 25p. 118
+Push the cable plug back onto the fuel pressure sensorp. 118
+Push the cable plug back onto the fuel pressure sensorp. 118
(Fig. 25)p. 118
Turn in the locking ring until it engages.p. 118
+Make sure the contacts are matching.p. 118
Make sure the contacts are matching.p. 118
Spulenkörpered the fuel system with the fuel hand pump on the fuel pre-cleaner.p. 118
+5.17 Diagnostics interfacep. 118
5.8 Fuel control unit FCUp. 118
+Fuel control unit (FCU)p. 118
Fuel control unit (FCU)p. 118
Fig. 26p. 118
+Functionp. 118
Functionp. 118
Here the fuel flowing into the pump elements is metered by an infinitely controllable solenoid valve (also referred to as "fuel control unit").p. 118
This valve is mounted to the FCU control block and adapts the fuel quantity supplied to the Rail to the system requirements. The solenoid valve is controlled by a pulse width modulated (PWM) signal. When controlling the valve, the piston is operated …p. 118
Fig. 27p. 119
+1 Plug with electric interfacep. 119
1 Plug with electric interfacep. 119
2 Solenoid housingp. 119
3 Bearingp. 119
4 Anchor with plungerp. 119
5 Winding with coil corep. 119
6 Bowlp. 119
7 Residual air gap discp. 119
8 Magnetic corep. 119
9 O-ringp. 119
10 Piston with control slotsp. 119
11 Springp. 119
12 Locking elementsp. 119
Fig. 28p. 119
+1 max. flow capacityp. 119
1 max. flow capacityp. 119
2 max. flow capacityp. 119
+5.17 Diagnostics interfacep. 120
5.9 Injectorsp. 120
+Injectorsp. 120
Injectorsp. 120
Fig. 29p. 120
+Functionp. 120
Functionp. 120
+The injectors are installed in the cylinder head. They have the same functions as nozzöe and nozzle holder in conventional injection systems. The injectors are connected with the pressure accumulator (Rail) by high pressure linesp. 120
(Fig. 30)p. 120
In the injector the beginning and end of injection of the nozzle are determined by a valve. The operating forces for opening and closing the valve are generated by a solenoid. The injectors work with approx. 50 to 70 Volt, instead of the 12 Volt vehi…p. 120
+The forces required to open and close the nozzle needle cannot be generated by a solenoid valve on its own. The nozzle needle is therefore indirectly controlled via an hydraulic booster system in the injectorp. 120
(Fig. 31)p. 120
Fig. 30p. 120
Fig. 31p. 120
+5.17 Diagnostics interfacep. 121
5.10 Oil pressure sensorp. 121
+Pressure sensorp. 121
Pressure sensorp. 121
Oil pressure monitoringp. 121
The operator is warned ifp. 121
+the oil pressure falls short of the warning limit and/orp. 121
the oil pressure falls short of the warning limit and/orp. 121
the power is reduced by the EMR after a pre-warning time, orp. 121
the oil pressure falls short of the shut-down limit and the engine is shut down after a pre-warning time.p. 121
Fig. 32 Oil pressure sensorp. 121
In case of a fault a fault code is transmitted via the CAN-bus connection to the multi-function display (see chapter "Fault code display engine").p. 121
+Installing the pressure sensorp. 121
Disassembling the pressure sensorp. 121
+Ensure absolute cleanliness when working in the lubrication oil system.p. 121
Ensure absolute cleanliness when working in the lubrication oil system.p. 121
Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 121
Immediately close all connections and openings with new and clean plugs/caps.p. 121
Only remove plugs/caps just before assembling.p. 121
+Catch engine oil and dispose of environmentally.p. 121
Catch engine oil and dispose of environmentally.p. 121
Fig. 33p. 121
+Unlock and pull out the cable plugp. 121
+Unlock and pull out the cable plugp. 121
(Fig. 33)p. 121
Unscrew the coolant temperature sensor.p. 121
+Installing the pressure sensorp. 122
Installing the pressure sensorp. 122
Fig. 34p. 122
+Insert the oil pressure sensor with a new seal ring and tighten.p. 122
Insert the oil pressure sensor with a new seal ring and tighten.p. 122
+Tightening torque: 20Nmp. 122
Tightening torque: 20Nmp. 122
+5.17 Diagnostics interfacep. 122
5.11 Charge air temperature – charge air pressure sensorp. 122
+Sensorp. 122
Sensorp. 122
+Combined charge air pressure / temperature sensorp. 122
Combined charge air pressure / temperature sensorp. 122
Fig. 35p. 122
This sensor unites two functions in one housing. The one function measures the charge air pressure in the and adapts the injection quantity in dependence on the measured pressure. On the other hand the EMR now detects the temperature of the passing a…p. 122
+With a faulty pressure sensor the engine continues to run with charge pressure simulation.p. 122
With a faulty pressure sensor the engine continues to run with charge pressure simulation.p. 122
With a defective temperature sensor the engine also carries on running.p. 122
Charge air temperature monitoringp. 122
The operator is warned ifp. 122
+the temperature exceeds the warning limit and/orp. 122
the temperature exceeds the warning limit and/orp. 122
the power is reduced by the EMR 3 after a pre- warning time, orp. 122
the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 122
+Disassembling the sensorp. 123
Disassembling the sensorp. 123
Fig. 36p. 123
+Unscrew screw 1p. 123
+Unscrew screw 1p. 123
(Fig. 36)p. 123
Remove the cover plate.p. 123
Fig. 37p. 123
+Unlock and pull out the cable plugp. 123
+Unlock and pull out the cable plugp. 123
(Fig. 37)p. 123
Remove the pressure/temperature sensor.p. 123
+Installing the sensorp. 123
Installing the sensorp. 123
Fig. 38p. 123
+Assemble a new O-ringp. 123
+Assemble a new O-ringp. 123
(Fig. 38)p. 123
Slightly cover the O-ring with grease.p. 123
Fig. 39p. 123
+Carefully insert the pressure/temperature sensorp. 123
+Carefully insert the pressure/temperature sensorp. 123
(Fig. 39)p. 123
Plug on the cable plug and engage the lock.p. 123
Fig. 40p. 124
+Attach the cover platelp. 124
+Attach the cover platelp. 124
(Fig. 40)p. 124
Tighten the screw (1).p. 124
+5.17 Diagnostics interfacep. 124
5.12 EMR coolant temperature sensorp. 124
+Temperature sensorp. 124
Temperature sensorp. 124
The coolant temperature has an effect on the calculated injection quantity and the preheating behaviour of the glow plugs.p. 124
Coolant temperature monitoringp. 124
The operator is warned ifp. 124
+the temperature exceeds the warning limit and/orp. 124
the temperature exceeds the warning limit and/orp. 124
the power is reduced by the EMR after a pre-warning time, orp. 124
the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 124
Fig. 41 Coolant temperature sensorp. 124
+Warning light engine overheatingp. 124
Warning light engine overheatingp. 124
+The coolant temperature is detected by the EMR control. In case of a fault a message is transmitted via the CAN-bus connection to the multi-function displayp. 124
(Fig. 42)p. 124
Fig. 42p. 124
+hp. 124
+hp. 124
hp. 124
lights if engine overheats. Warning buzzer sounds.p. 124
op. 124
Display of operating hours and engine fault codesp. 124
+Coolant temperature gaugep. 125
Coolant temperature gaugep. 125
+np. 125
+np. 125
np. 125
Gauge, coolant temperature.p. 125
+Installing the temperature sensorp. 125
Disassembling the temperature sensorp. 125
+Catch running out fluids in a suitable vessel and dispose of environmentally.p. 125
Catch running out fluids in a suitable vessel and dispose of environmentally.p. 125
+Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 125
Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 125
Fig. 43p. 125
+Unlock and pull out the cable plugp. 125
+Unlock and pull out the cable plugp. 125
(Fig. 43)p. 125
Fig. 44p. 125
+Unscrew the coolant temperature sensorp. 125
+Unscrew the coolant temperature sensorp. 125
(Fig. 44)p. 125
+Counter the adapter piece.p. 125
Counter the adapter piece.p. 125
+Installing the temperature sensorp. 126
Installing the temperature sensorp. 126
Fig. 45p. 126
+Tighten the coolant temperature sensorp. 126
+Tighten the coolant temperature sensorp. 126
(Fig. 45)p. 126
+Make sure that the seal rings are present .p. 126
Make sure that the seal rings are present .p. 126
+Tightening torque: 22p. 126
±2p. 126
Fig. 46p. 126
+Push on the cable plugp. 126
+Push on the cable plugp. 126
(Fig. 46)p. 126
+5.17 Diagnostics interfacep. 126
5.13 Glow plugsp. 126
+The circuitry is shown in the circuit diagram on page 10.2.p. 126
+The circuitry is shown in the circuit diagram on page 10.2.p. 126
The circuitry is shown in the circuit diagram on page 10.2.p. 126
The engines are equipped with glow plugs for cold starting as standard. Preheating the glow plugs in the combustion chamber of the diesel engine ensures perfect cold starting and post-heating of the glow plugs has a positive effect on the emissions f…p. 126
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 126
+JF 5p. 126
JF 5p. 126
100A- Pre-heating systemp. 126
Fig. 48 Relay JE1p. 126
+5.17 Diagnostics interfacep. 127
5.14 Sensor, water in fuel, C39p. 127
+The circuitry is shown in the circuit diagram on page 10.1.p. 127
+The circuitry is shown in the circuit diagram on page 10.1.p. 127
The circuitry is shown in the circuit diagram on page 10.1.p. 127
Fig. 1p. 127
+1 Sensor for water separatorp. 127
1 Sensor for water separatorp. 127
+Fault messagep. 127
Fault messagep. 127
The analog sensor is electronically monitored by the EMR-control. In case of a fault a fault code is transmitted via the CAN-bus connection to the multi-function display (see chapter "Fault code display").p. 127
+5.17 Diagnostics interfacep. 127
5.15 Air filter vacuum switch, C40p. 127
+The circuitry is shown in the circuit diagram on page 10.1.p. 127
+The circuitry is shown in the circuit diagram on page 10.1.p. 127
The circuitry is shown in the circuit diagram on page 10.1.p. 127
Fig. 1p. 127
The vacuum switch operates at a vacuum of > 50 mbar.p. 127
+Fault messagep. 127
Fault messagep. 127
The switch is electronically monitored by the EMR- control. In case of a fault a fault code is transmitted via the CAN-bus connection to the multi-function display (see chapter "Fault code display").p. 127
+5.17 Diagnostics interfacep. 128
5.16 Level probe coolant tank, C38p. 128
+The circuitry is shown in the circuit diagram on page 10.1.p. 128
+The circuitry is shown in the circuit diagram on page 10.1.p. 128
The circuitry is shown in the circuit diagram on page 10.1.p. 128
Fig. 1p. 128
The level probe works according to the capacitive principle. The capacity change, that is generated when an air surrounded, insulated electrode is submerged in a liquid medium, is detected. This capacity change on the sensor electrode excites an osci…p. 128
These level probes have a short circuit proof switching output. Since they do not contain any moveable parts, their function can neither be impaired by dirt particles, nor by other influences.p. 128
+Fault messagep. 128
Fault messagep. 128
The probe is electronically monitored by the EMR- control. In case of a fault a fault code is transmitted via the CAN-bus connection to the multi-function display (see chapter "Fault code display engine").p. 128
+5.17 Diagnostics interfacep. 128
5.17 Diagnostics interfacep. 128
Fig. 1 Diagnostic linkp. 128
+Ap. 128
Ap. 128
Battery plus (+)p. 128
Bp. 128
Battery minus (-)p. 128
Fp. 128
CAN2 lowp. 128
Gp. 128
CAN1 lowp. 128
Hp. 128
CAN1 highp. 128
Kp. 128
K-Linep. 128
Mp. 128
CAN2 highp. 128
Fig. 2 Diagnostics plugp. 128
SERDIA connectionp. 129
Fig. 3p. 129
+The KWP-protocol with encrypted dataflow is used via the K-line. For this purpose the PC or laptopp. 129
(Fig. 3)p. 129
Operation of SERDIA is described in a separate operation manual.p. 129
CAN-bus display connectionp. 129
Operation of the display is described in a separate operation manual.p. 129
Fig. 4p. 129
+Display for EMR controlp. 129
(Fig. 4)p. 129
BOMAG part-no.: 057 189 94p. 129
Fig. 5p. 129
The display is connected to the diagnostic interface by means of a special cable.p. 129
+Wiring loom for displayp. 129
(Fig. 5)p. 129
BOMAG part-no.: 079 900 19p. 129
5.18 Diagnose with CAN-busp. 130
+The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 130
The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 130
The display is a compact, robust and integratable modules which enables the user to invoke engine data and to display these in the following formats:p. 130
+Analog displayp. 130
Analog displayp. 130
Digital datap. 130
Multi data (a combination of analog and digital data)p. 130
Alarm messages currently presentp. 130
The different diagnostic screens enable detailed examination of the engine data flowp. 130
Fig. 1p. 130
+Display for EMR controlp. 130
(Fig. 1)p. 130
5.19 Diagnose with SERDIAp. 131
+SERDIAp. 131
SERDIAp. 131
+With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 131
With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 131
Fig. 1 Service-Software TCD 2012 / 2013p. 131
The SERDIA software is first choice for any diagnostics task.p. 131
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log.p. 131
This displays information onp. 131
+Location of fault (e.g. ’coolant temperature sensor’)p. 131
Location of fault (e.g. ’coolant temperature sensor’)p. 131
Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)p. 131
Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)p. 131
Number of fault locations and frequency of faultp. 131
Fault status (active – fault present / passive- fault no longer present)p. 131
Fault messages for non-present / rectified faults can be deleted with SERDIA.p. 131
Function testp. 131
The control outputs can be activated with the engine shut down.p. 131
Assignment of inputs/outputsp. 131
Display of the current input and output assignment of the EMR-control.p. 131
Representation of measuring valuesp. 132
Fig. 2p. 132
There is a vast variety of measuring values available for selection which can even be used if no EMR-fault is present (start behaviour, engine sawing, lack of power).p. 132
Representation of fault logp. 133
Fig. 3p. 133
When looking for the cause of a fault in the EMR3-system examining the fault log of the engine control unit usually provides useful information.p. 133
Fault code indication, diesel enginep. 134
Fig. 1 Displayp. 134
+ap. 134
ap. 134
lights, water in fuel filterp. 134
gp. 134
lights, if the fuel filter is blockedp. 134
hp. 134
lights if the engine overheatsp. 134
ip. 134
lights if the engine oil pressure is too lowp. 134
jp. 134
lights if the coolant level is too lowp. 134
kp. 134
lights if the battery is not being chargedp. 134
Ip. 134
lights in case of a faultp. 134
+op. 134
op. 134
Display of operating hours and engine fault codes (hexa-decimal code).p. 134
+When the warning buzzer sounds and the fault indicator (I) lights up, read out the hexa-decimal code in the window (o).p. 134
When the warning buzzer sounds and the fault indicator (I) lights up, read out the hexa-decimal code in the window (o).p. 134
+Hexa-decimal codes are explained in the following fault code list, column "p. 134
+Hexa-decimal codes are explained in the following fault code list, column "p. 134
SPN (hex)p. 134
+A detailed reading out of fault codes for the diesel engine is only possible with Deutz-Serdiap. 134
A detailed reading out of fault codes for the diesel engine is only possible with Deutz-Serdiap. 134
EMR3 List of fault codesp. 135
5.22 Generatorp. 208
+Generalp. 208
Generalp. 208
The generator should be of light weight, have a high rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already at idling speed.p. 208
Terminal designationsp. 208
+B61, L = charge controlp. 208
B61, L = charge controlp. 208
B+, B = battery plus, also with the designation "30"p. 208
B- = battery minus, also with the designation "31"p. 208
D+ = dynamo plus corresponds with terminal "61" and "L"p. 208
D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed)p. 208
DF = dynamo field (this designation is only found on D.C. generators or A.C. generators with regulator removed). Note: The designation DF is also found on older alternators with externally arranged regulator on the connection of the exciting coil to …p. 208
DF1 = dynamo field 1p. 208
DF2 = dynamo field 2p. 208
IG = "15" ignition switchp. 208
Three-phase generatorp. 208
+The AC-generator first of all produces AC-voltage / AC-current.p. 208
The AC-generator first of all produces AC-voltage / AC-current.p. 208
Why does AC-current need to be rectified?p. 208
There are a few components for which can either be operated with alternating current or direct current, because they work independently from the current flow direction.p. 208
This includes :p. 208
+Incandescent lampsp. 208
Incandescent lampsp. 208
Fluorescent lampsp. 208
Glow lampsp. 208
Electric heating elements.p. 208
There are also a few components that could be operated either with alternating current, direct current or three-phase current, if the components were designed accordingly.p. 208
This includes :p. 208
+Electric motorsp. 208
Electric motorsp. 208
Relays.p. 208
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.p. 208
This includes :p. 208
+Accumulatorsp. 208
Accumulatorsp. 208
Control unitsp. 208
All electronicsp. 208
Communication equipment.p. 208
+Design and functionp. 208
Design and functionp. 208
Fig. 2p. 208
+1 Fanp. 208
1 Fanp. 208
2 Holding platep. 208
3 Stator corep. 208
4 Stator windingp. 208
5 Brushp. 208
6 Brush holderp. 209
7 Rectifierp. 209
8 Bearing coverp. 209
9 Rotor windingp. 209
10 Rotorp. 209
11 V-belt pulleyp. 209
Fig. 3 Rotor with claw polesp. 209
+In the generator the armature windings are located inside the stationary statorp. 209
(Fig. 4)p. 209
(Fig. 3)p. 209
Fig. 4 Statorp. 209
+The three stator windingsp. 209
(Fig. 4)p. 209
Fig. 5 3-phase currentp. 209
+The wiring diagramp. 209
(Fig. 5)p. 209
The diodes D1, D2, D3 are also referred to as minus diodes, because they have B- as common connection (minus plate). The other diodes are the plus diodes.p. 209
The rectifier diodes have the effect that the negative half-wave is suppressed and only the positive section of the wave is allowed to pass, resulting in a pulsating D.C. voltage.p. 209
Charge control lightp. 210
The charge control light has two duties:p. 210
+Indication of the correct generator functionp. 210
Indication of the correct generator functionp. 210
External excitation of the generator during the starting phasep. 210
Fig. 6 plus controlled charging regulatorp. 210
+(Fig. 6) shows the current flow with the ignition switched on, engine stopped.p. 210
(Fig. 6)p. 210
Fig. 7 plus controlled charging regulatorp. 210
+(Fig. 7) shows the current flow with the ignition switched on, engine running.p. 210
(Fig. 7)p. 210
+1 Batteryp. 210
1 Batteryp. 210
2 Charge controllerp. 210
3 Ignition switchp. 210
4 Charge control lightp. 210
5 Rectifierp. 210
6 Rotorp. 210
7 Sliprings / carbon brushp. 210
8 Auxiliary rectifierp. 210
Normally the charge control light lights with the engine stopped and the ignition switched on and goes out at low engine speed, but at the latest after a single, short-term increase in engine speed from idle speed, because there is no longer a voltag…p. 210
Any other behaviour would indicate a defect on the generator (rectifier, carbon brushes, regulator) or a defect on the lamp, presumed the on-board battery is not discharged.p. 210
A far more important function of the lamp is the transition and provision of field current. At standstill there is no magnetic field in the de-energized generator. Since this is necessary for the generation of electric current, the rotor must be supp…p. 210
The current flows from the ignition switch via the charge control light through the generator winding against ground (terminal 31) and is limited to approx. 300 mA by the light bulb (4 W) (without the lamp the current flow would be 2 to 5 A). While t…p. 210
With used, older generators a weak permanent magnetic field may have developed over the lifetime, which does even exist when no voltage is applied. This type of machines can even start without charge control light and produce current during operation…p. 210
Charge controllerp. 211
The charge controller has the following functionsp. 211
+To regulate the voltage generated by the generatorp. 211
To regulate the voltage generated by the generatorp. 211
To protect against overloads caused by too high output currentp. 211
Protection against reverse currentp. 211
If the output voltage or the output current of the generator exceeds the determined maximum values, the field current and thus the electric power is reduced.p. 211
+Electronic charge regulatorp. 211
Electronic charge regulatorp. 211
Fig. 8p. 211
In AC-generators the electrically generated exciter field of the generator rotor is influenced by an attached electronic charge regulator. Together with the holder for the carbon brushes this regulator forms a unit, which transfers the field current …p. 211
Fig. 9 plus controlled regulatorp. 211
Fig. 10 minus controlled regulatorp. 211
Checking the generatorp. 212
+First one must check whether the generator is actually defective.p. 212
First one must check whether the generator is actually defective.p. 212
+This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 212
This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 212
When the engine is at rest, the charge control light must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously also possible.p. 212
The following points allow to contain faults in the voltage supply within certain limits.p. 212
+Cable connections on the generator OK?p. 212
Cable connections on the generator OK?p. 212
V-belt OK?p. 212
Generator ground (engine ground) OK?p. 212
Pre-excitation from vehicle electronics OK?p. 212
Only if all criteria mentioned above are OK, the fault must be in the generator itself. In this case it must be replaced or the following trouble shooting procedure must be performed.p. 212
Checking the pre-exciter circuit, D+ generatorp. 212
The most common reason for a 3-phase alternator not charging is a too low pre-excitation current. The pre- excitation current through connection D+ depends on the connected consumer (resistance), e.g. charge control light or relay of a MD+ engine con…p. 212
The pre-excitation current should be approx. 250 mA at 12 Volt. This corresponds with a 3 Watt light bulb or an equivalent combination of light bulb + resistance or an LED + resistance.p. 212
The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm.p. 212
In case of faults likep. 212
+charge control light stays onp. 212
charge control light stays onp. 212
no voltage increase, e.g. from 12 V to 14 Vp. 212
one should check that the correct resistance is assured.p. 212
Fig. 11 Connections on the three-phase alternator (exemplary design)p. 212
If the charge control light or LED stays on when the engine is running, you should proceed as follows:p. 212
+Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 212
+Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 212
(Fig. 11)p. 212
If this measure does not clear the fault, the alternator must be defective.p. 212
+Measuring the charge currentp. 213
Measuring the charge currentp. 213
+All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 213
All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 213
The generator ground connection must be OK.p. 213
During the measurement switch on as many consumers as possible.p. 213
+1 Attach the clip-on ammeter around the B+ line.p. 213
1 Attach the clip-on ammeter around the B+ line.p. 213
2 Gradually increase the engine speed.p. 213
3 The generator current must be at least as high as the total current of all switched on consumers.p. 213
Checking the rotorp. 213
+The rotor coils can only be measured in disassembled state.p. 213
The rotor coils can only be measured in disassembled state.p. 213
Fig. 12p. 213
+Measure the resistance between the sliprings.p. 213
Measure the resistance between the sliprings.p. 213
If the resistance does not comply with the factory specification, replace the rotor.p. 213
Use the resistance range of the continuity tester to check the continuity between slipring and core.p. 213
Replace the rotor if no infinite value is indicated.p. 213
+Factory specification for resistance: 2.8 to 5 OHM.p. 213
Factory specification for resistance: 2.8 to 5 OHM.p. 213
Checking the statorp. 214
+The stator coils can only be measured in disassembled state.p. 214
The stator coils can only be measured in disassembled state.p. 214
Fig. 13p. 214
+Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 214
Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 214
If the measuring value does not comply with the factory specification, replace the stator.p. 214
Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core.p. 214
Replace the stator if no infinite value is indicated.p. 214
+Factory specification for resistance: Less than 1 OHM.p. 214
Factory specification for resistance: Less than 1 OHM.p. 214
Checking the bearingsp. 214
Fig. 14p. 214
+Check whether the bearing rotates without obstruction.p. 214
Check whether the bearing rotates without obstruction.p. 214
Replace the bearing if it does not rotate properly.p. 214
Checking the regulator voltage with the generator testerp. 215
The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) thermal printer.p. 215
Fig. 15p. 215
The generator test assesses the regulator voltage and the ripple factor of the generator voltage.p. 215
+All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 215
All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 215
The generator ground connection must be OK.p. 215
The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 215
If possible switch off all consumers.p. 215
Perform the measurement at raised engine speed.p. 215
Checking the regulator voltage with the multimeterp. 215
Fig. 16p. 215
+All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 215
All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 215
The generator ground connection must be OK.p. 215
The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 215
If possible switch off all consumers.p. 215
Perform the measurement at raised engine speed.p. 215
The voltage (B+) should adjust itself at 13 to 14 Volt.p. 215
Checking the regulator in disassembled statep. 216
+On ap. 216
Bosch generatorp. 216
+Thep. 216
Delco-Remy generatorp. 216
+When testing the regulator one should be aware that there are 2 different types of regulators:p. 216
When testing the regulator one should be aware that there are 2 different types of regulators:p. 216
+If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon br…p. 216
If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon br…p. 216
D+ (vehicle wiring system)p. 216
D- (ground contact, mostly located on one of the fastening screws)p. 216
DF (Dynamo Field)p. 216
Fig. 17p. 216
+If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush is …p. 216
If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush is …p. 216
The basic function of a disassembled regulator can be easily tested with a 12V lamp and an adjustable D.C. power supply unit (0V … 20V).p. 216
Fig. 18p. 216
E.g minus controlled regulatorp. 216
+One connects the regulatorp. 216
(Fig. 18)p. 216
With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-.p. 216
Fig. 19p. 216
Fig. 20p. 216
+The illustrationsp. 216
(Fig. 19)p. 216
(Fig. 20)p. 216
Replacing carbon brushesp. 217
+On ap. 217
+On ap. 217
Bosch generatorp. 217
5 mmp. 217
+For replacing the carbon brushes in thep. 217
Delco- Remy generatorp. 217
5.23 Electric starterp. 217
+Generalp. 217
Generalp. 217
Combustion engines need to be started by means of a special device, because they are not able to start by themselves. Considerable resistances caused by compression and friction must thereby be overcome.p. 217
The starter converts the electric energy stored in the battery into mechanical energy. The starter can only generate its power when a battery with appropriate capacity is available.p. 217
Duties of the starter:p. 217
+to accelerate the combustion engine to start speed with lowest possible current consumption.p. 217
to accelerate the combustion engine to start speed with lowest possible current consumption.p. 217
establish the gear connection between starter and combustion engine.p. 217
to maintain this connection.p. 217
to switch on the starter current.p. 217
After starting the engine:p. 217
+to return the starter pinion to initial position.p. 217
to return the starter pinion to initial position.p. 217
to switch off the starter current.p. 217
Directly acting electric starterp. 218
+This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 218
This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 218
Fig. 21p. 218
+1 Magnetic switchp. 218
1 Magnetic switchp. 218
2 Armaturep. 218
3 Actuating leverp. 218
4 Freewheeling clutchp. 218
5 Resetting springp. 218
6 Brushp. 218
7 Exciting windingp. 218
8 Armaturep. 218
9 Collectorp. 218
+Ignition switch in position "START"p. 218
Ignition switch in position "START"p. 218
Fig. 22 Magnetic switch openp. 218
With the ignition switch (5) in "START" position current flows from the battery (10) through the holding winding (2) and the pick-up winding (3).p. 218
The armature (1) is magnetically picked up and forces the pinion (8) with the actuating lever (6) to engage with the ring gear (7).p. 218
+1 Armaturep. 218
1 Armaturep. 218
2 Holding windingp. 218
3 Pick-up windingp. 218
4 Magnetic switchp. 218
5 Ignition switchp. 218
6 Actuating leverp. 218
7 Ring gearp. 218
8 Pinionp. 218
9 Freewheeling clutchp. 218
10 (Batteryp. 218
+Pinion meshes with the ring gearp. 218
Pinion meshes with the ring gearp. 218
Fig. 23 Magnetic switch closedp. 218
When the pinion (3) meshes with the flywheel mounted ring gear (4) and the magnetic switch (2) is closed, a strong current flows from the battery (7) directly into the exciting winding (6) and the armature winding, but not into the pick-up winding.p. 218
This causes the armature (5) to rotate with high speed and drives the pinion, which in turn drives the ring gear (4) with a speed of 200 to 300 rpmp. 218
+1 Pick-up windingp. 218
1 Pick-up windingp. 218
2 Magnetic switchp. 218
3 Pinionp. 218
4 Ring gearp. 218
5 Armaturep. 218
6 Exciting windingp. 218
7 Batteryp. 218
+Engine runningp. 219
Engine runningp. 219
Fig. 24p. 219
Once the engine is running and drives the pinion (1) via the ring gear (2), the freewheeling clutch (3) will open and prevent the armature (4) from being driven by the engine.p. 219
+1 Pinionp. 219
1 Pinionp. 219
2 (Ring gearp. 219
3 Freewheeling clutchp. 219
4 Armaturep. 219
+Ignition switch releasedp. 219
Ignition switch releasedp. 219
Fig. 25p. 219
When releasing the ignition switch (6) it will return from position "START" to "ON" and interrupt the starter current circuit. Current will now flow from the battery (9) through the contact plate in the pick-up winding (3) and the holding winding (2)…p. 219
This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops.p. 219
+1 Armaturep. 219
1 Armaturep. 219
2 Holding windingp. 219
3 Pick-up windingp. 219
4 Resetting springp. 219
5 Magnetic switchp. 219
6 Ignition switchp. 219
7 Pinionp. 219
8 Ring gearp. 219
9 Batteryp. 219
Magnetic switchp. 220
Fig. 26 Direct acting electric motorp. 220
Fig. 27 Geared motorp. 220
Armature (4), contact plate (3) and armature guide (6) form a closed unit. When the ignition switch is turned to "START", the armature is picked up and causes the pinion of the clutch to disengage.p. 220
This causes the pinion and the ring gear to mesh, while the contact plate establishes a connection between the contacts, which enable the main current to flow into the armature. Once the ignition switch is opened, the resetting spring (5) will pull t…p. 220
+1 Holding windingp. 220
1 Holding windingp. 220
2 Pick-up windingp. 220
3 Contact platep. 220
4 Armaturep. 220
5 Resetting springp. 220
6 Armature guidep. 220
Freewheeling clutchp. 220
Fig. 28 Freewheeling clutchp. 220
The freewheeling clutch is designed in such a way, that the flow of force is automatically interrupted if the pinion (5) of the clutch rotates faster than the freewheeling ring (1) at higher engine speeds.p. 220
This makes sure that the armature will only drive the ring gear, but can never be driven by the engine.p. 220
+1 Freewheeling ringp. 220
1 Freewheeling ringp. 220
2 Rollerp. 220
3 Roller springp. 220
4 Splined shaftp. 220
5 Pinionp. 220
6 Pinionp. 220
Trouble shooting "Starter"p. 221
+The most frequent fault is definitely a fully discharged battery.p. 221
+The most frequent fault is definitely a fully discharged battery.p. 221
The most frequent fault is definitely a fully discharged battery.p. 221
+If the starter rotates too slowly, either the brushes are partly worn off, or parts of the exciter or armature winding is shorted. In some cases oxidized electric contacts or a soiled ground connection causing extremely high voltage losses in the overalp. 221
If the starter rotates too slowlyp. 221
+If the starter only emits a clicking sound,- either the magnetic switch is defect / soiled (dismantle and clean))- the main contacts on the magnetic switch are worn off / soiled (scrape off carefully with a file and clean)- the starter motor is defectivp. 221
If the starter only emits a clicking soundp. 221
Frequently a jammed return mechanism is the reason for a starter failure.p. 221
Occasionally worn contacts are found on the magnetic return switchp. 221
Defects on the actual starter motor including pinion and carbon brushes are very rare.p. 221
With a trouble shooting chart the faults in the starter system can be narrowed down. The starter system can only work when many conditions are fulfilled at the same time.p. 221
+Immobilizer deactivated?p. 221
Immobilizer deactivated?p. 221
Ignition switch OK?p. 221
Travel lever in correct position?p. 221
Emergency stop not actuated?p. 221
Battery sufficiently charged?p. 221
Battery poles OK?p. 221
Main battery fuse OK?p. 221
Main battery switch closed?p. 221
Main starter cable (terminal 30) OK?p. 221
Starter control cable (terminal 50) OK, voltage drop?p. 221
Ground cable OK?p. 221
Switching of magnetic switches OK?p. 221
The sequence of these tests is generally of no significance. It mainly depends on:p. 221
+the experience of the specialistp. 221
the experience of the specialistp. 221
the failure probability of the component to be tested and the testing effort for the respective part.p. 221
Only if all criteria mentioned above are OK, the fault must be in the starter itself. In this case it can be repaired or replaced.p. 221
Testing and measuring the starterp. 221
+Function control with the starter removedp. 221
Function control with the starter removedp. 221
+Fasten the starter to make sure that it will not come loose during the test.p. 221
Fasten the starter to make sure that it will not come loose during the test.p. 221
Fig. 29p. 221
+Connect a jumper lead between start terminal (1) and battery plus (2).p. 221
Connect a jumper lead between start terminal (1) and battery plus (2).p. 221
Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 221
+If the motor does not start, the starter is defective. Repair or replace the starter.p. 221
If the motor does not start, the starter is defective. Repair or replace the starter.p. 221
+Checking the magnetic switchp. 221
Checking the magnetic switchp. 221
Fig. 30p. 221
+Connect a jumper lead between start terminal (1) and battery plus (2).p. 221
Connect a jumper lead between start terminal (1) and battery plus (2).p. 221
Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 221
+If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 221
If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 221
+Continuity test for the magnetic switchp. 222
Continuity test for the magnetic switchp. 222
Fig. 31p. 222
+Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 222
Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 222
Replace the magnetic switch if no continuity is detected.p. 222
Removing and assembling the starterp. 222
+Removing the starterp. 222
Removing the starterp. 222
Fig. 32p. 222
+Switch the main battery switch to position "0"p. 222
+Switch the main battery switch to position "0"p. 222
(Fig. 32)p. 222
Fig. 33p. 222
+Disconnect the cable connections (terminal 30 and 50).p. 222
Disconnect the cable connections (terminal 30 and 50).p. 222
+Unscrew the screws (arrows)p. 222
(Fig. 33)p. 222
Take off the starter.p. 222
+Assembling the starterp. 223
Assembling the starterp. 223
Fig. 34p. 223
+Insert the starter.p. 223
Insert the starter.p. 223
+Tighten the screws (arrows)p. 223
(Fig. 34)p. 223
Connect the cables (terminal 30 and 50).p. 223
+Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 223
Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 223
+Terminal 30, 24p. 223
±4p. 223
Terminal 50, 1 – 1,3 Nmp. 223
To tightly tightened nuts can cause damage to starter components (e.g. cracks in the cover of the magnetic switch). Moisture entering into the starter can cause short circuit – or even cable fire.p. 223
Insufficiently tightened nuts can cause cable connections to come loose and thus short circuit – or even cable fire.p. 223
+6 Enginep. 225
+6 Enginep. 225
6.1 Diesel enginep. 226
+The road finishers of type BF600 are powered by a 4- cylinder Deutz diesel engine type TCD 2013.p. 226
The road finishers of type BF600 are powered by a 4- cylinder Deutz diesel engine type TCD 2013.p. 226
The engines are water cooled in-line engines with EMR3 electronics.p. 226
The engines are mainly designed in two-valve technology with turbo charging and intercooler. They are highly compact and come with a Deutz-Common-Rail injection system, called DCR in short.p. 226
All engines are designed with exhaust gas recirculation and thus reach emission values complying with EPA/ COM/ Tier/ stage lllp. 226
These engines are characterized by the following positive features:p. 226
+compact designp. 226
compact designp. 226
low noise levelp. 226
almost vibration free operationp. 226
low fuel consumptionp. 226
low exhaust emission EPA/COM IIlp. 226
high power densityp. 226
good access to all service points.p. 226
high reliabilityp. 226
low running costs,p. 226
long lifetimep. 226
Fig. 1 Deutz diesel engine TCD 2012 and 2013p. 226
6.2 Engine description TCD 2013, 4 and 6 cylinderp. 227
Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand sidep. 227
+1 Combustion air inlet (possibility to install a heating flange, optionally)p. 227
1 Combustion air inlet (possibility to install a heating flange, optionally)p. 227
2 Connection cabin heater ort compensation linep. 227
3 Fanp. 227
4 Generatorp. 227
5 Belt pulley on crankshaftp. 227
6 V-beltp. 227
7 Fuel lift pump drivep. 227
8 Fuel filterp. 227
9 Replaceable lubrication oil filterp. 227
10 Lubrication oil coolerp. 227
11 Possible installation of hydraulic pump or compressor (optional)p. 227
12 Lubrication oil return line crankcase ventilationp. 227
13 Central plug (for engine control)p. 227
14 Fuel control unitp. 227
15 High pressure pumpp. 227
16 Crankcase ventilation valvep. 227
17 Injectorp. 227
18 Lubrication oil filling neckp. 227
Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand sidep. 228
+1 Lubrication oil filling neck (optional)p. 228
1 Lubrication oil filling neck (optional)p. 228
2 Transmission connection (SAE)p. 228
3 Engine mountsp. 228
4 Lubrication oil drain plugp. 228
5 Lubrication oil sumpp. 228
6 Starter motorp. 228
7 Lubrication oil return line from exhaust gas turbo chargerp. 228
8 Exhaust turbo chargerp. 228
9 Coolant inletp. 228
10 Charge air connection to intercoolerp. 228
11 Coolant outletp. 228
12 Exhaust manifoldp. 228
13 Charge air linep. 228
14 Transport devicep. 228
Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand sidep. 229
+1 Combustion air inletp. 229
1 Combustion air inletp. 229
2 Lubrication oil filling neckp. 229
3 Transport devicep. 229
4 Fan hubp. 229
5 Generatorp. 229
6 Replaceable lubrication oil filterp. 229
7 Fuel filterp. 229
8 Lubrication oil sumpp. 229
9 Oil dipstickp. 229
10 Lubrication oil drain plugp. 229
11 Oil return line crankcase ventilationp. 229
12 Engine mountsp. 229
13 Transmission connection (SAE)p. 229
14 Central plug (for engine control)p. 229
15 High pressure pumpp. 229
16 Railp. 229
17 Crankcase ventilation valvep. 229
18 Injectorp. 229
Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand sidep. 230
+1 Exhaust turbo chargerp. 230
1 Exhaust turbo chargerp. 230
2 Exhaust manifoldp. 230
3 Starter motorp. 230
4 Lubrication oil flow to exhaust turbo chargerp. 230
5 Coolant drain plugp. 230
6 Coolant inletp. 230
7 Ribbed V-beltp. 230
8 Fan hubp. 230
9 Idler pulleyp. 230
10 Connection cabin heater ort compensation linep. 230
11 Ventilation line to compensation tankp. 230
12 Coolant line from engine to radiatorp. 230
6.3 Lubrication oil circuit TCD 2012 / 2013p. 231
Fig. 1 Lubrication oil diagramp. 231
+1 Lubrication oil sumpp. 231
1 Lubrication oil sumpp. 231
2 Lubrication oil suction pipep. 231
3 Lubrication oil pumpp. 231
4 Pressure relief valvep. 231
5 Lubrication oil coolerp. 231
6 Return flow check valve (only on 2012)p. 231
7 By-pass valvep. 231
8 By-pass valve lubrication oil filterp. 231
9 Pressure control valvep. 231
10 Replaceable lubrication oil filterp. 231
11 Main lubrication oil linesp. 231
12 Internally switched exhaust gas recirculationp. 231
13 Crankshaft bearingsp. 231
14 Conrod bearingsp. 231
15 Camshaft bearingsp. 231
16 Line to spray nozzlep. 231
17 Piston cooling nozzle with pressure maintaining valvep. 231
18 Plunger with rocker arm pulse lubricationp. 231
19 Push rod, lubrication oil supply for rocker arm lubricationp. 231
20 Rocker armp. 231
21 Return line to lubrication oil sumpp. 231
22 Lubrication oil flow to exhaust turbo chargerp. 231
23 Exhaust turbo chargerp. 231
24 Return line from compressor / hydraulic pump to crankcasep. 231
25 Compressor or hydraulic pumpp. 231
26 Lubrication oil line to crankshaft and camshaft, compressor / hydraulic pumpp. 231
27 Return flow from exhaust turbo chargerp. 231
6.4 Coolant circuit TCD 2012 / 2013p. 232
Fig. 1 Fuel diagramp. 232
+1 Coolant outlet on radiatorp. 232
1 Coolant outlet on radiatorp. 232
2 Thermostatp. 232
3 Coolant – supply to water pumpp. 232
4 Coolant pumpp. 232
5 Lubrication oil coolerp. 232
6 Cylinder coolingp. 232
7 Cylinder liner / head coolingp. 232
8 Coolant flow to heaterp. 232
9 Cabin heater (optional)p. 232
10 Coolant to thermostatp. 232
11 Connection for cabin heaterp. 232
12 Compensation linep. 232
13 Ventilation line to compensation tankp. 232
14 Coolant outlet to radiatorp. 232
15 Compensation tankp. 232
16 Compensation line to heat exchangerp. 232
6.5 Fuel system TCD 2012 / 2013p. 233
Fig. 1 Coolant diagramp. 233
+1 Fuel tank A= minimum distance 500 mmp. 233
1 Fuel tank A= minimum distance 500 mmp. 233
2 Fuel pre-filter with pre-pressure pumping possibility to fill the low pressure section (provided by customer)p. 233
3 Line to fuel lift pumpp. 233
4 Fuel lift pumpp. 233
5 Fuel filterp. 233
6 Fuel supply line to fuel control unitp. 233
7 Railp. 233
8 High pressure pumpp. 233
9 Fuel supply line to injectorp. 233
10 Injectorp. 233
11 FCU (Fuel Control Unit)p. 233
12 Fuel return flow on cylinder headp. 233
13 Fuel return line to fuel tankp. 233
14 Fuel lines from fuel control unit to high pressure pumps and Railp. 233
15 Fuel lift pump 2013p. 233
+Fuel pre-cleanerp. 234
Fuel pre-cleanerp. 234
Fig. 2 Fuel pre-cleanerp. 234
+1 Fuel supply to pumpp. 234
1 Fuel supply to pumpp. 234
2 Fuel return flow from FCU (Fuel Control Unit)p. 234
3 Manual fuel pump with bayonet lock to lock and unlockp. 234
4 Thermostat valve with shut-down leverp. 234
5 Filter cartridgep. 234
6 Possibility to connect an electric water level sensorp. 234
7 Drain tapp. 234
8 Water collecting bowlp. 234
9 Fuel inlet from fuel tankp. 234
10 Fuel return flow to fuel tankp. 234
A Electric water level sensorp. 234
6.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013p. 235
+The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" injection system, DCR in short.p. 235
The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" injection system, DCR in short.p. 235
The English term "Common Rail" indicates that the system is based on a common Rail. It describes the use of a common high pressure fuel line with corresponding branches to supply all cylinders with fuel.p. 235
The "Common Rail" injection is an injection system for combustion engines, in which a high pressure pump pressurizes the fuel to a high pressure level. The pressurized fuel fills a piping system, which is permanently under pressure while the engine i…p. 235
The general idea is the total isolation of the pressure generation from the actual injection process. An injection solely controlled by mapping is only possible under this condition. Injection timing and injection quantity are controlled by the engin…p. 235
The electric control is accomplished by the electronic control unit (EDC16) with EMR3, in dependence on the operating parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a r…p. 235
Fig. 1 TCD 2012 and 2013p. 235
Fig. 2 Schematic of the Deutz Common Rail System "DCR"p. 236
Under normal conditions the Rail pressure is between 300 and 1350 barp. 236
The PRV is set to 1600 barp. 236
If the PRV is defective or always open, the pressure in the Rail will only build up to max. 700 bar.p. 236
The Rail pressure must be at least 1.5 bar to start the diesel enginep. 236
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 236
The solenoid valve of the Fuel Control Unit (FCU) is dead, open towards the tank.p. 236
The voltage applied to the injectors is normally approx. 40 V.p. 236
FCU Fuel Control Unitp. 237
Fig. 3 Fuel Control Unit FCUp. 237
Two high pressure pumpsp. 237
Fig. 4 High pressure pumpp. 237
Injector)p. 238
Fig. 5 Injectorp. 238
6.7 Exhaust gas recirculation TCD 2012 / 2013p. 239
+In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 239
In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 239
On 4-cylinder 2-valve engines TCD 2012/2013 the exhaust gas recirculation has been realized internally through the intake valves, on 6-cylinder 2-valve engines through the exhaust valves. For this purpose the camshaft has been manufactured with an ad…p. 239
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013p. 239
6.8 Wastegate – charge pressure controller on TCD-enginesp. 240
+The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 240
The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 240
The Wastegate (exhaust gas bypass valve) is used to control the charge pressurep. 240
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust gas turbine into the exhaust withou…p. 240
The bypass valve is normally closedp. 240
Fig. 1 Exhaust gas turbocharger with Wastegatep. 240
Wastegate active, charge pressure control, i.e. bypass valve openp. 240
Fig. 1 Exhaust gas turbocharger with Wastegatep. 240
Wastegate on TCD 2013p. 241
Fig. 2 Exhaust gas turbocharger with Wastegatep. 241
6.9 Engine problemsp. 242
+Faultp. 242
Faultp. 242
+Possible causep. 242
Possible causep. 242
+Remedyp. 242
Remedyp. 242
+Engine does not start or starts poorlyp. 242
Engine does not start or starts poorlyp. 242
+Temperature below starting limitp. 242
Temperature below starting limitp. 242
Oil level too lowp. 242
Lubrication oil level too highp. 242
Lubrication oil cooler defectivep. 242
+Checkp. 242
Checkp. 242
Fill up lubrication oilp. 242
Check the lubrication oil level, drain off if necessaryp. 242
Checkp. 242
+Exhaust gas counter pressure too highp. 242
Exhaust gas counter pressure too highp. 242
+Checkp. 242
Checkp. 242
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 242
V-belt/ribbed V-belt (fuel pump in belt drive)p. 242
+check, whether torn or loosep. 242
check, whether torn or loosep. 242
+Engine oil with wrong SAE viscosity classp. 242
Engine oil with wrong SAE viscosity classp. 242
+Change the lubrication oilp. 242
Change the lubrication oilp. 242
+Fuel quality not as specified in the operating instructionsp. 242
Fuel quality not as specified in the operating instructionsp. 242
+Change the fuelp. 242
Change the fuelp. 242
+Air in the fuel systemp. 242
Air in the fuel systemp. 242
+Bleed the fuel systemp. 242
Bleed the fuel systemp. 242
+Battery defective or not chargedp. 242
Battery defective or not chargedp. 242
+Check the batteryp. 242
Check the batteryp. 242
+Cable to starter loose or oxidizedp. 242
Cable to starter loose or oxidizedp. 242
+Check cable connectionp. 242
Check cable connectionp. 242
+Starter defective or pinion does not engagep. 242
Starter defective or pinion does not engagep. 242
+Check starterp. 242
Check starterp. 242
+Engine does not start and diagnostic lamp flashingp. 242
Engine does not start and diagnostic lamp flashingp. 242
+Engine electronics prevent startingp. 242
Engine electronics prevent startingp. 242
+Check fault by fault code, repair as necessaryp. 242
Check fault by fault code, repair as necessaryp. 242
+Engine starts, but runs irregularly or misfiresp. 242
Engine starts, but runs irregularly or misfiresp. 242
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 242
V-belt/ribbed V-belt (fuel pump in belt drive)p. 242
+check, whether torn or loosep. 242
check, whether torn or loosep. 242
+Incorrect valve clearancep. 242
Incorrect valve clearancep. 242
+Adjustp. 242
Adjustp. 242
+Injector defectivep. 242
Injector defectivep. 242
+Replacep. 242
Replacep. 242
+Injection valve defectivep. 242
Injection valve defectivep. 242
+Check / replace the injection valvep. 242
Check / replace the injection valvep. 242
+Glow plug defectivep. 242
Glow plug defectivep. 242
+Replacep. 242
Replacep. 242
+Air in the fuel systemp. 242
Air in the fuel systemp. 242
+Bleed the fuel systemp. 242
Bleed the fuel systemp. 242
+Fuel pre-cleaner soiledp. 242
Fuel pre-cleaner soiledp. 242
+Clean/replacep. 242
Clean/replacep. 242
+Fuel quality not as specified in the operating instructionsp. 242
Fuel quality not as specified in the operating instructionsp. 242
+Change the fuelp. 242
Change the fuelp. 242
+Injection line leakingp. 242
Injection line leakingp. 242
+Check the injection linep. 242
Check the injection linep. 242
+Speed changes are possible and diagnostic lamp lightsp. 242
Speed changes are possible and diagnostic lamp lightsp. 242
+Engine electronics detected a system fault and activates a substitute speedp. 242
Engine electronics detected a system fault and activates a substitute speedp. 242
+Check fault by fault code, repair as necessaryp. 242
Check fault by fault code, repair as necessaryp. 242
+Engine overheating, temperature warning system respondsp. 243
Engine overheating, temperature warning system respondsp. 243
+Bleeding line cloggedp. 243
Bleeding line cloggedp. 243
+Clean ventilation linep. 243
Clean ventilation linep. 243
+Injector defectivep. 243
Injector defectivep. 243
+Replacep. 243
Replacep. 243
+Coolant heat exchanger soiledp. 243
Coolant heat exchanger soiledp. 243
+Cleanp. 243
Cleanp. 243
+Coolant pump defective (V-belt torn or loose)p. 243
Coolant pump defective (V-belt torn or loose)p. 243
+check, whether torn or loosep. 243
check, whether torn or loosep. 243
+Lack of coolantp. 243
Lack of coolantp. 243
+Fill upp. 243
Fill upp. 243
+Charge air pipe leakingp. 243
Charge air pipe leakingp. 243
+Check the charge air pipep. 243
Check the charge air pipep. 243
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 243
V-belt/ribbed V-belt (fuel pump in belt drive)p. 243
+check, whether torn or loosep. 243
check, whether torn or loosep. 243
+Lubrication oil filter soiledp. 243
Lubrication oil filter soiledp. 243
+Replacep. 243
Replacep. 243
+Lubrication oil level too lowp. 243
Lubrication oil level too lowp. 243
+Fill up lubrication oilp. 243
Fill up lubrication oilp. 243
+Lubrication oil level too highp. 243
Lubrication oil level too highp. 243
+Check the lubrication oil level, drain off if necessaryp. 243
Check the lubrication oil level, drain off if necessaryp. 243
Air filter clogged / exhaust turbocharger defectivep. 244
+Check/replacep. 244
Check/replacep. 244
+Charge air pipe leakingp. 244
Charge air pipe leakingp. 244
+Check charge air linep. 244
Check charge air linep. 244
+Injection valve defectivep. 244
Injection valve defectivep. 244
+Check / replace the injection valvep. 244
Check / replace the injection valvep. 244
+Injector defectivep. 244
Injector defectivep. 244
+Replacep. 244
Replacep. 244
+6.10 Check the engine oil levelp. 245
6.10 Check the engine oil levelp. 245
+Danger of injury!p. 245
+Danger of injury!p. 245
Danger of injury!p. 245
Support the engine hood for all maintenance and repair work.p. 245
+The machine must be parked horizontally with the engine shut down.p. 245
The machine must be parked horizontally with the engine shut down.p. 245
+Open the engine hood.p. 245
Open the engine hood.p. 245
Fig. 3p. 245
+Pull the dipstickp. 245
+Pull the dipstickp. 245
(Fig. 3)p. 245
Pull the dipstick back out again.p. 245
If the oil level is below the "MAX" mark fill in oil.p. 245
If the oil level is above the “MAX” mark, determine the cause and drain off oil.p. 245
+Before longer work periods you should always top the oil up to the "MAX"-mark.p. 245
Before longer work periods you should always top the oil up to the "MAX"-mark.p. 245
For quality and quantity of oil refer to the table of fuels and lubricantsp. 245
+6.11 Changing engine oil and oil filter cartridgep. 245
6.11 Changing engine oil and oil filter cartridgep. 245
+The oil change at 250 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 245
+The oil change at 250 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 245
The oil change at 250 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 245
Refer also to the chapter 5.2, fuels and lubricants.p. 245
Drain the engine oil only when the engine is warm.p. 245
+Danger of scalding!p. 245
Danger of scalding!p. 245
When draining off hot oil.p. 245
By hot oil when unscrewing the engine oil filter.p. 245
+Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.p. 245
Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.p. 245
Fig. 4p. 245
+Unscrew the drain hosep. 245
+Unscrew the drain hosep. 245
(Fig. 4)p. 245
Reassemble the drain hose.p. 245
Fig. 5p. 246
+Thoroughly clean the outside of the filter cartridgep. 246
+Thoroughly clean the outside of the filter cartridgep. 246
(Fig. 5)p. 246
Unscrew the filter cartridge using an appropriate filter wrench.p. 246
+Clean the sealing face on the filter carrier from any dirt.p. 246
Clean the sealing face on the filter carrier from any dirt.p. 246
Slightly oil the rubber seal on the new filter cartridge.p. 246
Fig. 6p. 246
+Turn the new filter cartridgep. 246
+Turn the new filter cartridgep. 246
(Fig. 6)p. 246
Tighten the filter element for another half turn.p. 246
Fig. 7p. 246
+Fill in new engine oilp. 246
+Fill in new engine oilp. 246
(Fig. 7)p. 246
For quality and quantity of oil refer to the table of fuels and lubricants.p. 246
+Tighten the oil filler cap properly.p. 246
Tighten the oil filler cap properly.p. 246
+Before starting crank the engine with the starter motor until the oil pressure warning light goes out.p. 246
Before starting crank the engine with the starter motor until the oil pressure warning light goes out.p. 246
+After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 246
After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 246
Check filter cartridge and drain hose for leaks after a short test run.p. 246
Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump.p. 246
Check the oil level again , if necessary fill up to the Max.-mark.p. 246
+6.12 Change the fuel pre-filter cartridgep. 247
6.12 Change the fuel pre-filter cartridgep. 247
+Fire hazard!p. 247
+Fire hazard!p. 247
Fire hazard!p. 247
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 247
Catch running out fuel, do not let it seep into the ground.p. 247
Do not inhale any fuel fumes.p. 247
Fig. 8p. 247
+Slacken the bleeding screwp. 247
+Slacken the bleeding screwp. 247
(Fig. 8)p. 247
Fig. 9p. 247
+Pull the cable off the water separator and unscrew the fuel filter cartridgep. 247
+Pull the cable off the water separator and unscrew the fuel filter cartridgep. 247
(Fig. 9)p. 247
Clean the sealing face on the filter carrier from any dirt.p. 247
Fig. 10p. 247
+Unscrew the water separator from the filter cartridgep. 247
+Unscrew the water separator from the filter cartridgep. 247
(Fig. 10)p. 247
Fig. 11p. 247
+Apply a thin coat of oil to the rubber seal of the water separator 1p. 247
+Apply a thin coat of oil to the rubber seal of the water separator 1p. 247
(Fig. 11)p. 247
Screw the water separator on by hand (2), until the seal contacts.p. 247
Tighten the water separator for another half turn (3).p. 247
Fill the filter cartridge with clean diesel fuel (4).p. 247
Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.p. 247
Tighten the filter element for another half turn (6).p. 247
Plug the water sensor cable back on.p. 247
Check the filter cartridge for leaks after a short test run.p. 247
+Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 247
Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 247
Therefore bleed the fuel system after changing the fuel pre-filter.p. 247
+Catch running out fuel and dispose of environmentally.p. 248
Catch running out fuel and dispose of environmentally.p. 248
Fig. 12p. 248
+With the bleeding pump loosened operate the hand pump manually, until fuel flows out of the slackened bleeding screwp. 248
+With the bleeding pump loosened operate the hand pump manually, until fuel flows out of the slackened bleeding screwp. 248
(Fig. 12)p. 248
Then tighten the bleeding screw while pumping.p. 248
+6.13 Change the fuel filter cartridgep. 248
6.13 Change the fuel filter cartridgep. 248
+Fire hazard!p. 248
+Fire hazard!p. 248
Fire hazard!p. 248
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 248
Catch running out fuel, do not let it seep into the ground.p. 248
Do not inhale any fuel fumes.p. 248
+Open and secure the floor flap in the operator's stand.p. 248
Open and secure the floor flap in the operator's stand.p. 248
Fig. 13p. 248
+Loosen and unscrew fuel filter cartridges 1 and 2p. 248
+Loosen and unscrew fuel filter cartridges 1 and 2p. 248
(Fig. 13)p. 248
Clean the sealing face on the filter carrier from any dirt.p. 248
Slightly oil the rubber seal on the new filter cartridge.p. 248
Fill the filter cartridge with clean diesel fuel.p. 248
Fig. 14p. 248
+Turn the new filter cartridgesp. 248
+Turn the new filter cartridgesp. 248
(Fig. 14)p. 248
Tighten the filter cartridges for another half turn.p. 248
Check the filter cartridge for leaks after a short test run.p. 248
+6.14 Check, clean the water separatorp. 249
6.14 Check, clean the water separatorp. 249
+Danger of injury!p. 249
+Danger of injury!p. 249
Danger of injury!p. 249
Support the engine hood for all maintenance and repair work.p. 249
+The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.p. 249
The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.p. 249
If a to high quantity is drained off, the filter must be refilled with fuel. See chapter "maintenance as required", bleeding the fuel system.p. 249
+Catch running out fuel and dispose of environmentally.p. 249
Catch running out fuel and dispose of environmentally.p. 249
+Open the access door on the right side of the vehicle.p. 249
Open the access door on the right side of the vehicle.p. 249
Fig. 15p. 249
+Slacken the drain plugp. 249
+Slacken the drain plugp. 249
(Fig. 15)p. 249
Tighten the drain plug again and check for leaks, if necessary replace the seal ring.p. 249
+6.15 Check the coolant levelp. 249
6.15 Check the coolant levelp. 249
+Danger of scalding!p. 249
+Danger of scalding!p. 249
Danger of scalding!p. 249
Fill up coolant only when the engine is cold.p. 249
+If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 249
If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 249
+Open the engine flap and secure it.p. 249
Open the engine flap and secure it.p. 249
Fig. 16p. 249
+Check the coolant levelp. 249
+Check the coolant levelp. 249
(Fig. 16)p. 249
+Top up coolant, if necessary.p. 249
Top up coolant, if necessary.p. 249
For quality of coolant refer to the chapter 5.2, fuels and lubricants.p. 249
+6.16 Change the coolantp. 250
6.16 Change the coolantp. 250
+Danger of scalding!p. 250
+Danger of scalding!p. 250
Danger of scalding!p. 250
Change the coolant only when the engine is cold.p. 250
+Catch running out coolant and dispose of environmentally.p. 250
Catch running out coolant and dispose of environmentally.p. 250
Fig. 17p. 250
+Unscrew the drain plugp. 250
+Unscrew the drain plugp. 250
(Fig. 17)p. 250
+Turn the drain plug tightly back in.p. 250
Turn the drain plug tightly back in.p. 250
Fig. 18p. 250
+Open the radiator capp. 250
+Open the radiator capp. 250
(Fig. 18)p. 250
For quality of coolant refer to the chapter 5.2, fuels and lubricants.p. 250
+Start the diesel engine and run it warm to operating temperature.p. 250
Start the diesel engine and run it warm to operating temperature.p. 250
Let the engine cool down and check the coolant level again, top up if necessary.p. 250
+6.17 Combustion air filter servicep. 250
6.17 Combustion air filter servicep. 250
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 250
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 250
Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 250
Fig. 19p. 250
+Maintenance of the dry air filter is due when control light gp. 250
(Fig. 19)p. 250
However, the filter cartridge must be replaced at the latest after two years.p. 250
After completion of the filter service reset the indicator piston back to "Zero" by pressing the button.p. 250
+Open the engine hood completely and secure it.p. 250
Open the engine hood completely and secure it.p. 250
+Removing the main filter elementp. 250
Removing the main filter elementp. 250
Fig. 20p. 250
+Loosen the strapp. 250
+Loosen the strapp. 250
(Fig. 20)p. 250
+Loosen both snap hooks on the housing cover and take the cover off.p. 250
Loosen both snap hooks on the housing cover and take the cover off.p. 250
Fig. 21p. 251
+Pull the main filter elementp. 251
+Pull the main filter elementp. 251
(Fig. 21)p. 251
+Cleaning the main filter elementp. 251
Cleaning the main filter elementp. 251
+If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years.p. 251
If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years.p. 251
The number of cleaning intervals of the main filter element can be marked on the safety element with a ball pen or a felt pen.p. 251
Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new filter cartridge.p. 251
Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine.p. 251
Replace the safety cartridge if the main filter element is defective!p. 251
Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.p. 251
Fig. 22p. 251
+Blow the cartridgep. 251
+Blow the cartridgep. 251
(Fig. 22)p. 251
Fig. 23p. 251
+Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 251
+Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 251
(Fig. 23)p. 251
+Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 251
Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 251
+Installing the main filter elementp. 251
Installing the main filter elementp. 251
+Slide the main filter element carefully into the housing.p. 251
Slide the main filter element carefully into the housing.p. 251
When closing the housing cover the main filter element is automatically forced in the correct position.p. 251
+Changing the safety filter elementp. 251
Changing the safety filter elementp. 251
+The safety filter element must not be cleaned and should not be used again after it has been removed.p. 251
The safety filter element must not be cleaned and should not be used again after it has been removed.p. 251
Break the seal only to replace the safety filter element.p. 251
The safety filter element must be replaced:p. 251
If the main filter element is defective.p. 251
after five service intervals of the filter cartridge,p. 251
at the latest after 2 years,p. 251
if the warning light comes on again after servicing the main filter cartridge.p. 251
+Remove the housing cover and pull the main filter element off.p. 251
Remove the housing cover and pull the main filter element off.p. 251
Fig. 24p. 252
+Pull the safety elementp. 252
+Pull the safety elementp. 252
(Fig. 24)p. 252
Push in a new safety filter element.p. 252
Reassemble main filter element and cover.p. 252
+Make sure that the cover locks engage correctly.p. 252
Make sure that the cover locks engage correctly.p. 252
+6.18 Adjusting the valve clearancep. 252
6.18 Adjusting the valve clearancep. 252
+We recommend to have this work carried out by trained personnel or our after sales service.p. 252
+We recommend to have this work carried out by trained personnel or our after sales service.p. 252
We recommend to have this work carried out by trained personnel or our after sales service.p. 252
Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 °C.p. 252
After a short test run check the engine for leaks.p. 252
+Attach the cranking device over the V-belt pulley fastening screws.p. 252
Attach the cranking device over the V-belt pulley fastening screws.p. 252
+Remove the valve covers.p. 252
Remove the valve covers.p. 252
Crank the engine, until the valves on cylinder 1 overlap.p. 252
The individual cylinder positions can be taken from the section "valve adjustment schematic".p. 252
+Adjusting the valve clearancep. 252
Adjusting the valve clearancep. 252
Fig. 25p. 252
+Loosen counter nut 1p. 252
+Loosen counter nut 1p. 252
(Fig. 25)p. 252
Fig. 26p. 253
Fig. 27p. 253
+Attach the rotation angle disc 3p. 253
+Attach the rotation angle disc 3p. 253
(Fig. 27)p. 253
(Fig. 26)p. 253
+Fix the magnet (5) of the rotation angle disc.p. 253
Fix the magnet (5) of the rotation angle disc.p. 253
+Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 253
Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 253
+Turn the rotation angle disc clockwise, until the specified angle is reached.p. 253
Turn the rotation angle disc clockwise, until the specified angle is reached.p. 253
+Intake valve INp. 253
Intake valve INp. 253
90° (0,4 mm)p. 253
Exhaust valves EXp. 253
150° (0,6 mm)p. 253
+Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 253
+Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 253
(Fig. 25)p. 253
Repeat this adjustment procedure an all other cylinders, after cranking the crankshaft accordingly.p. 253
+Assemble the cylinder head cover with a new gasket.p. 253
Assemble the cylinder head cover with a new gasket.p. 253
+Intake valve clearance adjustment in case of exhaust gas recirculationp. 253
Intake valve clearance adjustment in case of exhaust gas recirculationp. 253
Fig. 28p. 253
+Loosen counter nut 6p. 253
+Loosen counter nut 6p. 253
(Fig. 28)p. 253
Fig. 29p. 253
Fig. 30p. 253
+Attach the rotation angle disc 3p. 253
+Attach the rotation angle disc 3p. 253
(Fig. 29)p. 253
(Fig. 30)p. 253
+Fix the magnet 5p. 253
(Fig. 29)p. 253
+Turn the rotation angle disc 3p. 253
(Fig. 29)p. 253
+Turn the rotation angle disc 3p. 254
(Fig. 29)p. 254
+Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 6p. 254
(Fig. 28)p. 254
Repeat the adjustment procedure on each intake valve.p. 254
+Valve adjustment schematicp. 254
Valve adjustment schematicp. 254
+Firing order 1-3-4-2p. 254
Firing order 1-3-4-2p. 254
+Valvesp. 254
Valvesp. 254
+Cylinderp. 254
Cylinderp. 254
+overlappingp. 254
overlappingp. 254
+1p. 254
1p. 254
+3p. 254
3p. 254
+4p. 254
4p. 254
+2p. 254
2p. 254
+adjustmentp. 254
adjustmentp. 254
+4p. 254
4p. 254
+2p. 254
2p. 254
+1p. 254
1p. 254
+3p. 254
3p. 254
Overlapping of valves:p. 254
Exhaust valve not yet closed,p. 254
intake valve starts to open.p. 254
+With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 254
With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 254
This is no valve overlap condition!p. 254
+6.19 Adjusting the control piston playp. 254
6.19 Adjusting the control piston playp. 254
+This work must be performed after adjusting the valve clearance.p. 254
+This work must be performed after adjusting the valve clearance.p. 254
This work must be performed after adjusting the valve clearance.p. 254
+Crank the engine, until the valves on cylinder 1 overlap.p. 254
Crank the engine, until the valves on cylinder 1 overlap.p. 254
The cylinders to be adjusted can be taken from the section "Adjustment Schematic".p. 254
+Adjusting the control piston playp. 254
Adjusting the control piston playp. 254
Fig. 31p. 254
+Loosen counter nut 1p. 254
+Loosen counter nut 1p. 254
(Fig. 31)p. 254
Fig. 32p. 254
+Plug rotation angle disc and socket onto the setscrew 2p. 254
+Plug rotation angle disc and socket onto the setscrew 2p. 254
(Fig. 32)p. 254
+Fix the magnet of the rotation angle disc.p. 254
Fix the magnet of the rotation angle disc.p. 254
+Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 254
Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 254
+Turn the rotation angle disc anti-clockwise, until the specified angle is reached.p. 254
Turn the rotation angle disc anti-clockwise, until the specified angle is reached.p. 254
+Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 255
+Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 255
(Fig. 31)p. 255
Repeat this adjustmennt procedure on each control piston according to the crankshaft position.p. 255
+Assemble the cylinder head cover with a new gasket.p. 255
Assemble the cylinder head cover with a new gasket.p. 255
+Adjustment schematicp. 255
Adjustment schematicp. 255
+Firing order 1-3-4-2p. 255
Firing order 1-3-4-2p. 255
+Valvesp. 255
Valvesp. 255
+Cylinderp. 255
Cylinderp. 255
+overlappingp. 255
overlappingp. 255
+1p. 255
1p. 255
+3p. 255
3p. 255
+4p. 255
4p. 255
+2p. 255
2p. 255
+adjustmentp. 255
adjustmentp. 255
+4p. 255
4p. 255
+2p. 255
2p. 255
+1p. 255
1p. 255
+3p. 255
3p. 255
Overlapping of valves:p. 255
Exhaust valve not yet closed,p. 255
intake valve starts to open.p. 255
+With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 255
With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 255
This is no valve overlap condition!p. 255
+6.20 Clean the cooling fins on engine and hydraulic oil coolerp. 255
6.20 Clean the cooling fins on engine and hydraulic oil coolerp. 255
+Danger of injury!p. 255
+Danger of injury!p. 255
Danger of injury!p. 255
Perform cleaning work only after the engine has cooled down and with the engine stopped.p. 255
+Do not damage any cooling fins on the cooler core when cleaning.p. 255
Do not damage any cooling fins on the cooler core when cleaning.p. 255
+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. 255
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. 255
+Cleaning with compressed airp. 255
Cleaning with compressed airp. 255
Fig. 33p. 255
+Start to blow out from the exhaust side.p. 255
Start to blow out from the exhaust side.p. 255
+Blow radiator and hydraulic oil coolerp. 255
+Blow radiator and hydraulic oil coolerp. 255
(Fig. 33)p. 255
Fig. 34p. 256
+Start to blow out from the exhaust side.p. 256
Start to blow out from the exhaust side.p. 256
+Blow the intercoolerp. 256
+Blow the intercoolerp. 256
(Fig. 34)p. 256
+Cleaning with cold cleansing agentp. 256
Cleaning with cold cleansing agentp. 256
+Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 256
Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 256
+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. 256
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. 256
Run the engine warm for a while to avoid corrosion.p. 256
+6.21 Check the engine mountsp. 256
6.21 Check the engine mountsp. 256
Fig. 35p. 256
+Tighten fastenings of intake and exhaust manifoldsp. 256
+Tighten fastenings of intake and exhaust manifoldsp. 256
(Fig. 35)p. 256
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. 256
Retighten the fastening screws for oil sump and engine mounts.p. 256
+6.22 Replacing the crank case ventilation valvep. 257
6.22 Replacing the crank case ventilation valvep. 257
Fig. 36p. 257
+Replace the crank case ventilation valvep. 257
+Replace the crank case ventilation valvep. 257
(Fig. 35)p. 257
+6.23 Electronic injector test EMRp. 257
6.23 Electronic injector test EMRp. 257
+This work must only be performed by authorized service personnel.p. 257
+This work must only be performed by authorized service personnel.p. 257
This work must only be performed by authorized service personnel.p. 257
+6.24 Engine conservationp. 258
6.24 Engine conservationp. 258
+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. 258
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. 258
+6.25 Checking/replacing the heating generator toothed beltp. 258
+6.25 Checking/replacing the heating generator toothed beltp. 258
only with electric screed heatingp. 258
+Danger of injury!p. 258
+Danger of injury!p. 258
Danger of injury!p. 258
Work on the toothed belt must only be performed with the engine shut down.p. 258
+Checking the toothed beltp. 258
Checking the toothed beltp. 258
Fig. 37p. 258
+Inspect the entire circumference of the toothed beltp. 258
+Inspect the entire circumference of the toothed beltp. 258
(Fig. 37)p. 258
Check with thumb pressure whether the toothed belt can be depressed between the toothed belt pulleys, retighten if necessary.p. 258
+Tensioning the toothed beltp. 258
Tensioning the toothed beltp. 258
Fig. 38p. 258
+Loosen the counter nut on spindle 3p. 258
+Loosen the counter nut on spindle 3p. 258
(Fig. 38)p. 258
Turn the spindle to adjust the toothed belt tension.p. 258
+Replacing the toothed beltp. 258
Replacing the toothed beltp. 258
+Turn spindle 3p. 258
+Turn spindle 3p. 258
+Turn spindle 3p. 258
+Turn spindle 3p. 258
(Fig. 38)p. 258
Unscrew the fastening screws (1) from the pump flange.p. 259
Loosen the clamping screws of the bracket (2) on both sides.p. 259
Pull the pump flange away from the engine housing to a distance of approx. 50-60 mm.p. 259
Take off the old toothed belt.p. 259
Fit the new toothed belt to the toothed belt pulleys.p. 259
Carefully reassemble pump flange and bracket and tighten the fastening screws with the specified torque.p. 259
Tension the toothed belt as described above.p. 259
+Check the toothed belt tension after a running time of 30 minutes.p. 259
Check the toothed belt tension after a running time of 30 minutes.p. 259
+6.26 Check, tension, replace the V- beltp. 259
6.26 Check, tension, replace the V- beltp. 259
+Danger of accident!p. 259
+Danger of accident!p. 259
Danger of accident!p. 259
Perform this work only with the engine shut down!p. 259
+Check the V-beltp. 259
Check the V-beltp. 259
+Remove the guard.p. 259
Remove the guard.p. 259
Fig. 39p. 259
+Check the entire circumference of the V-beltsp. 259
+Check the entire circumference of the V-beltsp. 259
(Fig. 39)p. 259
Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm between the V-belt pulleys, retighten if necessary.p. 259
+Tensioning the generator V-beltp. 259
Tensioning the generator V-beltp. 259
Fig. 40p. 259
+Slightly slacken fastening screws 1, 2 and 3p. 259
+Slightly slacken fastening screws 1, 2 and 3p. 259
(Fig. 40)p. 259
Turn the tensioning screw (4), until the correct V- belt tension is achieved.p. 259
Retighten all fastening screws.p. 259
+Replacing the generator V-beltp. 260
Replacing the generator V-beltp. 260
+Slightly slacken the fastening screws 1, 2 and 3.p. 260
Slightly slacken the fastening screws 1, 2 and 3.p. 260
Screw in the tensioning screw (4).p. 260
Take the old V-belt off.p. 260
Fit the new V-belt to the V-belt pulleys.p. 260
Tension the V-belt as previously described.p. 260
+Check the V-belt tension after a running time of 30 minutes.p. 260
Check the V-belt tension after a running time of 30 minutes.p. 260
+Tightening the V-belt, coolant/fuel pumpp. 260
Tightening the V-belt, coolant/fuel pumpp. 260
Fig. 41p. 260
+Slacken the fastening screws 1 and 2p. 260
+Slacken the fastening screws 1 and 2p. 260
(Fig. 41)p. 260
Press the idler pulley in direction of arrow, until the correct V-belt tension is reached.p. 260
Retighten all fastening screws.p. 260
+Replacing the V-belt, coolant/fuel pumpp. 260
Replacing the V-belt, coolant/fuel pumpp. 260
+Take of the fan generator V-belt, see following section.p. 260
Take of the fan generator V-belt, see following section.p. 260
Slightly slacken fastening screws 1 and 2.p. 260
Press the idler pulley in opposite direction to the arrow completely against the engine.p. 260
Take the old V-belt off.p. 260
Fit the new V-belt to the V-belt pulleys.p. 260
Tension the V-belt as previously described.p. 260
Reassemble the generator V-belt.p. 260
+Check the V-belt tension after a running time of 30 minutes.p. 260
Check the V-belt tension after a running time of 30 minutes.p. 260
6.27 Special tools, Deutz engine (TCD 2013 2V)p. 261
+7 Service Training Hydraulicsp. 281
7 Service Training Hydraulicsp. 281
+Documentationp. 282
Generalp. 282
+Forewordp. 282
Forewordp. 282
+These training documents were prepared for the road finisher series BF 600 C. It shall help the service engineer to perform trouble shooting in the most effective way and to carry out any necessary repairs and adjustment work.p. 282
These training documents were prepared for the road finisher series BF 600 C. It shall help the service engineer to perform trouble shooting in the most effective way and to carry out any necessary repairs and adjustment work.p. 282
The road finisher BF 600 C is especially characterized by its simple operation, power, reliability and efficiency. Its robust design, the high material throughput, the variable paving width and its maximum tractive power make this machine first choic…p. 282
This documentation is by no means complete. Technical data and machine details that may have changed since the date of issue of the documentation must be updated by the corresponding trained while preparing the training course.p. 282
The chapter “Documentation” contains notes on further documents, which are additionally available for this machine.p. 282
+Documentationp. 282
Documentationp. 282
For the BOMAG machine described in this manual the following documentation is additionally available:p. 282
+The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.p. 282
The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.p. 282
+Operating and maintenance instructionsp. 282
Operating and maintenance instructionsp. 282
+Generalp. 282
Generalp. 282
+The road finisher BF 600 C is a heavy-duty machine for applications in asphalt construction.p. 282
The road finisher BF 600 C is a heavy-duty machine for applications in asphalt construction.p. 282
The BOMAG road finishers "BF" of this series 600 C are powered by water cooled Deutz diesel engines of series TCD 2013 L04 V2 Tier 3.p. 282
The travel, conveyor screw and gear pumps, which are directly driven by the engine, transfer the output power of the engine via hydrostatic circuits to travel drive, vibration motors for tampers and screeds, conveyor screw and scraper chain motors, f…p. 282
The machines are equipped with a crawler track assembly, which is driven by two axial piston drive motors with drive gear. The track tension is controlled by two hydraulic cylinders, which are supplied by the scraper chain pump with constant pressure…p. 282
When the engine is started and the brake releasing valve is actuated, the spring loaded multi-disc holding brakes in the travel gears are release by the hydraulic oil pressure generated by the scraper chain pump. With the brake releasing valve not ac…p. 282
The functions of the hopper side wall adjustment, the screed lock and the screw height adjustment have been realized in form of a series connection with a gear pump and integrated control valve. The valves for drawing point adjustment and screed up/d…p. 282
Both mobile screeds are hydraulically adjusted via the gear pump for the left hand scraper chain drive.p. 283
The vibration and tamper motors of screed/mobile screeds are both driven in parallel by a gear pump, whereby the vibration and tamper motors of the screed are additionally connected by a universal shaft. This ensures synchronous amplitudes and preven…p. 283
The fan motors are driven by engine mounted gear pumps. The gear pump also has the function of a hydraulic oil circulation pump, which pumps the hot hydraulic oil to the oil cooler and subsequently to the hydraulic oil filters.p. 283
The function and design of travel, adjustment, vibration, conveyor screw, scraper chain and fan drive are described in the corresponding following chapters in detail.p. 283
+Travel pumpsp. 284
Travel systemp. 284
+Travel systemp. 284
Travel systemp. 284
On the machine described in this documentation the travel system works with a closed hydraulic circuit, i.e. the hydraulic oil remains in the pressure lines and circulates permanently between travel pump and travel motor.p. 284
+The system is driven by a diesel engine, the output of which is transferred to the attached pumps (e.g. travel pumps and gear pumps)p. 284
(Fig. 42)p. 284
The most essential components of the travel system arep. 284
the two travel pumps with integrated safety elements,p. 284
a brake releasing valve,p. 284
the gear pumps to release the brakes and to tension the crawler tracks,p. 284
the travel motors with integrated safety elements,p. 284
andp. 284
the travel gears with integrated brakes.p. 284
Fig. 42 Travel drive – excerpt from hydraulic diagramp. 285
+1p. 286
1p. 286
+Brake releasing valvep. 286
Brake releasing valvep. 286
+7p. 286
7p. 286
+Travel motor, rightp. 286
Travel motor, rightp. 286
+2p. 286
2p. 286
+Travel pumpsp. 286
Travel pumpsp. 286
+8p. 286
8p. 286
+Electric-hydraulic two-point control, travel motor rightp. 286
Electric-hydraulic two-point control, travel motor rightp. 286
+3p. 286
3p. 286
+Diesel enginep. 286
Diesel enginep. 286
+9p. 286
9p. 286
+Electric-hydraulic two-point control, travel motor leftp. 286
Electric-hydraulic two-point control, travel motor leftp. 286
+4p. 286
4p. 286
+10p. 286
10p. 286
+Travel motor, leftp. 286
Travel motor, leftp. 286
+5p. 286
5p. 286
+11p. 286
11p. 286
+Travel gear, leftp. 286
Travel gear, leftp. 286
+6p. 286
6p. 286
+Travel gear, rightp. 286
Travel gear, rightp. 286
+12p. 286
12p. 286
+Valve block crawler track tensioningp. 286
Valve block crawler track tensioningp. 286
The travel pumps, which are linked to a tandem unit, have the function of supplying the complete travel drive with hydraulic oil.p. 286
The hydraulic oil is filtered by a charge pressure filter, which is fitted with an electric blockage monitoring facility and is hydraulically installed direftly after the charge pumps for the charge oil circuit. The charge circuit also supplies the c…p. 286
The gear pump at the auxiliary output of the engine is used for the brake releasing valve to release the hydraulically released spring accumulator multi-disc brakes and for the valve block for tensioning the crawler tracks.p. 286
The two travel motors are both flanged to a travel gear and can be switched between a fast speed range (low torque) and a slow speed range (high torque). Moreover, the travel motors are each hydraulically connected with an independently controllable …p. 286
+Brake circuit and valve block for crawler track tensioningp. 286
Brake circuit and valve block for crawler track tensioningp. 286
When the travel/working speed is returned towards neutral position or the travel direction is changed, the displacement of both or one travel pump is adjusted towards zero accordingly and the machine is hydraulically braked.p. 286
To avoid creeping movements of the machine, the machine is additionally equipped with spring accumulator multi-disc parking brakes in the travel gears. These close in neutral position of the travel lever and when the machine is stopped.p. 286
The spring accumulator multi-disc parking brake and the valve block for tensioning the crawler tracks are controlled via an electrically actuated 4/2-way solenoid valve (see section "Brake circuit"). In de-energized state the hydraulic oil supply fro…p. 286
+Travel pumpsp. 286
Travel pumpsp. 286
+Both rotor pumps are linked to a tandem unit.p. 286
Both rotor pumps are linked to a tandem unit.p. 286
Two swash plate operated axial piston pumps with variable displacement from Sauer Danfoss , type 90R42- KA57 serve as travel pumps.p. 286
The pumps are equipped with all control and safety elements needed for operation in a closed hydraulic circuit. These are:p. 286
+Charge pressure relief valve (2/p. 286
+Charge pressure relief valve (2/p. 286
(Fig. 43)p. 286
servo control with electric control via 4/3-way proportional valve (3),p. 286
variable displacement pump with control cylinder (5),p. 286
charge pump (6),p. 286
multi-function valves (7)p. 286
and ap. 286
+charge pressure filter (1).p. 286
charge pressure filter (1).p. 286
Fig. 43 Travel pumps – excerpt from hydraulic diagramp. 287
+1p. 287
1p. 287
+Charge pressure filterp. 287
Charge pressure filterp. 287
+5p. 287
5p. 287
+Variable displacement pumpp. 287
Variable displacement pumpp. 287
+2p. 287
2p. 287
+Charge pressure relief valvep. 287
Charge pressure relief valvep. 287
+6p. 287
6p. 287
+Charge pumpp. 287
Charge pumpp. 287
+3p. 287
3p. 287
+Servo control (4/3-way proportional valve)p. 287
Servo control (4/3-way proportional valve)p. 287
+7p. 287
7p. 287
+Multi-function valvesp. 287
Multi-function valvesp. 287
+4p. 287
4p. 287
+Diesel enginep. 287
Diesel enginep. 287
Fig. 44 Sectional view of travel pump (vertical)p. 288
+1p. 288
1p. 288
+High pressure portp. 288
High pressure portp. 288
+10p. 288
10p. 288
+Lateral swash plate guidancep. 288
Lateral swash plate guidancep. 288
+2p. 288
2p. 288
+Swashing lever hold-downp. 288
Swashing lever hold-downp. 288
+11p. 288
11p. 288
+Lateral swash plate guidancep. 288
Lateral swash plate guidancep. 288
+3p. 288
3p. 288
+Sliding blockp. 288
Sliding blockp. 288
+12p. 288
12p. 288
+Swash platep. 288
Swash platep. 288
+4p. 288
4p. 288
+Control pistonp. 288
Control pistonp. 288
+13p. 288
13p. 288
+Swash plate resetp. 288
Swash plate resetp. 288
+5p. 288
5p. 288
+Swashing leverp. 288
Swashing leverp. 288
+14p. 288
14p. 288
+Cylinder blockp. 288
Cylinder blockp. 288
+6p. 288
6p. 288
+Slipper padp. 288
Slipper padp. 288
+15p. 288
15p. 288
+Working pistonsp. 288
Working pistonsp. 288
+7p. 288
7p. 288
+Servo valve (4/3-way proportional valve)p. 288
Servo valve (4/3-way proportional valve)p. 288
+16p. 288
16p. 288
+End housingp. 288
End housingp. 288
+8p. 288
8p. 288
+Recirculationp. 288
Recirculationp. 288
+17p. 288
17p. 288
+Charge pumpp. 288
Charge pumpp. 288
+9p. 288
9p. 288
+Swash plate bearingp. 288
Swash plate bearingp. 288
+Function and designp. 289
Travel pump control unitp. 289
The travel pump control unit is an integral part of the pump housing and consists mainly of:p. 289
+Electro-hydraulic servo valve (7/p. 289
+Electro-hydraulic servo valve (7/p. 289
(Fig. 44)p. 289
(Fig. 45)p. 289
+swashing lever (5/p. 289
(Fig. 44)p. 289
control piston (4)p. 289
swash plate (12)p. 289
swash plate bearing (9)p. 289
swash plate reset (13).p. 289
Fig. 45 Cross-sectional drawing of travel pump controlp. 289
+1p. 289
1p. 289
+Servo valve (4/3-way proportional valve)p. 289
Servo valve (4/3-way proportional valve)p. 289
+2p. 289
2p. 289
+Pilot control valvep. 289
Pilot control valvep. 289
+Function and designp. 289
Function and designp. 289
+The pilot valve (2/p. 289
(Fig. 45)p. 289
(Fig. 44)p. 289
+The resulting displacement of the swash plate (12/p. 289
(Fig. 44)p. 289
(Fig. 46)p. 289
(Fig. 44)p. 289
(Fig. 46)p. 289
(Fig. 44)p. 289
(Fig. 46)p. 289
(Fig. 44)p. 289
Once the control piston has reached the position that is determined by the input signal, the travel pump displacement will remain at a constant level. If the input signal is changed, e.g. by reversing the travel direction, the control elements will b…p. 289
The hydraulic oil from the opposite control chamber flows directly back into the hydraulic oil tank, together with the leakage oil.p. 289
Since the travel pump control is spring centred, the swash plate will automatically return to neutral position when the engine is shut down or in case of a pressure drop in the charge circuit.p. 289
+As a measure to prevent metal to metal contact between the slipper pads (6/p. 289
(Fig. 44)p. 289
(Fig. 46)p. 289
+When operating the travel lever pressure builds up in the hydraulic lines between travel pump outlet and travel motor inlet, which is dependent on the load applied to the travel motors. This pressure keeps the boost check valve inside the multi-funct…p. 290
(Fig. 46)p. 290
+In order to be able to operate and control the travel system at all, the travel pump is equipped with a pump shaft driven charge pump (17/p. 290
(Fig. 44)p. 290
(Fig. 46)p. 290
The multi-function valve limits possibly occurring extreme pressure peaks to the setting of the valve. When these valves react, hydraulic oil flows out of the high pressure side and re-enters into the low pressure side. Since the cross-sections of th…p. 290
The bypass function (4) in the multi-function valve enables free circulation of the hydraulic oil, which may be needed when having to tow the machine. Opening of the bypass valve thereby causes a closed hydraulic circuit which bypasses the travel pum…p. 290
Fig. 46 Sectional view of travel pump (horizontal)p. 290
+1p. 290
1p. 290
+Multi-function valvep. 290
Multi-function valvep. 290
+6p. 290
6p. 290
+Drive shaftp. 290
Drive shaftp. 290
+2p. 290
2p. 290
+Cylinder blockp. 290
Cylinder blockp. 290
+7p. 290
7p. 290
+Valve platep. 290
Valve platep. 290
+3p. 290
3p. 290
+Working pistonsp. 290
Working pistonsp. 290
+8p. 290
8p. 290
+Multi-function valvep. 290
Multi-function valvep. 290
+4p. 290
4p. 290
+Slipper padp. 290
Slipper padp. 290
+9p. 290
9p. 290
+End housingp. 290
End housingp. 290
+5p. 290
5p. 290
+Swash platep. 290
Swash platep. 290
+10p. 290
10p. 290
+Charge pumpp. 290
Charge pumpp. 290
+Charge pumpp. 291
+Charge pumpp. 291
Charge pumpp. 291
+The charge pump (1/p. 291
(Fig. 47)p. 291
Fig. 47 Charge pump – detail from hydraulic diagramp. 291
+1p. 291
1p. 291
+Charge pumpp. 291
Charge pumpp. 291
The pump is driven by the engine via coupler gear and pump shaft of the corresponding travel pump.p. 291
The charge pump supplies the servo control of the variable displacement pump with the required amount of hydraulic oil through the charge pressure relief valve (see section "Charge pressure relief valve") and the charge pressure filter (see section "…p. 291
The boost check valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and flushing quantities.p. 291
It has the function of limiting the fed flow volume to the value set by the valve and to direct any excess oil to the hydraulic oil tank.p. 292
In order to be able to compensate for leak oil and flushing quantities in the closed hydraulic circuit, the hydraulic pressure in the low pressure side is identical with the charge pressure.p. 292
Due to the pressure drop in the hydraulic circuit caused by filtration, the charge pressure filter is installed as close as possible after the pump.p. 292
For safety reasons the charge pressure filter is equipped with a bypass valve (2), so that all machine functions can be maintained using unfiltered charge oil, if the filter is blocked. In this case the higher charge pressure will open the bypass val…p. 292
The condition of the charge pressure filter is electrically monitored by a sensor on the filter housing. In case of blockage the display and control elements on the operatorsstandwillindicatethatthechargepressurefilterneedstobecheckedandreplaced.'p. 292
+Multi-function valvep. 293
+Multi-function valvep. 293
Multi-function valvep. 293
+The travel pump is protected by two multi-function valves (1/p. 293
(Fig. 50)p. 293
Fig. 50 Multi-function valve – detail from hydraulic diagramp. 293
+1p. 293
1p. 293
+Multi-function valvep. 293
Multi-function valvep. 293
+4p. 293
4p. 293
+Boost check valvep. 293
Boost check valvep. 293
+2p. 293
2p. 293
+Zero-flow controlp. 293
Zero-flow controlp. 293
+5p. 293
5p. 293
+bypassp. 293
bypassp. 293
+3p. 293
3p. 293
+High pressure relief valvep. 293
High pressure relief valvep. 293
+Once the maximum system pressure in the travel circuit set by the multi-function valve (1/p. 293
(Fig. 51)p. 293
The boost check valve (3) in the corresponding low pressure side compensates for leak oil and oil quantities flushed out of the travel circuit. The boost check valve connects the charge circuit with the low pressure side, because the hydraulic pressu…p. 293
The bypass valve (4), which is also integrated in the multi-function valve, enables free circulation of the hydraulic oil, which is required, e.g. when towing the machine. Opening the bypass valve directly connects both pressure lines, making sure th…p. 293
+The travel motor is connected with the corresponding travel pump via the high pressure ports A and B (see section "Travel pumps"). Hydraulic oil flows under high pressure through the adjustable valve segment (2/p. 295
(Fig. 53)p. 295
+Since the angle of the cylinder block to the drive shaft can be changed via the electric hydraulic two-point control (8 or 9) to two different positions, the piston strokes of the working pistons are of different length, depending on the angle. With …p. 295
(Fig. 53)p. 295
Once the respective working piston (4) has reached its lower dead centre, the slot in the valve plate takes it over to the low pressure side . The pressurized working pistons on the high pressure side now move this particular working piston back to i…p. 295
The synchronizing shaft (5) ensures uniform rotation of output shaft and cylinder block. The ball joints of the working pistons run in journal bearings, which are pressed into the outer shaft by two tapered roller bearings (7).p. 296
The flushing pressure relief valve (12) flushes hydraulic oil out of the low pressure side into the motor housing to cool the high pressure circuit and to remove contaminants from the circuit. The flushing pressure relief valve limits the flushing pr…p. 296
Fig. 53 Sectional view of travel motorp. 296
+1p. 296
1p. 296
+Setting of swashing anglep. 296
Setting of swashing anglep. 296
+8p. 296
8p. 296
+Output shaftp. 296
Output shaftp. 296
+2p. 296
2p. 296
+Valve segmentp. 296
Valve segmentp. 296
+9p. 296
9p. 296
+RPM-sensorp. 296
RPM-sensorp. 296
+3p. 296
3p. 296
+Bearing platep. 296
Bearing platep. 296
+10p. 296
10p. 296
+Working piston (moving towards the top dead centre)p. 296
Working piston (moving towards the top dead centre)p. 296
+4p. 296
4p. 296
+Working piston (moving towards the bottom dead centre)p. 296
Working piston (moving towards the bottom dead centre)p. 296
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature household of the hydraulic system is maintained at a permissible level.p. 297
The travel gears are planetary gears for mobile equipment made by Bonfiglioli, type 707 C3B, which are each driven by a flange mounted travel motor (see section "Travel motors").p. 298
Function and designp. 298
The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor is also flanged with its housing side to the travel gear and meshes directly with the drive shaft. A second flange on the bearing axl…p. 298
The drive shaft transfers the travel motor torque via an external gearing to the spur wheel of the planet gear set. The rotation is transferred from the spur wheel via the sun gear to the planet gears, which are rotably mounted in tapered roller bear…p. 298
The drive shaft also carries the hydraulically released spring accumulator multi-disc parking brake, which is supplied with pressurized hydraulic oil from the gear pump, when the brake releasing valve is operated. This hydraulic oil pressure works ag…p. 298
Fig. 56 Travel gear, left hand sidep. 299
+Brake circuitp. 299
Brake circuitp. 299
+The brake circuit mainly consists of a brake releasing valve (1/p. 299
(Fig. 57)p. 299
Fig. 57 Brake circuit – excerpt from hydraulic diagramp. 300
With the 4/2-way solenoid valve (5) not actuated and when the engine is shut down, the parking brakes (see section "Travel gears") are automatically closed by the spring loaded disc packages, so that the machine is no longer able to drive or to creep…p. 300
With the 4/2-way solenoid valve actuated the spring force of the parking brake is overcome by the hydraulic oil pressure generated by the scraper chain pump, so that the brake discs are forced apart against the spring pressure, releasing the drive sh…p. 300
The pressure switch (1), which is also installed after the 4/2-way solenoid valve, is actuated by hydraulic oil pressure and transmits the corresponding switching state to the vehicle control in form of an electric signal.p. 300
+Brake valve and solenoid valve for crawler tracksp. 301
Brake valve and solenoid valve for crawler tracksp. 301
Fig. 58 Detail from hydraulic diagramp. 301
Fig. 59 Brake valve and solenoid valve for crawler tracksp. 301
+1p. 301
1p. 301
+Valve block for crawler tracksp. 301
Valve block for crawler tracksp. 301
+4p. 301
4p. 301
+Brake valvep. 301
Brake valvep. 301
+2p. 301
2p. 301
+Pressure test port, crawler track rightp. 301
Pressure test port, crawler track rightp. 301
+5p. 301
5p. 301
+Pressure switchp. 301
Pressure switchp. 301
+Brake pressure gaugep. 302
Brake pressure gaugep. 302
Fig. 60 Pressure gaugep. 302
+Valve block for track tensioningp. 302
Valve block for track tensioningp. 302
Fig. 61 Valve block for track tensioning – detail from hydraulic diagramp. 303
+1p. 303
1p. 303
+Tensioning cylinderp. 303
Tensioning cylinderp. 303
+2p. 303
2p. 303
+Check valvesp. 303
Check valvesp. 303
+3p. 303
3p. 303
+Pressure relief valvesp. 303
Pressure relief valvesp. 303
Function and designp. 303
The valve block for track tensioning is controlled via a 4/2-way solenoid valve (brake releasing valve, see section "Brake circuit"). Only by operating the 4/2-way solenoid valve, the valve block for track tensioning is supplied with hydraulic oil fr…p. 303
+Due to the function of the two fixed pressure relief valves (3/p. 303
(Fig. 61)p. 303
+Test and adjustment pointsp. 304
Test and adjustment pointsp. 304
+Travel pump, tandem unit with gear pump on through-drive sidep. 304
Travel pump, tandem unit with gear pump on through-drive sidep. 304
Fig. 62 Travel pump, excerpt from hydraulic diagramp. 304
Fig. 63 Travel pump, tandem pump bottom viewp. 304
+Posp. 304
Posp. 304
+Designationp. 304
Designationp. 304
+Position in hydraulic diagramp. 304
Position in hydraulic diagramp. 304
+Position in wiring diagramp. 304
Position in wiring diagramp. 304
+Measuring values and switching pointsp. 304
Measuring values and switching pointsp. 304
+1p. 304
1p. 304
+Travel pump for travel drive, right hand sidep. 304
Travel pump for travel drive, right hand sidep. 304
+3p. 304
3p. 304
+2p. 304
2p. 304
Travel pump for travel drive, left hand sidep. 304
+4p. 304
4p. 304
+Pressure test ports, travel pump for travel drive right hand sidep. 305
Pressure test ports, travel pump for travel drive right hand sidep. 305
Fig. 64 Pressure test port high pressure, travel pump for travel lever right hand sidep. 305
Pressure test ports, travel pump for travel lever left hand sidep. 305
Fig. 65 Pressure test port high pressure, travel pump for travel drive left hand sidep. 305
+Posp. 305
Posp. 305
+Designationp. 305
Designationp. 305
+Position in hydraulic diagramp. 305
Position in hydraulic diagramp. 305
+Position in wiring diagramp. 305
Position in wiring diagramp. 305
+Measuring values and switching pointsp. 305
Measuring values and switching pointsp. 305
+1p. 305
1p. 305
+Pressure test port, high pressure – right hand side, forward-reversep. 305
Pressure test port, high pressure – right hand side, forward-reversep. 305
+3- M1p. 305
3- M1p. 305
+Pressure override 410bar, HP 440barp. 305
Pressure override 410bar, HP 440barp. 305
+2p. 305
2p. 305
+Pressure test port, high pressure – right hand side, forward-reversep. 305
Pressure test port, high pressure – right hand side, forward-reversep. 305
+3- M2p. 305
3- M2p. 305
+Pressure override 410bar, HP 440barp. 305
Pressure override 410bar, HP 440barp. 305
+3p. 305
3p. 305
+Pressure test port, high pressure – left hand side, forward-reversep. 305
Pressure test port, high pressure – left hand side, forward-reversep. 305
+4- M1p. 305
4- M1p. 305
+Pressure override 410bar, HP 440barp. 305
Pressure override 410bar, HP 440barp. 305
+4p. 305
4p. 305
+Pressure test port, high pressure – left hand side, forward-reversep. 305
Pressure test port, high pressure – left hand side, forward-reversep. 305
+4- M2p. 305
4- M2p. 305
+Pressure override 410bar, HP 440barp. 305
Pressure override 410bar, HP 440barp. 305
+Charge pressure test port on travel pumpp. 306
Charge pressure test port on travel pumpp. 306
Fig. 66 Travel pump, excerpt from hydraulic diagramp. 306
Fig. 67 Charge pressure test port on travel pumpp. 306
+Posp. 306
Posp. 306
+Designationp. 306
Designationp. 306
+Position in hydraulic diagramp. 306
Position in hydraulic diagramp. 306
+Position in wiring diagramp. 306
Position in wiring diagramp. 306
+Measuring values and switching pointsp. 306
Measuring values and switching pointsp. 306
+1p. 306
1p. 306
+Pressure test port, charge pressurep. 306
Pressure test port, charge pressurep. 306
+4- M3p. 306
4- M3p. 306
+25 barp. 306
25 barp. 306
+Travel pump control control, proportional valvep. 307
Travel pump control control, proportional valvep. 307
Fig. 68 Proportional controlp. 307
Fig. 69 Travel drive – excerpt from wiring diagramp. 307
Unlike the travel drive, the actuator drive is an open hydraulic circuit, i.e. the gear pump (10) draws hydraulic oil from the hydraulic oil tank, delivers it to the consumers and subsequently through the cooler back to the tank.p. 313
+The essential components are gear pump (10/p. 313
(Fig. 77)p. 313
Fig. 77 Actuation – excerpt from hydraulic diagramp. 313
+1p. 314
1p. 314
+Load control system screed (L.S.C.)p. 314
Load control system screed (L.S.C.)p. 314
+8p. 314
8p. 314
+Screw height adjustmentp. 314
Screw height adjustmentp. 314
+2p. 314
2p. 314
+Screed up/downp. 314
Screed up/downp. 314
+9p. 314
9p. 314
+Diesel enginep. 314
Diesel enginep. 314
+3p. 314
3p. 314
+Draw point adjustment screed rightp. 314
Draw point adjustment screed rightp. 314
+10p. 314
10p. 314
+Gear pumpp. 314
Gear pumpp. 314
+4p. 314
4p. 314
+Draw point adjustment screed leftp. 314
Draw point adjustment screed leftp. 314
+11p. 314
11p. 314
+Volume flow distributionp. 314
Volume flow distributionp. 314
+5p. 314
5p. 314
+Hopper side wall adjustment, leftp. 314
Hopper side wall adjustment, leftp. 314
+12p. 314
12p. 314
+Service blockp. 314
Service blockp. 314
+6p. 314
6p. 314
+Hopper side wall adjustment, rightp. 314
Hopper side wall adjustment, rightp. 314
+13p. 314
13p. 314
+Crown adjustmentp. 314
Crown adjustmentp. 314
+7p. 314
7p. 314
+Screed interlockp. 314
Screed interlockp. 314
+14p. 314
14p. 314
+Levelling blockp. 314
Levelling blockp. 314
The outer gear pump of the tandem pump unit serves the hydraulic oil supply for the actuator circuit with service and levelling blocks.p. 314
A flow divider at the inlet of the service block divides the volume flow and thus enables parallel operation of service and levelling block.p. 314
A pressure relief valve with fixed setting protects the service block against overpressure. The functions of hopper side wall, right and left, screed interlock as well as screw height adjustment can be electrically controlled via a 4/3-way solenoid v…p. 314
A flow divider in the levelling block in turn divides the hydraulic oil flow for load control system screed (L.C.S.), screed up/down as well as draw point and crown adjustment. The functions for screed up/down, draw point adjustment right and left as…p. 314
Lifting/lowering the screed is accomplished by two hydraulic cylinders at the rear ends of both side arms. These control cylinders lift/lower or release the screed by means of the screed load control system (L.C.S.) intervening in the hydraulic circu…p. 314
The crown adjustment enables individual adjustment of the screed with respect to the mobile screeds as required for the "transverse profile" of the finished road. By well directed adjustment of the screed and changing the lateral inclination angle of…p. 314
+Service blockp. 314
Service blockp. 314
+Control with solenoid valves in an open circuitp. 314
Control with solenoid valves in an open circuitp. 314
+The service block (18/p. 314
(Fig. 78)p. 314
Fig. 78 Service block – excerpt from hydraulic diagramp. 315
+1p. 315
1p. 315
+Diesel enginep. 315
Diesel enginep. 315
+48p. 315
48p. 315
+Check valves, unlockable (locking block)p. 315
Check valves, unlockable (locking block)p. 315
+7p. 315
7p. 315
+Gear pumpp. 315
Gear pumpp. 315
+18p. 315
18p. 315
+Service blockp. 315
Service blockp. 315
+37p. 315
37p. 315
+Adjusting cylinders for screw height adjustmentp. 315
Adjusting cylinders for screw height adjustmentp. 315
+19 and 33p. 315
19 and 33p. 315
+Volume flow and pressure relief valvep. 315
Volume flow and pressure relief valvep. 315
+40p. 315
40p. 315
+Adjusting cylinder hopper wall adjustment, right and leftp. 315
Adjusting cylinder hopper wall adjustment, right and leftp. 315
+26p. 315
26p. 315
+Pressure relief valve, retraction of screedp. 315
Pressure relief valve, retraction of screedp. 315
+55p. 315
55p. 315
+4/3-way solenoid valve, adjusting cylinder for screw height adjustmentp. 315
4/3-way solenoid valve, adjusting cylinder for screw height adjustmentp. 315
+62 and 63p. 315
62 and 63p. 315
+Screed adjustment, extension/retractionp. 315
Screed adjustment, extension/retractionp. 315
+Service blockp. 315
Service blockp. 315
The service block is hydraulically installed between gear pump and the downstream levelling block. The consumers are the adjusting cylinders for hopper side wall adjustment (4), the screed control (62 and 63) and the screw height adjustment.p. 315
Solenoid valvep. 316
Function and designp. 316
+The 4/3-way solenoid valves mounted to the service block are solenoid operated spool valves to control the start, stop and direction of the volume flow to the connected consumers. The spool valves mainly consist of the hosing (2/p. 316
(Fig. 79)p. 316
If not operated the control piston (3) is retained in middle or initial position by the resetting springs (4) and thus blocks both the high and low pressure lines.. Operation of the control piston is indicated by a lighting diode on the corresponding…p. 316
When the magnet is excited, the plunger (1) applies a force to the control piston, pushes it out of its resting position to the corresponding end position. The flow direction is released and the the oil volume flows into the adjusting cylinder and ad…p. 316
+Besides the actual spool valve the 4/3-way solenoid valve of the screw height adjustment contains additional unlockable check valves (48/p. 316
+Check valves, adjusting cylinder draw point, rightp. 320
Check valves, adjusting cylinder draw point, rightp. 320
+15p. 320
15p. 320
+One-way restrictorp. 320
One-way restrictorp. 320
+8p. 320
8p. 320
+4/3-way solenoid valve, adjusting cylinder draw point, rightp. 320
4/3-way solenoid valve, adjusting cylinder draw point, rightp. 320
+Function and designp. 320
Function and designp. 320
The levelling block is hydraulically arranged between service block (see section "Service block") and the consumers connected in series. The consumers are the screed load control system (L.C.S.), the control cylinders for screed up/down (3), the cont…p. 321
The high and low pressure lines of the service block are internally connected and combined as central ports.p. 321
+The 4/3-way solenoid valves (8, 11 and 14) mounted to the service block are solenoid operated spool valves to control the start, stop and direction of the volume flow to the connected consumers. The spool valves mainly consist of the hosing (2/p. 321
(Fig. 85)p. 321
If not operated the control piston (3) is retained in middle or initial position by the resetting springs (4) and thus blocks both the high and low pressure lines..p. 321
Operation of the control piston is indicated by a lighting diode on the corresponding connecting plug. When the magnet is excited, the plunger (1) applies a force to the control piston, pushes it out of its resting position to the corresponding end p…p. 321
The complete screed levelling is accomplished via one flow divider, which is installed upstream of the 4/3-way solenoid valves. This flow divider divides the volume flows for screed up/down, screed draw point adjustment, screed load control system (L…p. 321
With the 4/3-way solenoid valve (crown adjustment) operated, the same piston sides of both cylinders are supplied with pressure through the locking valve in the high pressure side. The increasing hydraulic oil pressure level in the high pressure line…p. 321
The load control system (L.S.C.) consists of two 2/2-way solenoid valves, each with a downstream installed pressure relief valve with different, freely adjustable pressure ranges. The pressure reduction of one of these pressure relief valves in "floa…p. 321
The adjusting cylinders for screed up/down are equipped with a one-way restrictor (15) integrated in the high pressure line of the 4/3-way solenoid valve. The throttle restricts the hydraulic oil flow to a pre-set volume, to accommodate sensitive adj…p. 321
The 4/3-way solenoid valve of the screed draw point adjustment is additionally equipped with unlockable locking valves (4 and 7) in high and low pressure lines. With this the adjusting cylinders for draw point can be permanently held in position.p. 321
+Solenoid valve, screed draw point adjustment left, up/downp. 324
Solenoid valve, screed draw point adjustment left, up/downp. 324
+17 / 38p. 324
17 / 38p. 324
+A17 / B17, Page 150p. 324
A17 / B17, Page 150p. 324
+0 / 24 Vp. 324
0 / 24 Vp. 324
+3p. 324
3p. 324
+Solenoid valve, screed draw point adjustment right, up/downp. 324
Solenoid valve, screed draw point adjustment right, up/downp. 324
+17 / 38p. 324
17 / 38p. 324
+B15 / A15, Page 160.1p. 324
B15 / A15, Page 160.1p. 324
+0 / 24 Vp. 324
0 / 24 Vp. 324
+4p. 324
4p. 324
+Pressure test port, screed height adjustmentp. 324
Pressure test port, screed height adjustmentp. 324
+17 / M1p. 324
17 / M1p. 324
+Pressure relief valve 175 barp. 324
Pressure relief valve 175 barp. 324
+5p. 324
5p. 324
+Pressure test port, draw point adjustmentp. 324
Pressure test port, draw point adjustmentp. 324
+17 / M2p. 324
17 / M2p. 324
+Pressure relief valve 120 barp. 324
Pressure relief valve 120 barp. 324
+Design and function of a gear pumpp. 324
Design and function of a gear pumpp. 324
The driven gear of the actuator pump is connected with the drive shaft of the flanged on vibration and tamper pump via the drive shaft (7). The drive force of the engine is transferred to the pump drive shafts via the coupling gear.p. 324
The tooth flank spaces between inside wall of the pump housing and bearing plate faces form the displacement chambers (5) for the hydraulic oil to be delivered. When the pump is running the displacement chambers transport hydraulic oil from the sucti…p. 324
+The bearing plates (9 and 10/p. 324
(Fig. 89)p. 324
The hydraulic oil in between the tooth flanks is discharged from the tooth gaps by the meshing gears, before the rotation would transport it back to the suction side (see arrows). Due to this displacement and the bearing plate (1) on the pressure sid…p. 325
Fig. 89 Sectional drawing of gear pumpp. 325
+1p. 325
1p. 325
+Coverp. 325
Coverp. 325
+6p. 325
6p. 325
+Gearp. 325
Gearp. 325
+2p. 325
2p. 325
+Seals and gasketsp. 325
Seals and gasketsp. 325
+7p. 325
7p. 325
+Drive shaftp. 325
Drive shaftp. 325
+3p. 325
3p. 325
+Housingp. 325
Housingp. 325
+8p. 325
8p. 325
+Flangep. 325
Flangep. 325
+4p. 325
4p. 325
+Gear (driven)p. 325
Gear (driven)p. 325
+9p. 325
9p. 325
+Bearing platep. 325
Bearing platep. 325
+5p. 325
5p. 325
+Displacement chamberp. 325
Displacement chamberp. 325
+10p. 325
10p. 325
+Bearing platep. 325
Bearing platep. 325
+Scraper chain motorsp. 326
Scraper chain drivep. 326
+Scraper chain and conveyor screw drivep. 326
Scraper chain and conveyor screw drivep. 326
The scraper chain and conveyor screw drives on right and left hand sides are two open hydraulic circuits.p. 326
+The essential components of these circuits are the two gear pumps (5 and 7), a valve block (14) consisting of 4/ 3-way solenoid valves and the hydraulic motors for scraper chain right/left (43) and conveyor screw right/left (44).p. 326
(Fig. 90)p. 326
Fig. 90 Scraper chain and conveyor screw drive – excerpt from hydraulic diagramp. 326
+1p. 326
1p. 326
+Diesel enginep. 326
Diesel enginep. 326
+14p. 326
14p. 326
+Valve block, scraper chain and conveyor screwp. 326
Valve block, scraper chain and conveyor screwp. 326
+5p. 326
5p. 326
+Gear pump, scraper chain and conveyor screw, right hand sidep. 326
Gear pump, scraper chain and conveyor screw, right hand sidep. 326
+43p. 326
43p. 326
+Scraper chain motor, right and leftp. 326
Scraper chain motor, right and leftp. 326
+7p. 326
7p. 326
+Gear pump, scraper chain and conveyor screw, left hand sidep. 326
Gear pump, scraper chain and conveyor screw, left hand sidep. 326
+44p. 326
44p. 326
+Scraper chain motor, right and leftp. 326
Scraper chain motor, right and leftp. 326
The scraper chain and conveyor screw pump for the right hand side (7) is located at the front face of the diesel engine. It is the first gear pump on the tandem unit.p. 327
The gear pump for the left hand side (5) is located on the travel pump through-drive side.p. 327
The pump deliver oil to the valve block (14).p. 327
The hydraulic oil supply for the conveyor screw motor, right or left, is accomplishes via a separately controllable 4/3-way proportional valve in the valve block, right or left. It enables individual speeds of right or left hand motor, depending on t…p. 327
For the right or left scraper chain drives 4/3-way control valves are used instead of the 4/3-way proportional valves.p. 327
Valve arrangementp. 327
Fig. 91 Valves underneath the floor platep. 327
+Valve block for scraper chain and conveyor screwp. 328
Valve block for scraper chain and conveyor screwp. 328
Fig. 92 Valve blockp. 328
+Posp. 328
Posp. 328
+Designationp. 328
Designationp. 328
+Position in hydraulic diagramp. 328
Position in hydraulic diagramp. 328
+Position in wiring diagramp. 328
Position in wiring diagramp. 328
+Measuring values and switching pointsp. 328
Measuring values and switching pointsp. 328
+1p. 328
1p. 328
+Proportional valve, conveyor screw leftp. 328
Proportional valve, conveyor screw leftp. 328
+14p. 328
14p. 328
+A/B 24,p. 328
A/B 24,p. 328
Page 100p. 328
+Prop.p. 328
Prop.p. 328
+2p. 328
2p. 328
+Proportional valve, conveyor screw rightp. 328
Proportional valve, conveyor screw rightp. 328
+14p. 328
14p. 328
+A/B 23,p. 328
A/B 23,p. 328
Page 100.1p. 328
+Prop.p. 328
Prop.p. 328
+3p. 328
3p. 328
+Solenoid valve, scraper chain leftp. 328
Solenoid valve, scraper chain leftp. 328
+14p. 328
14p. 328
+A/B 26,p. 328
A/B 26,p. 328
Page 90p. 328
+0 /24 Vp. 328
0 /24 Vp. 328
+4p. 328
4p. 328
+Solenoid valve, scraper chain rightp. 328
Solenoid valve, scraper chain rightp. 328
+14p. 328
14p. 328
+A/B 25,p. 328
A/B 25,p. 328
Page 90.1p. 328
+0 /24 Vp. 328
0 /24 Vp. 328
+5p. 328
5p. 328
+Pressure test port, conveyor screw leftp. 328
Pressure test port, conveyor screw leftp. 328
+14 / MA4p. 328
14 / MA4p. 328
+A/B 24,p. 328
A/B 24,p. 328
+PRV, 260 barp. 328
PRV, 260 barp. 328
+6p. 328
6p. 328
+Pressure test port, conveyor screw rightp. 328
Pressure test port, conveyor screw rightp. 328
+14 / MA1p. 328
14 / MA1p. 328
+A/B 23,p. 328
A/B 23,p. 328
+PRV, 260 barp. 328
PRV, 260 barp. 328
+7p. 328
7p. 328
+Pressure test port, scraper chain leftp. 328
Pressure test port, scraper chain leftp. 328
+14 / MA2p. 328
14 / MA2p. 328
+A/B 26,p. 328
A/B 26,p. 328
+PRV, 190 barp. 328
PRV, 190 barp. 328
+8p. 328
8p. 328
+Pressure test port, scraper chain rightp. 328
Pressure test port, scraper chain rightp. 328
+14 / MA3p. 328
14 / MA3p. 328
+A/B 25,p. 328
A/B 25,p. 328
+PRV, 190 barp. 328
PRV, 190 barp. 328
Gear pumps assigned fro left and right hand sidesp. 329
Fig. 93 Scraper chain and conveyor screw pump, left hand sidep. 329
Fig. 94 Scraper chain and conveyor screw pump, right hand sidep. 329
+The working principle of the orbital motor is based on an internal gear, which consists of a displacement ring (1/p. 330
(Fig. 96)p. 330
The pressurizing (example: Pos. 6) of the working chambers (example: Pos. 4) controlled by the distributor valve (7) causes a planetary movement of the rotor, whereby one tooth of the rotor is moved from one tooth gap in the displacement ring to the …p. 330
Both the distributor valve and the reduction gear are synchronously driven by the output torque or output speed transmitted by the rotor to the universal shaft (valve drive shaft) and the axle shaft.p. 330
Fig. 96 Operational principle (pressurizing of working chamber – control slot)p. 330
+1p. 330
1p. 330
+Displacement ringp. 330
Displacement ringp. 330
+5p. 330
5p. 330
+Pressurizing of working chamber – control slotp. 330
Pressurizing of working chamber – control slotp. 330
+2p. 330
2p. 330
+Working chamber (low pressure side)p. 330
Working chamber (low pressure side)p. 330
+6p. 330
6p. 330
+Control slot (high pressure side)p. 330
Control slot (high pressure side)p. 330
+3p. 330
3p. 330
+Rotorp. 330
Rotorp. 330
+7p. 330
7p. 330
+Distributor valve (plate valve)p. 330
Distributor valve (plate valve)p. 330
+4p. 330
4p. 330
+Working chamber (high pressure side)p. 330
Working chamber (high pressure side)p. 330
+8p. 330
8p. 330
+Control slot (low pressure side)p. 330
Control slot (low pressure side)p. 330
A balancing plate equalizes the hydraulic forces around the distributor valve and thus ensures high efficiency of the motor.p. 330
Due to the 3-chamber design of the orbital motor, high pressure has no direct connection to the inside of the housing or the radial seal, which enables an external leak oil connection and operation with very high return flow pressures.p. 331
The orbital motor is equipped with two additional check valves, which make sure that the pressure acting on the radial seal does not exceed the pressure in the low pressure line.p. 331
Due to the movement of the drive shaft in the housing no seals can be fitted at the shaft outlet, so that the leak oil from the orbital motor flows into the reduction gear, from where it is returned to the hydraulic oil tank.p. 331
+Test and adjustment pointsp. 332
Test and adjustment pointsp. 332
+Scraper chain motor rightp. 332
Scraper chain motor rightp. 332
Fig. 97 Detail from hydraulic diagramp. 332
Fig. 98 Pressure test port M – valve block scraper chain motor, rightp. 332
+1p. 332
1p. 332
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 332
+Hydraulic test casep. 332
[BOMAG Part-No.: 079 930 01]p. 332
+4p. 332
4p. 332
+Scraper chain motor, rightp. 332
Scraper chain motor, rightp. 332
+2p. 332
2p. 332
+High pressure gauge (600 bar)p. 332
High pressure gauge (600 bar)p. 332
+5p. 332
5p. 332
+Service door side, rightp. 332
Service door side, rightp. 332
Scraper chain motor leftp. 333
Fig. 99 Pressure test port – excerpt from hydraulic diagramp. 333
Fig. 100 Scraper chain motor, leftp. 333
+1p. 333
1p. 333
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 333
+Hydraulic test casep. 333
[BOMAG Part-No.: 079 930 01]p. 333
+2p. 333
2p. 333
+High pressure gauge (600 bar)p. 333
High pressure gauge (600 bar)p. 333
+4p. 333
4p. 333
+Scraper chain motor, leftp. 333
Scraper chain motor, leftp. 333
+Conveyor screw motorp. 334
+Conveyor screw motorp. 334
Conveyor screw motorp. 334
+The conveyor screw motors (1/p. 334
(Fig. 101)p. 334
Fig. 101 Conveyor screw motor – excerpt from hydraulic diagramp. 334
+1p. 334
1p. 334
+Leakage linep. 334
Leakage linep. 334
+3p. 334
3p. 334
+Check valvep. 334
Check valvep. 334
+2p. 334
2p. 334
+Conveyor screw motor with reduction gear;p. 334
Conveyor screw motor with reduction gear;p. 334
+3-way flow divider (pressure compensated)p. 334
+3-way flow divider (pressure compensated)p. 334
3-way flow divider (pressure compensated)p. 334
+The flow divider installed between variable displacement pump and adjusting drive (see section "Adjusting drive") (6/p. 334
The constant and pressure compensated volumetric flow required for the main flow (7) is generated by the control valve (2), which is integrated in the supply (4), after a minimum pressure differential exists between feed and main flow. The excess par…p. 334
A pressure relief valve (1) downstream of the control valve protects the main flow to the adjusting drive against pressure peaks. If the pressure of the main flow rises above the setting of the pressure relief valve, the pressure relief valve of the …p. 334
This hydraulic oil discharged into the bypass also serves the charge pressure supply for the conveyor screw pump (see section "Conveyor screw drive").p. 335
+The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "Pp. 335
+The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "Pp. 335
1p. 335
2p. 335
+The bearing plates (9 and 10(p. 335
(Fig. 104)p. 335
Due to this displacement and the bearing plate (1) on the pressure side it is assured that the hydraulic oil is transported from the suction to the pressure side, almost without any losses. The system pressure loaded pressure fields press the bearing…p. 335
Fig. 104 Sectional drawing – gear motorp. 336
+1p. 336
1p. 336
+Coverp. 336
Coverp. 336
+6p. 336
6p. 336
+Gear (driven)p. 336
Gear (driven)p. 336
+2p. 336
2p. 336
+Seals and gasketsp. 336
Seals and gasketsp. 336
+7p. 336
7p. 336
+Drive shaftp. 336
Drive shaftp. 336
+3p. 336
3p. 336
+Housingp. 336
Housingp. 336
+8p. 336
8p. 336
+Flangep. 336
Flangep. 336
+4p. 336
4p. 336
+Gear (driving)p. 336
Gear (driving)p. 336
+9p. 336
9p. 336
+Bearing platep. 336
Bearing platep. 336
+5p. 336
5p. 336
+Displacement chamberp. 336
Displacement chamberp. 336
+10p. 336
10p. 336
+Bearing platep. 336
Bearing platep. 336
+Valve blocksp. 337
Vibration and tamper drivep. 337
+Vibration and tamper drivep. 337
Vibration and tamper drivep. 337
Similar to the scraper chain drive, the vibration and tamper drive is also an open hydraulic circuit.p. 337
+The essential components are the vibration (4) and tamper pumps (5) flanged to the auxiliary output of the engine (7/p. 337
(Fig. 105)p. 337
Fig. 105 Vibration and tamper drive – excerpt from hydraulic diagramp. 337
+1p. 337
1p. 337
+Valve block for vibration drivep. 337
Valve block for vibration drivep. 337
+9p. 337
9p. 337
+Vibration motor, mobile screed rightp. 337
Vibration motor, mobile screed rightp. 337
+2p. 337
2p. 337
+Valve block for tamper operationp. 337
Valve block for tamper operationp. 337
+10p. 337
10p. 337
+Vibration motor, screed rightp. 337
Vibration motor, screed rightp. 337
+3p. 337
3p. 337
+11p. 337
11p. 337
+Tamper motor, screed rightp. 337
Tamper motor, screed rightp. 337
+4p. 337
4p. 337
+Vibration pumpp. 337
Vibration pumpp. 337
+12p. 337
12p. 337
+Tamper motor, screed leftp. 337
Tamper motor, screed leftp. 337
+5p. 337
5p. 337
+Tamper pumpp. 337
Tamper pumpp. 337
+13p. 337
13p. 337
+Vibration motor, screed rightp. 337
Vibration motor, screed rightp. 337
+6p. 337
6p. 337
+Tandem pumpp. 337
Tandem pumpp. 337
+14p. 337
14p. 337
+Vibration motor, mobile screed leftp. 337
Vibration motor, mobile screed leftp. 337
+7p. 337
7p. 337
+Diesel enginep. 337
Diesel enginep. 337
+15p. 337
15p. 337
+Tamper motor, mobile screed leftp. 337
Tamper motor, mobile screed leftp. 337
+8p. 337
8p. 337
+Tamper motor, mobile screed rightp. 337
Tamper motor, mobile screed rightp. 337
The vibration and tamper pumps are joined together to a tandem gear pump and are driven by the auxiliary output of the diesel engine (7). The vibration and tamper pumps (4 and 5) supply the corresponding hydraulic circuits for vibration and tamping w…p. 337
This hydraulic oil supply runs through separate valve blocks for vibration drive (1) and tamper drive (2). For pressure limitation these are equipped with a pressure relief valve with fixed setting for pressure override and one proportionally adjusta…p. 337
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. These eccentrically mounted connecting rods cause an up and down movement of the…p. 337
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. 338
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. 338
+Valve blocksp. 338
Valve blocksp. 338
+The two valve blocks (1 and 6/p. 338
+The two valve blocks (1 and 6/p. 338
(Fig. 106)p. 338
Fig. 106 Valve blocks – excerpt from hydraulic diagramp. 338
+Vibration motors (screed and mobile screeds)p. 338
Vibration motors (screed and mobile screeds)p. 338
+Function and designp. 338
Function and designp. 338
The corresponding valve block is hydraulically installed between the pumps (see section "Vibration and tamper pump" and the correspondingly controlled motors for screed and mobile screeds (7 and 8) (see section "Vibration and tamper motors").p. 338
The high and low pressure lines of the valve block are internally connected and combined as central ports.p. 338
+The oil volume flowing in through port "A" is subsequently regulated by the adjustable throttle of the 3-way flow divider, which is controlled by the proprtional solenoid (1/p. 339
(Fig. 106)p. 339
+Vibration and tamper motorsp. 339
+Vibration and tamper motorsp. 339
Vibration and tamper motorsp. 339
+The vibration and tamper motors on screed and both mobile screeds are gear motors from Sauer Danfoss, type SNM2. The vibration motors (1, 3, 6 and 15/p. 339
(Fig. 108)p. 339
Fig. 108 Vibration and tamper motors – excerpt from hydraulic diagramp. 340
+Pressure relief valve, vibration motor rightp. 340
Pressure relief valve, vibration motor rightp. 340
+18p. 340
18p. 340
+Low pressure line, tamper motorsp. 340
Low pressure line, tamper motorsp. 340
Function and designp. 340
+The hydraulic oil delivered by the respective pump flows through the upstream valve block into the high pressure side "Pp. 340
1p. 340
+The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "Pp. 340
+The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "Pp. 340
1p. 340
2p. 340
+The bearing plates (9 and 10(p. 340
(Fig. 104)p. 340
Due to this displacement and the bearing plate (1) on the pressure side it is assured that the hydraulic oil is transported from the suction to the pressure side, almost without any losses. The system pressure loaded pressure fields press the bearing…p. 340
Fig. 109 Sectional drawing – gear motorp. 341
+1p. 341
1p. 341
+Coverp. 341
Coverp. 341
+6p. 341
6p. 341
+Gear (driven)p. 341
Gear (driven)p. 341
+2p. 341
2p. 341
+Seals and gasketsp. 341
Seals and gasketsp. 341
+7p. 341
7p. 341
+Drive shaftp. 341
Drive shaftp. 341
+3p. 341
3p. 341
+Housingp. 341
Housingp. 341
+8p. 341
8p. 341
+Flangep. 341
Flangep. 341
+4p. 341
4p. 341
+Gear (driving)p. 341
Gear (driving)p. 341
+9p. 341
9p. 341
+Bearing platep. 341
Bearing platep. 341
+5p. 341
5p. 341
+Displacement chamberp. 341
Displacement chamberp. 341
+10p. 341
10p. 341
+Bearing platep. 341
Bearing platep. 341
+Test and adjustment pointsp. 342
Test and adjustment pointsp. 342
+Valve block vibration and tamper operationp. 342
Valve block vibration and tamper operationp. 342
Fig. 110 Vibration and tamper operation – excerpt from hydraulic diagramp. 342
+Valve block vibration and tamperp. 343
Valve block vibration and tamperp. 343
Fig. 111 Valve block, vibration and tamperp. 343
+Posp. 343
Posp. 343
+Designationp. 343
Designationp. 343
+Position in hydraulic diagramp. 343
Position in hydraulic diagramp. 343
+Position in wiring diagramp. 343
Position in wiring diagramp. 343
+Measuring values and switching pointsp. 343
Measuring values and switching pointsp. 343
+1p. 343
1p. 343
+Proportional valve, tamperp. 343
Proportional valve, tamperp. 343
+15p. 343
15p. 343
+A8, Page 200p. 343
A8, Page 200p. 343
+Prop.p. 343
Prop.p. 343
+2p. 343
2p. 343
+Proportional valve, vibrationp. 343
Proportional valve, vibrationp. 343
+15p. 343
15p. 343
+A7, Page 200p. 343
A7, Page 200p. 343
+Prop.p. 343
Prop.p. 343
+3p. 343
3p. 343
+Pressure test port, tamperp. 343
Pressure test port, tamperp. 343
+15 / M1p. 343
15 / M1p. 343
+Pressure relief valve 200 barp. 343
Pressure relief valve 200 barp. 343
+4p. 343
4p. 343
+Pressure test port, vibrationp. 343
Pressure test port, vibrationp. 343
+15 / Mp. 343
15 / Mp. 343
+Pressure relief valve 180 barp. 343
Pressure relief valve 180 barp. 343
+Pressure test port Mp. 344
+Pressure test port Mp. 344
1p. 344
+Fig. 112 Pressure test port Mp. 344
1p. 344
+Fig. 113 Pressure test port Mp. 344
1p. 344
+1p. 344
1p. 344
+Vibration motor screed, rightp. 344
Vibration motor screed, rightp. 344
+4p. 344
4p. 344
+High pressure gauge (600 bar)p. 344
High pressure gauge (600 bar)p. 344
+2p. 344
2p. 344
+Screed, rightp. 344
Screed, rightp. 344
+5p. 344
5p. 344
+Pressure test port M1p. 344
+Pressure test port Mp. 344
1p. 344
+3p. 344
3p. 344
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 344
+Hydraulic test casep. 344
[BOMAG Part-No.: 079 930 01]p. 344
+Pressure test port Mp. 345
+Pressure test port Mp. 345
1p. 345
+Fig. 114 Pressure test port Mp. 345
1p. 345
+Fig. 115 Pressure test port Mp. 345
1p. 345
+1p. 345
1p. 345
+Screed, leftp. 345
Screed, leftp. 345
+4p. 345
4p. 345
+High pressure gauge (600 bar)p. 345
High pressure gauge (600 bar)p. 345
+2p. 345
2p. 345
+Vibration motor screed, leftp. 345
Vibration motor screed, leftp. 345
+5p. 345
5p. 345
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 345
+Hydraulic test casep. 345
[BOMAG Part-No.: 079 930 01]p. 345
+3p. 345
3p. 345
+Pressure test port M1p. 345
+Pressure test port Mp. 345
1p. 345
+Pressure test port Mp. 346
+Pressure test port Mp. 346
1p. 346
+Fig. 116 Pressure test port Mp. 346
1p. 346
+Fig. 117 Pressure test port Mp. 346
1p. 346
+1p. 346
1p. 346
+Screedp. 346
Screedp. 346
+4p. 346
4p. 346
+Mobile screed, rightp. 346
Mobile screed, rightp. 346
+2p. 346
2p. 346
+Tamper motor mobile screed, rightp. 346
Tamper motor mobile screed, rightp. 346
+5p. 346
5p. 346
+High pressure gauge (600 bar)p. 346
High pressure gauge (600 bar)p. 346
+3p. 346
3p. 346
+Pressure test port M1p. 346
+Pressure test port Mp. 346
1p. 346
+6p. 346
6p. 346
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 346
+Hydraulic test casep. 346
[BOMAG Part-No.: 079 930 01]p. 346
+Pressure test port Mp. 347
+Pressure test port Mp. 347
1p. 347
+Fig. 118 Pressure test port Mp. 347
1p. 347
+Fig. 119 Pressure test port Mp. 347
1p. 347
+1p. 347
1p. 347
+Tamper motor mobile screed, leftp. 347
Tamper motor mobile screed, leftp. 347
+4p. 347
4p. 347
+High pressure gauge (600 bar)p. 347
High pressure gauge (600 bar)p. 347
+2p. 347
2p. 347
+Pressure test port M1p. 347
+Pressure test port Mp. 347
1p. 347
+5p. 347
5p. 347
+Hydraulic test case [BOMAG Part-No.: 079 930 01]p. 347
+Hydraulic test casep. 347
[BOMAG Part-No.: 079 930 01]p. 347
+3p. 347
3p. 347
+Screedp. 347
Screedp. 347
+6p. 347
6p. 347
+Mobile screed, leftp. 347
Mobile screed, leftp. 347
+Adjustment points valve block vibration and valve block tampingp. 348
Adjustment points valve block vibration and valve block tampingp. 348
Fig. 120 Adjustment point valve block vibration and valve block tamping – excerpt from hydraulic diagramp. 348
+Pressure relief valve vibration (shown) and tamping (not shown)p. 348
Pressure relief valve vibration (shown) and tamping (not shown)p. 348
+4p. 348
4p. 348
+Valve block for vibrationp. 348
Valve block for vibrationp. 348
+2p. 348
2p. 348
+Solenoid valve tamping (control symbol no.: A8)p. 348
Solenoid valve tamping (control symbol no.: A8)p. 348
+5p. 348
5p. 348
+Solenoid valve vibration (control symbol no.: A7)p. 348
Solenoid valve vibration (control symbol no.: A7)p. 348
+3p. 348
3p. 348
+Valve block for tampingp. 348
Valve block for tampingp. 348
+6p. 348
6p. 348
+Opening, maintenance flap driver's standp. 348
Opening, maintenance flap driver's standp. 348
+Adjustment point for vibration drive mobile screed, rightp. 349
Adjustment point for vibration drive mobile screed, rightp. 349
Fig. 122 Adjustment point for vibration drive mobile screed, right – excerpt from hydraulic diagramp. 349
Fig. 123 Adjustment point for vibration drive mobile screed, rightp. 349
+1p. 349
1p. 349
+Vibration motor, mobile screed rightp. 349
Vibration motor, mobile screed rightp. 349
+3p. 349
3p. 349
+Exciter housingp. 349
Exciter housingp. 349
+2p. 349
2p. 349
+Pressure relief valvep. 349
Pressure relief valvep. 349
+4p. 349
4p. 349
+Mobile screed, rightp. 349
Mobile screed, rightp. 349
+Adjustment point for vibration drive mobile screed, leftp. 350
Adjustment point for vibration drive mobile screed, leftp. 350
Fig. 124 Adjustment point for vibration drive mobile screed, left – excerpt from hydraulic diagramp. 350
Fig. 125 Adjustment point for vibration drive mobile screed, leftp. 350
+1p. 350
1p. 350
+Pressure relief valvep. 350
Pressure relief valvep. 350
+3p. 350
3p. 350
+Exciter housingp. 350
Exciter housingp. 350
+2p. 350
2p. 350
+Vibration motorp. 350
Vibration motorp. 350
+4p. 350
4p. 350
+Mobile screed, leftp. 350
Mobile screed, leftp. 350
+Adjustment point for tamper drive mobile screed, rightp. 351
Adjustment point for tamper drive mobile screed, rightp. 351
Fig. 126 Adjustment point for tamper drive mobile screed, right – excerpt from hydraulic diagramp. 351
Fig. 127 Adjustment point for tamper drive mobile screed, rightp. 351
+1p. 351
1p. 351
+Tamper motor, mobile screed rightp. 351
Tamper motor, mobile screed rightp. 351
+3p. 351
3p. 351
+Pressure relief valvep. 351
Pressure relief valvep. 351
+2p. 351
2p. 351
+Mobile screed, rightp. 351
Mobile screed, rightp. 351
+Adjustment point for tamper drive mobile screed, leftp. 352
Adjustment point for tamper drive mobile screed, leftp. 352
Fig. 128 Adjustment point for tamper drive mobile screed, left – excerpt from hydraulic diagramp. 352
Fig. 129 Adjustment point for tamper drive mobile screed, leftp. 352
+1p. 352
1p. 352
+Mobile screed, leftp. 352
Mobile screed, leftp. 352
+3p. 352
3p. 352
+Pressure relief valvep. 352
Pressure relief valvep. 352
+2p. 352
2p. 352
+Tamper motor, mobile screed leftp. 352
Tamper motor, mobile screed leftp. 352
+Test and adjustment pointsp. 353
Fan drivep. 353
+Fan drivep. 353
Fan drivep. 353
The fan drive also is an open hydraulic circuit.p. 353
+The most essential components are the tandem pumo (8) flanged to the auxiliary output of the engine (1), the two fan motors (77 and 78), the check valve (27) and three temeprature switches (33, 35, 36) with control valve (29).p. 353
(Fig. 130)p. 353
Fig. 130 Fan drive – excerpt from hydraulic diagramp. 353
+1p. 353
1p. 353
+Diesel enginep. 353
Diesel enginep. 353
+36p. 353
36p. 353
+Temperature switch hydraulic oil coolerp. 353
Temperature switch hydraulic oil coolerp. 353
+8p. 353
8p. 353
+Tandem gear pumpp. 353
Tandem gear pumpp. 353
+70p. 353
70p. 353
+Combination cooler colamnt/hydraulic oilp. 353
Combination cooler colamnt/hydraulic oilp. 353
+27p. 353
27p. 353
+Check valvep. 353
Check valvep. 353
+71p. 353
71p. 353
+Intercoolerp. 353
Intercoolerp. 353
+29p. 353
29p. 353
+Control valvep. 353
Control valvep. 353
+77p. 353
77p. 353
+Fan motor – intercoolerp. 353
Fan motor – intercoolerp. 353
+32p. 353
32p. 353
+Temperature switch intercoolerp. 353
Temperature switch intercoolerp. 353
+78p. 353
78p. 353
+Fan motor – combination coolerp. 353
Fan motor – combination coolerp. 353
+35p. 353
35p. 353
+Coolant temperature switchp. 353
Coolant temperature switchp. 353
The tandem pump (8), which is directly drive by an auxiliary drive of the diesel engine (1), supplies both fan circuits with hydraulic oil. The fan motors (77 and 78) are connected in series and always run at the same time.p. 354
Under normal conditions only the oil from the first pump flows to the fan motors (77 and 78), because the control valve (29) is energized in cold condition and thus directs the oil from the second pump directly back into the hydraulic oil tank.p. 354
If one of the three temperature switches (32, 35, 36) responds, the control valve (29) is de-energized and the second pump delivers its oil also to the fan circuit, to both fan motors (77and 78).p. 354
This means if one pump is used, the control valve (29) is energized (24V) and the fan speed is approx. 900 rpm. If both pumps are used, the control valve (29) is de-energized and the fan speed is approx. 2100 rpm. A pressure relief valve in the fan m…p. 354
The fan motors work with two different speeds, which are realized by the second gear pump being switched on or off. The signal for the control valve to switch on the second pump is submitted by the three temperature switches.p. 355
+Test and adjustment pointsp. 355
Test and adjustment pointsp. 355
+Fan circuitp. 355
Fan circuitp. 355
Componentsp. 355
Fig. 131 Tandem gear pumpp. 355
Fig. 132 Fan motor fr intercoolerp. 356
+Test port for fan pressurep. 356
Test port for fan pressurep. 356
Fig. 133 Fan motor for combined coolant/hydraulic oil coolerp. 356
Fig. 134 PRV fan circuit on fan motor for combined coolant/hydraulic oil coolerp. 357
+Control valve (29) and check valve (27)p. 357
Control valve (29) and check valve (27)p. 357
Fig. 135 Control valvep. 357
Fig. 136 Check valvep. 358
+Temperature switchp. 358
Temperature switchp. 358
Fig. 137 Temperature switch on coolersp. 358
Fig. 138 Excerpt from the wiring diagramp. 359
+8 Tests and adjustmentsp. 361
8 Tests and adjustmentsp. 361
+8.1 Check and adjustp. 362
8.1 Check and adjustp. 362
+Checking and adjusting the vibrationp. 362
Checking and adjusting the vibrationp. 362
+Special toolsp. 362
Special toolsp. 362
+Hydraulic test casep. 362
[BOMAG Part-No.: 079 930 01]p. 362
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 362
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 362
+Pressure test vibration drive, mobile screed right and leftp. 362
Pressure test vibration drive, mobile screed right and leftp. 362
+Fig. 1p. 362
Fig. 1p. 362
+1. Extend right and left hand screed (1) completely.p. 362
1. Extend right and left hand screed (1) completely.p. 362
+2. If necessary raise and lock the screed (2/p. 362
+2. If necessary raise and lock the screed (2/p. 362
(Fig. 1)p. 362
+Fig. 2p. 362
Fig. 2p. 362
+Perform work steps 3 to 14 on vibration motor for left mobile screed accordingly.p. 362
Perform work steps 3 to 14 on vibration motor for left mobile screed accordingly.p. 362
+3. Disconnect the hydraulic line (1) from the right vibration motor, screed (3) and close the hydraulic line/port with a plug.p. 362
3. Disconnect the hydraulic line (1) from the right vibration motor, screed (3) and close the hydraulic line/port with a plug.p. 362
+4. Connect a high pressure gauge (600 bar) (2) to pressure test port Mp. 362
+4. Connect a high pressure gauge (600 bar) (2) to pressure test port Mp. 362
1p. 362
(Fig. 2)p. 362
+Fig. 3p. 363
Fig. 3p. 363
+5. Start the engine, set switchp. 363
+5. Start the engine, set switchp. 363
(Fig. 3)p. 363
+Fig. 4p. 363
Fig. 4p. 363
+6. Activate the hydraulic systemp. 363
+6. Activate the hydraulic systemp. 363
(Fig. 4)p. 363
+Fig. 5p. 363
Fig. 5p. 363
+7. Select "Work"-modep. 363
+7. Select "Work"-modep. 363
(Fig. 5)p. 363
+Fig. 6p. 363
Fig. 6p. 363
+Run the following pressure test only for max. 5 seconds.p. 363
Run the following pressure test only for max. 5 seconds.p. 363
+8. Switch on vibration with switch (b/p. 363
+8. Switch on vibration with switch (b/p. 363
(Fig. 6)p. 363
+Fig. 7p. 364
Fig. 7p. 364
+9. Read the hydraulic pressure on the high pressure gauge (600 bar) (2/p. 364
+9. Read the hydraulic pressure on the high pressure gauge (600 bar) (2/p. 364
(Fig. 7)p. 364
+Fig. 8p. 364
Fig. 8p. 364
+10. Switch off vibration with switch (b/p. 364
+10. Switch off vibration with switch (b/p. 364
(Fig. 8)p. 364
+Nominal valuep. 364
Nominal valuep. 364
See chapter "Technical data", "Pressure limitation, vibration motor mobile screed left/right".p. 364
+Evaluation of testp. 364
Evaluation of testp. 364
+If the nominal value of the pressure limitation is not reached, adjust the pressure relief valve (1/p. 364
(Fig. 7)p. 364
+Repeat testing and adjustment as specified in steps 8 to 10, until the nominal value is reached.p. 364
Repeat testing and adjustment as specified in steps 8 to 10, until the nominal value is reached.p. 364
+Fig. 9p. 364
Fig. 9p. 364
+11. Deactivate the hydraulic systemp. 364
+11. Deactivate the hydraulic systemp. 364
(Fig. 9)p. 364
+Fig. 10p. 364
Fig. 10p. 364
+12. Turn the switchp. 364
+12. Turn the switchp. 364
(Fig. 10)p. 364
+Fig. 11p. 365
Fig. 11p. 365
+13. Disconnect the high pressure gauge (600 bar) from test port Mp. 365
+13. Disconnect the high pressure gauge (600 bar) from test port Mp. 365
1p. 365
+14. Unscrew the plugs and connect the hydraulic line (1/p. 365
+14. Unscrew the plugs and connect the hydraulic line (1/p. 365
(Fig. 11)p. 365
+8.2 Checking and adjusting the tamping pressure limitationp. 366
8.2 Checking and adjusting the tamping pressure limitationp. 366
+Special toolsp. 366
Special toolsp. 366
+Hydraulic test casep. 366
[BOMAG Part-No.: 079 930 01]p. 366
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 366
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 366
+Pressure test tamper drive, mobile screed right and leftp. 366
Pressure test tamper drive, mobile screed right and leftp. 366
+Fig. 1p. 366
Fig. 1p. 366
+1. Extend right and left hand screed (1) completely.p. 366
1. Extend right and left hand screed (1) completely.p. 366
+2. If necessary raise and lock the screed (2/p. 366
+2. If necessary raise and lock the screed (2/p. 366
(Fig. 1)p. 366
+Fig. 2p. 366
Fig. 2p. 366
+Perform work steps 3 to 14 on tamper motor for left mobile screed accordingly.p. 366
Perform work steps 3 to 14 on tamper motor for left mobile screed accordingly.p. 366
+3. Disconnect the hydraulic line (5) from the right tamper motor for the right mobile screed (2) and close the hydraulic line/port with a plug.p. 366
3. Disconnect the hydraulic line (5) from the right tamper motor for the right mobile screed (2) and close the hydraulic line/port with a plug.p. 366
+4. Connect a high pressure gauge (600 bar) (4) to pressure test port Mp. 366
+4. Connect a high pressure gauge (600 bar) (4) to pressure test port Mp. 366
1p. 366
(Fig. 2)p. 366
+Fig. 3p. 366
Fig. 3p. 366
+5. Start the engine, set switchp. 366
+5. Start the engine, set switchp. 366
(Fig. 3)p. 366
+Fig. 4p. 367
Fig. 4p. 367
+6. Activate the hydraulic systemp. 367
+6. Activate the hydraulic systemp. 367
(Fig. 4)p. 367
+Fig. 5p. 367
Fig. 5p. 367
+7. Select "Work"-modep. 367
+7. Select "Work"-modep. 367
(Fig. 5)p. 367
+Fig. 6p. 367
Fig. 6p. 367
+Run the following pressure test only for max. 5 seconds.p. 367
Run the following pressure test only for max. 5 seconds.p. 367
+8. Switch on the tamper with switch (a/p. 367
+8. Switch on the tamper with switch (a/p. 367
(Fig. 6)p. 367
+Fig. 7p. 367
Fig. 7p. 367
+9. Read the hydraulic pressure on the high pressure gauge (600 bar) (4/p. 367
+9. Read the hydraulic pressure on the high pressure gauge (600 bar) (4/p. 367
(Fig. 7)p. 367
+Fig. 8p. 368
Fig. 8p. 368
+10. Switch off the tamper with switch (a/p. 368
+10. Switch off the tamper with switch (a/p. 368
(Fig. 8)p. 368
+Nominal valuep. 368
Nominal valuep. 368
See chapter "Technical data", "Pressure limitation, tamper motor mobile screed left/right".p. 368
+Evaluation of testp. 368
Evaluation of testp. 368
+If the nominal value of the pressure limitation is not reached, adjust the pressure relief valve (3/p. 368
(Fig. 7)p. 368
+Repeat testing and adjustment as specified in steps 8 to 10, until the nominal value is reached.p. 368
Repeat testing and adjustment as specified in steps 8 to 10, until the nominal value is reached.p. 368
+Fig. 9p. 368
Fig. 9p. 368
+11. Deactivate the hydraulic systemp. 368
+11. Deactivate the hydraulic systemp. 368
(Fig. 9)p. 368
+Fig. 10p. 368
Fig. 10p. 368
+12. Turn the switchp. 368
+12. Turn the switchp. 368
(Fig. 10)p. 368
+Fig. 11p. 368
Fig. 11p. 368
+13. Disconnect the high pressure gauge (600 bar) (4) from pressure test port Mp. 368
+13. Disconnect the high pressure gauge (600 bar) (4) from pressure test port Mp. 368
1p. 368
+14. Unscrew the plugs and connect the hydraulic line (5/p. 368
+14. Unscrew the plugs and connect the hydraulic line (5/p. 368
(Fig. 11)p. 368
Pressure measurement tamper drive, tamper system valve block.p. 369
+Fig. 12p. 369
Fig. 12p. 369
+1. Block the universal shaft (1) of the tamper motors, screed (2/p. 369
+1. Block the universal shaft (1) of the tamper motors, screed (2/p. 369
(Fig. 12)p. 369
+Fig. 13p. 369
Fig. 13p. 369
+2. Connect a high pressure gauge (600 bar) (1) to pressure test port Mp. 369
+2. Connect a high pressure gauge (600 bar) (1) to pressure test port Mp. 369
1p. 369
(Fig. 13)p. 369
+Fig. 14p. 369
Fig. 14p. 369
+3. Start the engine, set switchp. 369
+3. Start the engine, set switchp. 369
(Fig. 14)p. 369
+8.3 Checking and adjusting charge pressurerelief/high pressure relief and pressure override travel pumpp. 370
8.3 Checking and adjusting charge pressurerelief/high pressure relief and pressure override travel pumpp. 370
+Special toolsp. 370
Special toolsp. 370
+Hydraulic test casep. 370
[BOMAG Part-No.: 079 930 01]p. 370
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 370
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 370
+For the following pressure tests the brakes on both tracks must be applied.p. 370
For the following pressure tests the brakes on both tracks must be applied.p. 370
+The multi-function valve (pressure relief valve and zero-flow control valve [pressure override]) are adjusted at the same time. The value of the pressure relief valve is automatically higher than the setting of the zero-flow control valve by a fixed …p. 370
The multi-function valve (pressure relief valve and zero-flow control valve [pressure override]) are adjusted at the same time. The value of the pressure relief valve is automatically higher than the setting of the zero-flow control valve by a fixed …p. 370
Pressure test high pressure side "A" travel pump, leftp. 370
+Fig. 1p. 370
Fig. 1p. 370
+1. Block the left and right hand tracks by ´disconnecting the electrical connection (1) on the brake valve (2/p. 370
+1. Block the left and right hand tracks by ´disconnecting the electrical connection (1) on the brake valve (2/p. 370
(Fig. 1)p. 370
+Fig. 2p. 370
Fig. 2p. 370
+Run the following pressure test only for max. 5 seconds.p. 370
Run the following pressure test only for max. 5 seconds.p. 370
+2. Connect a high pressure gauge (600 bar) (3) to pressure test port Mp. 370
+2. Connect a high pressure gauge (600 bar) (3) to pressure test port Mp. 370
1p. 370
(Fig. 2)p. 370
+Fig. 3p. 371
Fig. 3p. 371
+3. Start the engine, set switchp. 371
+3. Start the engine, set switchp. 371
(Fig. 3)p. 371
+Fig. 4p. 371
Fig. 4p. 371
+4. Activate the hydraulic systemp. 371
+4. Activate the hydraulic systemp. 371
(Fig. 4)p. 371
+Fig. 5p. 371
Fig. 5p. 371
+5. Select "Work"-modep. 371
+5. Select "Work"-modep. 371
(Fig. 5)p. 371
+Fig. 6p. 371
Fig. 6p. 371
+6. Slightly actuate the potentiometer for speedp. 371
+6. Slightly actuate the potentiometer for speedp. 371
(Fig. 6)p. 371
+Fig. 7p. 372
Fig. 7p. 372
+7. Shift the travel leverp. 372
+7. Shift the travel leverp. 372
(Fig. 7)p. 372
+8. Read the hydraulic pressure on the high pressure gauge (600 bar) (3/p. 372
+8. Read the hydraulic pressure on the high pressure gauge (600 bar) (3/p. 372
(Fig. 8)p. 372
+9. Shift the travel leverp. 372
+9. Shift the travel leverp. 372
(Fig. 7)p. 372
+Nominal valuep. 372
Nominal valuep. 372
See chapter "Technical data", "Travel pump".p. 372
+Fig. 8p. 372
Fig. 8p. 372
+Evaluation of testp. 372
Evaluation of testp. 372
If the nominal values for pressure relief and pressure override are not correct, adjust the multi- function valve (4) on travel pump, left (1).p. 372
+Repeat testing and adjustment as specified in steps 7 to 9, until the nominal value is reached.p. 372
Repeat testing and adjustment as specified in steps 7 to 9, until the nominal value is reached.p. 372
+Turn the adjusting screw clockwise = increase pressure relief and pressure override settings.p. 372
Turn the adjusting screw clockwise = increase pressure relief and pressure override settings.p. 372
+Turn the adjusting screw counter-clockwise = reduce pressure relief and pressure override settings.p. 372
Turn the adjusting screw counter-clockwise = reduce pressure relief and pressure override settings.p. 372
+10. Disconnect the high pressure gauge (600 bar) (3) from pressure test port Mp. 372
+10. Disconnect the high pressure gauge (600 bar) (3) from pressure test port Mp. 372
1p. 372
(Fig. 8)p. 372
+Fig. 9p. 372
Fig. 9p. 372
+11. Deactivate the hydraulic systemp. 372
+11. Deactivate the hydraulic systemp. 372
(Fig. 9)p. 372
+Fig. 10p. 373
Fig. 10p. 373
+12. Turn the switchp. 373
+12. Turn the switchp. 373
(Fig. 10)p. 373
+Fig. 11p. 373
Fig. 11p. 373
+For proper operation the brakes on both track drives must be returned to good working order!p. 373
For proper operation the brakes on both track drives must be returned to good working order!p. 373
+13. Connect the electrical supply (1) to the brake valve (2/p. 373
+13. Connect the electrical supply (1) to the brake valve (2/p. 373
(Fig. 11)p. 373
+8.4 Checking and adjusting the adjusting times and pressure limitations for mobile screedsp. 374
8.4 Checking and adjusting the adjusting times and pressure limitations for mobile screedsp. 374
+Special toolsp. 374
Special toolsp. 374
+Hydraulic test casep. 374
[BOMAG Part-No.: 079 930 01]p. 374
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 374
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 374
+Time measurement for extension and retraction of mobile screedsp. 374
Time measurement for extension and retraction of mobile screedsp. 374
+Fig. 1p. 374
Fig. 1p. 374
+1. Start the engine, set switchp. 374
+1. Start the engine, set switchp. 374
(Fig. 1)p. 374
+Fig. 2p. 374
Fig. 2p. 374
+2. Activate the hydraulic systemp. 374
+2. Activate the hydraulic systemp. 374
(Fig. 2)p. 374
+Fig. 3p. 374
Fig. 3p. 374
+3. Select "Work"-modep. 374
+3. Select "Work"-modep. 374
(Fig. 3)p. 374
+Fig. 4p. 375
Fig. 4p. 375
+4. If necessary raise and lock the screed (2).p. 375
4. If necessary raise and lock the screed (2).p. 375
+5. If neceary retract the right and left hand mobile screed (1/p. 375
+5. If neceary retract the right and left hand mobile screed (1/p. 375
(Fig. 4)p. 375
(Fig. 5)p. 375
+Fig. 5p. 375
Fig. 5p. 375
+6. Measure the time for complete and synchronous extension of right and left mobile screeds (c and d).p. 375
6. Measure the time for complete and synchronous extension of right and left mobile screeds (c and d).p. 375
+Nominal valuep. 375
Nominal valuep. 375
See chapter "Technical data", "Mobile screeds, extension time".p. 375
+7. Measure the time for complete and synchronous retraction of right and left mobile screeds (c and d/p. 375
+7. Measure the time for complete and synchronous retraction of right and left mobile screeds (c and d/p. 375
(Fig. 5)p. 375
+Nominal valuep. 375
Nominal valuep. 375
See chapter "Technical data", "Mobile screeds, retraction time".p. 375
+Fig. 6p. 375
Fig. 6p. 375
+Evaluation of testp. 375
Evaluation of testp. 375
+If the nominal values for extension and retraction of the mobile screeds are not reached, adjust the volume flow divider for scraper chain/mobile screeds (2) on the distributor block for scraper chain/mobile screeds (1/p. 375
(Fig. 6)p. 375
+Repeat testing and adjustment as specified in steps 6 to 7, until the nominal value is reached.p. 375
Repeat testing and adjustment as specified in steps 6 to 7, until the nominal value is reached.p. 375
+Increase flow volume = shorter time for extension and retraction Rediuce volume flow = longer time for extension and retractionp. 375
Increase flow volume = shorter time for extension and retraction Rediuce volume flow = longer time for extension and retractionp. 375
+Changing the volume flow on the flow divider for scraper chain/mobile screeds also influences the max. rotary speed of the scraper chain drive.p. 375
Changing the volume flow on the flow divider for scraper chain/mobile screeds also influences the max. rotary speed of the scraper chain drive.p. 375
+Fig. 7p. 376
Fig. 7p. 376
+8. Deactivate the hydraulic systemp. 376
+8. Deactivate the hydraulic systemp. 376
(Fig. 7)p. 376
+Fig. 8p. 376
Fig. 8p. 376
+9. Turn the switchp. 376
+9. Turn the switchp. 376
(Fig. 8)p. 376
Pressure limitation mobile screedsp. 376
+Fig. 9p. 376
Fig. 9p. 376
+1. Connect a high pressure gauge (600 bar) (1) to pressure test port M (2) on the valve block for mobile screed adjusting cylinders (3/p. 376
+1. Connect a high pressure gauge (600 bar) (1) to pressure test port M (2) on the valve block for mobile screed adjusting cylinders (3/p. 376
(Fig. 9)p. 376
+Fig. 10p. 376
Fig. 10p. 376
+2. Start the engine, set switchp. 376
+2. Start the engine, set switchp. 376
(Fig. 10)p. 376
+Fig. 11p. 377
Fig. 11p. 377
+3. Activate the hydraulic systemp. 377
+3. Activate the hydraulic systemp. 377
(Fig. 11)p. 377
+Fig. 12p. 377
Fig. 12p. 377
+4. Extend right and left hand screeds (c and d) completely.p. 377
4. Extend right and left hand screeds (c and d) completely.p. 377
+For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 377
For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 377
+5. Retract the mobile screeds completely and synchronously against block (c and d/p. 377
+5. Retract the mobile screeds completely and synchronously against block (c and d/p. 377
(Fig. 12)p. 377
(Fig. 13)p. 377
+Nominal valuep. 377
Nominal valuep. 377
See chapter "Technical data", "Mobile screeds".p. 377
+Fig. 13p. 377
Fig. 13p. 377
+Evaluation of testp. 377
Evaluation of testp. 377
+If the nominal value of the pressure limitation is not reached, adjust the pressure relief valve (1) on the valve block for mobile screed adjusting cylinders (3/p. 377
(Fig. 13)p. 377
+Repeat testing and adjustment as specified in steps 4 to 5, until the nominal value is reached.p. 377
Repeat testing and adjustment as specified in steps 4 to 5, until the nominal value is reached.p. 377
+Fig. 14p. 377
Fig. 14p. 377
+6. Disconnect the high pressure gauge (600 bar) (1) to pressure test port M (2) on the valve block for mobile screed adjusting cylinders (3/p. 377
+6. Disconnect the high pressure gauge (600 bar) (1) to pressure test port M (2) on the valve block for mobile screed adjusting cylinders (3/p. 377
(Fig. 14)p. 377
+7. Retract right and left hand screeds completely.p. 377
7. Retract right and left hand screeds completely.p. 377
+Fig. 15p. 378
Fig. 15p. 378
+8. Deactivate the hydraulic systemp. 378
+8. Deactivate the hydraulic systemp. 378
(Fig. 15)p. 378
+Fig. 16p. 378
Fig. 16p. 378
+9. Turn the switchp. 378
+9. Turn the switchp. 378
(Fig. 16)p. 378
+8.5 Measuring the max. fan motor speedp. 379
8.5 Measuring the max. fan motor speedp. 379
+Special toolsp. 379
Special toolsp. 379
+Digital RPM-meterp. 379
[BOMAG Part-No.: 059 711 12]p. 379
+Digital RPM-meter, optical/mechanicalp. 379
[BOMAG Part-No.: 079 948 98]p. 379
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 379
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 379
+The max. speed of the fan motor in 2nd speed range should not exceed 2100 rpm.p. 379
The max. speed of the fan motor in 2nd speed range should not exceed 2100 rpm.p. 379
Engine speed measurementp. 379
+Fig. 1p. 379
Fig. 1p. 379
+1. Connect the RPM-meterp. 379
+1. Connect the RPM-meterp. 379
(Fig. 1)p. 379
+Fig. 2p. 379
Fig. 2p. 379
+2. Start the engine, set switchp. 379
+2. Start the engine, set switchp. 379
(Fig. 2)p. 379
+3. Measure the rotation speeds.p. 379
3. Measure the rotation speeds.p. 379
+Nominal value high idle speedp. 379
Nominal value high idle speedp. 379
See chapter "Technical data", "Engine at high idle".p. 379
+Evaluation of testp. 379
Evaluation of testp. 379
If the nominal value is not reached, adjust the engine speed or perform trouble shooting on the engine.p. 379
+Fig. 3p. 380
Fig. 3p. 380
+4. Activate the hydraulic systemp. 380
+4. Activate the hydraulic systemp. 380
(Fig. 3)p. 380
+Fig. 4p. 380
Fig. 4p. 380
+5. Select "Work"-modep. 380
+5. Select "Work"-modep. 380
(Fig. 4)p. 380
+6. Switch on all consumers, e.g. vibration, tampers and scraper chains.p. 380
6. Switch on all consumers, e.g. vibration, tampers and scraper chains.p. 380
+7. Measure the rotation speeds.p. 380
7. Measure the rotation speeds.p. 380
+Setpoint nominal speedp. 380
Setpoint nominal speedp. 380
See chapter "Technical data", "Engine at nominal speed".p. 380
+Evaluation of testp. 380
Evaluation of testp. 380
If the nominal value is not reached, adjust the engine speed or perform trouble shooting on the engine.p. 380
+Fig. 5p. 380
Fig. 5p. 380
+8. Turn the switchp. 380
+8. Turn the switchp. 380
(Fig. 5)p. 380
+Fig. 6p. 380
Fig. 6p. 380
+9. Disconnect the RPM-meterp. 380
+9. Disconnect the RPM-meterp. 380
(Fig. 6)p. 380
Rotary speed of fan motorp. 381
+The speed is realized by a fixed ratio restrictor inside the fan motor. This restrictor cannot be used to adjust the rotary speed.p. 381
The speed is realized by a fixed ratio restrictor inside the fan motor. This restrictor cannot be used to adjust the rotary speed.p. 381
+Fig. 7p. 381
Fig. 7p. 381
+1. Bridge the solenoid valve (1) of the fan motor by pulling off the jumper (3/p. 381
+1. Bridge the solenoid valve (1) of the fan motor by pulling off the jumper (3/p. 381
(Fig. 7)p. 381
+Fig. 8p. 381
Fig. 8p. 381
+2. Start the engine, set switchp. 381
+2. Start the engine, set switchp. 381
(Fig. 8)p. 381
+Fig. 9p. 381
Fig. 9p. 381
+3. Activate the hydraulic systemp. 381
+3. Activate the hydraulic systemp. 381
(Fig. 9)p. 381
+Fig. 10p. 382
Fig. 10p. 382
+4. Measure the speed of the fan/fan motor optically/ mechanicallyp. 382
+4. Measure the speed of the fan/fan motor optically/ mechanicallyp. 382
(Fig. 10)p. 382
+Nominal valuep. 382
Nominal valuep. 382
See chapter "Technical data", "Fan motor 2nd speed range".p. 382
+Fig. 11p. 382
Fig. 11p. 382
+Evaluation of testp. 382
Evaluation of testp. 382
+If the nominal rotary speed is not reached, adjust the pressure relief valve (1) for the fan motor (2/p. 382
(Fig. 11)p. 382
+Repeat testing and adjustment as specified in step 4, until the nominal value is reached.p. 382
Repeat testing and adjustment as specified in step 4, until the nominal value is reached.p. 382
+Fig. 12p. 382
Fig. 12p. 382
+5. Deactivate the hydraulic systemp. 382
+5. Deactivate the hydraulic systemp. 382
(Fig. 12)p. 382
+Fig. 13p. 382
Fig. 13p. 382
+6. Turn the switchp. 382
+6. Turn the switchp. 382
(Fig. 13)p. 382
+9 Central lubrication systemp. 383
+9 Central lubrication systemp. 383
BF 600C with HC screed, 32 lubrication pointsp. 384
+After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be extended or reduced, as required.p. 385
After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be extended or reduced, as required.p. 385
BF 600C with HC screed, 34 lubrication pointsp. 386
+After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be extended or reduced, as required.p. 387
After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be extended or reduced, as required.p. 387
+(Fig. 3) Through grease nipple with hand-operated or pneumatic grease gunp. 388
(Fig. 3)p. 388
9.4 Electric pumpp. 389
+Electric pump EP-1p. 389
Electric pump EP-1p. 389
+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. 389
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. 389
Fig. 4 EP-1 with 4 kg container and integrated electronic controlp. 389
Technical dadap. 389
Motor:p. 389
+Operating voltagep. 389
Operating voltagep. 389
12/24 V DCp. 389
Rated speedp. 389
15 rpmp. 389
Power consumption at idle speedp. 389
0.4 Ap. 389
Power consumption at full load speedp. 389
1.1 Ap. 389
Fusep. 389
3 Ap. 389
Pump:p. 389
+Max. operating pressurep. 389
Max. operating pressurep. 389
280 barp. 389
Permissible operating temperaturep. 389
-35°C to +80°Cp. 389
Container capacityp. 389
1.9 kg, 2.5 kg, 4 kg or 8 kgp. 389
Rotation of agitatorp. 389
counter-clockwisep. 389
Installation positionp. 389
Container vertically uprightp. 389
Protection classp. 389
IP5K9K acc. to DIN 40050p. 389
Working principlep. 390
Fig. 5p. 390
+A DC-motor 10p. 390
(Fig. 5)p. 390
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. 390
The pressure relief valve (9) is factory set to 280 bar.p. 390
Fig. 6 Pump element drawing in greasep. 390
Fig. 7 Pump element pumpingp. 390
Pump element PE-120Vp. 391
+Max. flow capacityp. 391
Max. flow capacityp. 391
+Pump element factory set to full strokep. 391
Pump element factory set to full strokep. 391
max. flow capacity 0.12 cm with full strokep. 391
Reduction of 0.013 cm per detent = 1/2 revolutionp. 391
Flow capacity regulation:p. 391
+Unscrew the plug 2p. 391
+Unscrew the plug 2p. 391
(Fig. 8)p. 391
The setscrew (3) is then regulated with a screwdriverp. 391
Turning clockwise reduces the flow capacityp. 391
Turn anti-clockwise increases the flow capacityp. 391
Max. stroke of setscrew is 2.4 mm = 6 detents.p. 391
1 turn of the setscrew is 0.8 mm = 2 detentsp. 391
Tighten the plug (2) with the seal ring.p. 391
Technical data:p. 391
+Max. flow capacityp. 391
Max. flow capacityp. 391
+0.04 to 0.12 cmp. 391
3p. 391
Flow capacity regulationp. 391
6 detents per 1/2 turnp. 391
Reductionp. 391
+0.013 cmp. 391
3p. 391
Piston returnp. 391
forcedp. 391
Fig. 8p. 391
Fig. 9p. 391
Installation of pump elementp. 392
+Installation and removal only with the pump stopped.p. 392
Installation and removal only with the pump stopped.p. 392
+Assembly of the pump element with the piston (4) partly pulled out, insert upwards under a slanted angle into the housing borep. 392
(Fig. 10)p. 392
+Once the piston head touches the pressing ring – move the element to horizontal positionp. 392
(Fig. 11)p. 392
The piston head must run in the groove of the guide ring.p. 392
Tighten the pump element.p. 392
Disassemble in reverse order.p. 392
+When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 392
When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 392
Fig. 10p. 392
Fig. 11p. 392
9.5 Integrated electronic controlp. 393
+The control unit is equipped with a data memory which logs the following values:p. 393
The control unit is equipped with a data memory which logs the following values:p. 393
+Control typep. 393
Control typep. 393
Version of control serial numberp. 393
Manufacturing datep. 393
Type of operation (time or speed control)p. 393
Settings (setting ranges).p. 393
+Functional sequencep. 393
Functional sequencep. 393
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. 393
+Each initial connection of the control triggers a lubrication process, the green LED 2p. 393
(Fig. 12)p. 393
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. 393
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. 393
Fig. 12p. 393
+1 Push button to trigger intermediate lubricationp. 393
1 Push button to trigger intermediate lubricationp. 393
2 Green LED to indicate functionp. 393
3 Red LED to indicate faultsp. 393
Technical data:p. 393
+Supply voltagep. 393
Supply voltagep. 393
10 to 60 V DCp. 393
Current load max.p. 393
6.0 Ap. 393
Fuse (not contained in the unit)p. 393
6.3 Ap. 393
Output for signal lampp. 393
0.4 Ap. 393
Temperature rangep. 393
-35°C to +75°Cp. 393
Protection classp. 393
IP 65p. 393
+Summary of signal displaysp. 394
Modes of operationp. 394
+A) Timer controlp. 394
A) Timer controlp. 394
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. 394
Fig. 13p. 394
+B) RPM-controlp. 394
B) RPM-controlp. 394
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. 394
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. 394
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. 394
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. 394
+Summary of signal displaysp. 394
Setting parametersp. 394
The cycle or lubrication times can be set with the help of maintained-contact switches in the inspection window of the control.p. 394
Fig. 14p. 394
+For setting the time disassemble the red frame from the motor protection housing of the pump using a flat screwdriverp. 394
(Fig. 14)p. 394
The cycle or lubrication time can be set with a flat screwdriver.p. 394
+The cycle time must not be changed.p. 394
The cycle time must not be changed.p. 394
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. 394
Fig. 15p. 394
+1 Connection of system diagnosep. 394
1 Connection of system diagnosep. 394
2 Maintained-contact switch to set the lubrication timep. 394
3 Maintained-contact switch to set the cycle timep. 394
Lubrication times:p. 395
1 to 16 min. (16 contacts for 1 min. each)p. 395
2 to 32 min. (16 contacts for 2 min. each)p. 395
2 to 32 sec. (16 contacts for 2 sec. each)p. 395
Cycle times:p. 395
0.5 to 8 h (16 contacts for 0.5 h each)p. 395
2 to 32 min. (16 contacts for 2 min. each)p. 395
2 to 32 h (16 contacts for 2 h each)p. 395
Pump revolutions:p. 395
1 to 16 revolutions (16 contacts for 1 revolution each)p. 395
10 to 160 revolutions (16 contacts for 10 revolution each)p. 395
170 to 320 revolutions (16 contacts for 10 revolution each)p. 395
+Summary of signal displaysp. 395
Summary of signal displaysp. 395
+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. 395
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. 395
Fig. 1 Indication of functional readinessp. 395
+1 Red LED to indicate faultsp. 395
1 Red LED to indicate faultsp. 395
2 Green LED to indicate functionp. 395
+a) Functional readinessp. 395
a) Functional readinessp. 395
Fig. 2 Indication of functional readinessp. 395
+b) Lubrication activep. 395
b) Lubrication activep. 395
Fig. 3 Lubrication sequencep. 395
+c) Rotary speed faultp. 395
c) Rotary speed faultp. 395
Fig. 4 Rotary speed fault on pump motorp. 395
+d) Fault CPU/memoryp. 395
d) Fault CPU/memoryp. 395
Fig. 5 Fault CPU/memoryp. 395
+e) Test lubrication (permanent lubrication)p. 395
e) Test lubrication (permanent lubrication)p. 395
Fig. 6 Test lubricationp. 395
+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. 395
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. 395
+Terminal diagramp. 396
Terminal diagramp. 396
Fig. 7p. 396
+(No. …) = Cable no. for mono-colour cablep. 396
(No. …) = Cable no. for mono-colour cablep. 396
9.6 Progressive distributorp. 397
+The progressive distributor can be employed as main or a secondary distributor.p. 397
The progressive distributor can be employed as main or a secondary distributor.p. 397
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. 397
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. 397
The different displacements per piston stroke are achieved by different piston diameters.p. 397
For correct functioning a progressive distributor requires at least three pistons, i.e. at lest three pumping elements.p. 397
Technical data:p. 397
+Operating pressure at inletp. 397
Operating pressure at inletp. 397
max. 300 barp. 397
Temperature rangep. 397
-35°C to + 80°Cp. 397
Number of elementsp. 397
Min. 3 piston elements, Max. 12 piston elementsp. 397
Fig. 8 Example: 4 piston elements and 8 outletsp. 397
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. 397
+Element designationp. 397
Element designationp. 397
+Max. flow capacityp. 397
Max. flow capacityp. 397
+Pistonp. 397
Pistonp. 397
+Æp. 397
Æp. 397
+per outletp. 397
per outletp. 397
+per elementp. 397
per elementp. 397
+MX- F25p. 397
MX- F25p. 397
+25 mm3p. 397
+25 mmp. 397
3p. 397
+50 mm3p. 397
+50 mmp. 397
3p. 397
+3 mmp. 397
3 mmp. 397
+MX- F45p. 397
MX- F45p. 397
+45 mm3p. 397
+45 mmp. 397
3p. 397
+90 mm3p. 397
+90 mmp. 397
3p. 397
+4 mmp. 397
4 mmp. 397
+MX- F75p. 397
MX- F75p. 397
+75 mm3p. 397
+75 mmp. 397
3p. 397
+150 mm3p. 397
+150 mmp. 397
3p. 397
+5 mmp. 397
5 mmp. 397
+MX- F105p. 397
MX- F105p. 397
+105 mm3p. 397
+105 mmp. 397
3p. 397
+210 mm3p. 397
+210 mmp. 397
3p. 397
+6 mmp. 397
6 mmp. 397
Description of functionp. 398
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 398
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 398
(Fig. 1)p. 398
(Fig. 2)p. 398
+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. 398
(Fig. 3)p. 398
Then the metering pistons (II) and (III) are displaced in succession and lubricant is pressed to outlets 5 and 6.p. 398
+After the displacement of pumping piston (III) the lubricant is once again guided to the right side of the pumping pistonp. 398
(Fig. 1)p. 398
Fig. 1p. 398
Fig. 2p. 398
Fig. 3p. 398
Connection of 2 outletsp. 399
For large lubrication points it may be necessary to join two or more outlets on the progressive distributor together.p. 399
The individual discs of the progressive distributor have two outlets.p. 399
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. 399
+2 outlets per distributor elementp. 399
+2 outlets per distributor elementp. 399
(Fig. 4)p. 399
Fig. 4 2 outletsp. 399
+1 Sealing screwp. 399
1 Sealing screwp. 399
+1 outlet per distributor elementp. 399
+1 outlet per distributor elementp. 399
(Fig. 5)p. 399
Fig. 5 1 outletp. 399
+1 Plugp. 399
1 Plugp. 399
For connecting outlets, plugs are required.p. 399
Connection of several outletsp. 399
+Connection of outlets with bridging pipes without outletp. 399
Connection of outlets with bridging pipes without outletp. 399
+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. 399
(Fig. 6)p. 399
Fig. 6 Bridging pipep. 399
+3 outlets joined togetherp. 399
(Fig. 7)p. 399
+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. 399
(Fig. 7)p. 399
The metered quantity is calculated on the basis of the metering parameters for all joined piston sides.p. 399
Fig. 7 3 outletsp. 399
+1 Sealing screwp. 399
1 Sealing screwp. 399
+4 outlets joined togetherp. 399
(Fig. 8)p. 399
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. 399
Fig. 8 4 outletsp. 400
Distributor bridge without outletp. 400
+Distributor bridge without check valvep. 400
+Distributor bridge without check valvep. 400
(Fig. 9)p. 400
Fig. 9 without check valvep. 400
+Distributor bridge with integrated check valvep. 400
Distributor bridge with integrated check valvep. 400
+In order to ensure proper functioning of a progressive distributor with three delivering elements but only two outletsp. 400
(Fig. 10)p. 400
(Fig. 11)p. 400
Fig. 10p. 400
Fig. 11 with check valvep. 400
Connection of outlets with distributor bridges with outletp. 401
Fig. 12 Distributor bridge with outletp. 401
+2 outlets joined togetherp. 401
+2 outlets joined togetherp. 401
(Fig. 13)p. 401
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. 401
Fig. 13 2 outletsp. 401
+3 outlets joined togetherp. 401
+3 outlets joined togetherp. 401
(Fig. 14)p. 401
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. 401
Fig. 14 3 outletsp. 401
+4 outlets joined togetherp. 401
+4 outlets joined togetherp. 401
(Fig. 15)p. 401
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. 401
Fig. 15 4 outletsp. 401
Check valvesp. 402
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. 402
There are two versions of check valves available, on which the pipe socket is screwed in.p. 402
+Check valve for main distributorp. 402
+Check valve for main distributorp. 402
(Fig. 16)p. 402
Fig. 16p. 402
+1 Cap screwp. 402
1 Cap screwp. 402
2 Duplex ringp. 402
+Check valve for secondary distributorp. 402
+Check valve for secondary distributorp. 402
(Fig. 17)p. 402
Fig. 17p. 402
+1 Cap nut and cutting ringp. 402
1 Cap nut and cutting ringp. 402
9.7 Fault – Cause – Remedyp. 403
+Faultp. 403
Faultp. 403
+Causep. 403
Causep. 403
+Remedyp. 403
Remedyp. 403
+Pump does not workp. 403
Pump does not workp. 403
+Integrated electronic control defectivep. 403
Integrated electronic control defectivep. 403
+Replace the lower part of the motor protection housingp. 403
Replace the lower part of the motor protection housingp. 403
+Electric line interruptedp. 403
Electric line interruptedp. 403
+Replace the electric linep. 403
Replace the electric linep. 403
+Pump defectivep. 403
Pump defectivep. 403
+Replace the pumpp. 403
Replace the pumpp. 403
+Pump works, but does not deliverp. 403
Pump works, but does not deliverp. 403
+Air cushion in pumping pistonp. 403
Air cushion in pumping pistonp. 403
+Vent the pumpp. 403
Vent the pumpp. 403
+Min. filling level fallen short ofp. 403
Min. filling level fallen short ofp. 403
+Fill up the provision containerp. 403
Fill up the provision containerp. 403
+Pump element defectivep. 403
Pump element defectivep. 403
+Replace the pump elementp. 403
Replace the pump elementp. 403
+No grease collar at the lubrication pointsp. 403
No grease collar at the lubrication pointsp. 403
+Pump does not workp. 403
Pump does not workp. 403
+See "Pump does not work"p. 403
See "Pump does not work"p. 403
+Pause time too long or lubrication period too shortp. 403
Pause time too long or lubrication period too shortp. 403
+Reduce pause time or extend lubrication timep. 403
Reduce pause time or extend lubrication timep. 403
+System blockedp. 403
System blockedp. 403
+See "Grease emerging from pressure relief valve"p. 403
See "Grease emerging from pressure relief valve"p. 403
+No grease collars at various lubrication pointsp. 403
No grease collars at various lubrication pointsp. 403
+Supply line to secondary distributor burst or leakingp. 403
Supply line to secondary distributor burst or leakingp. 403
+Replace the linep. 403
Replace the linep. 403
+Screw fittings leakingp. 403
Screw fittings leakingp. 403
+Retighten or replace screw fittingp. 403
Retighten or replace screw fittingp. 403
+No grease collar on one lubrication pointp. 403
No grease collar on one lubrication pointp. 403
+Corresponding grease line burst or leakingp. 403
Corresponding grease line burst or leakingp. 403
+Replace the linep. 403
Replace the linep. 403
+Screw fitting leakingp. 403
Screw fitting leakingp. 403
+Retighten or replace screw fittingp. 403
Retighten or replace screw fittingp. 403
+Pump speed too lowp. 403
Pump speed too lowp. 403
+High system pressure or low ambient temperaturep. 403
High system pressure or low ambient temperaturep. 403
+Check system / bearing pointp. 403
Check system / bearing pointp. 403
No damage (perform 1 or 2 intermediate lubrication cycles)p. 403
+Grease emerging from pressure relief valvep. 403
Grease emerging from pressure relief valvep. 403
+System pressure too highp. 403
System pressure too highp. 403
+Check systemp. 403
Check systemp. 403
+Progressive distributor blockedp. 403
Progressive distributor blockedp. 403
+Replace the distributorp. 403
Replace the distributorp. 403
+System blockedp. 403
System blockedp. 403
+Repair blocked / seized bearing pointsp. 403
Repair blocked / seized bearing pointsp. 403
+Valve spring defectivep. 403
Valve spring defectivep. 403
+Replace the pressure relief valvep. 403
Replace the pressure relief valvep. 403
+LED-displayp. 403
LED-displayp. 403
+The LED of the control flashes or is permanently onp. 403
The LED of the control flashes or is permanently onp. 403
+See "Summary of signal displays"p. 403
See "Summary of signal displays"p. 403
+Cause for a blockage in the systemp. 403
Cause for a blockage in the systemp. 403
+A crushed or blocked lubricant linep. 403
A crushed or blocked lubricant linep. 403
A bearing overfilled with lubricant or blockedp. 403
An unsuitable lubricant for central lubrication systemsp. 403
A blocked distributor outletp. 403
A blocked distributorp. 403
Indication of a blockagep. 403
+Grease emerging from pressure relief valvep. 403
Grease emerging from pressure relief valvep. 403
Identify the location of the blockagep. 404
+All repair work must be carried out with utmost cleanliness.p. 404
All repair work must be carried out with utmost cleanliness.p. 404
Fig. 18p. 404
+1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 404
1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 404
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. 404
3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication point.p. 404
Fig. 19 KIT to check central lubrication systemsp. 404
Repair of a blocked distributorp. 405
+Repair of a blocked distributorp. 405
Repair of a blocked distributorp. 405
+All repair work must be carried out with utmost cleanliness.p. 405
All repair work must be carried out with utmost cleanliness.p. 405
Fig. 20 Examplep. 405
Remove the distributor from the system. .p. 405
+Note the sequence of distributor discs.p. 405
Note the sequence of distributor discs.p. 405
+Remove the draw bars 1p. 405
(Fig. 20)p. 405
Take off the distributor disc(s).p. 405
+Pistons are not exchangeable among each other .p. 405
Pistons are not exchangeable among each other .p. 405
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. 405
+Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 405
Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 405
+Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 405
Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 405
Screw the plugs back in.p. 405
Check the next distributor disc, until the blocked piston is found.p. 405
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. 405
+In case of severe damage replace the distributor disc.p. 405
In case of severe damage replace the distributor disc.p. 405
+Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 405
Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 405
To prevent jamming of the pistons tighten the draw bars with 12 Nm.p. 405
Check function of the distributor.p. 405
+10 Suppliers documentationp. 407
+10 Suppliers documentationp. 407
10.1 Travel pumpp. 409
10.2 Travel motorp. 563
10.3 Conveyor screws – scraper belt motorp. 645
10.4 Travel gearp. 663
+11 Circuit diagramsp. 699
+11 Circuit diagramsp. 699
11.1 Hydraulic diagram 2542306p. 701
11.2 Wiring diagram DE006002p. 705
Taken as a whole, the manual connects general workshop practice with machine-specific systems. A technician can move from service data and maintenance requirements to component operation, diagnostic logic, pressure testing, adjustment and supplier-level component documentation without relying on a single narrow section. The included hydraulic and electrical drawings are particularly useful when tracing how a symptom relates to pumps, motors, valves, sensors, control units, fuses or machine functions.
Supplier Component Documentation and Drawings
The later portion of the manual incorporates supplier documentation for major drive components. The travel-pump section includes Series 90 axial-piston closed-circuit pump service information with operation, operating parameters, technical specifications, start-up, pressure measurement, troubleshooting, adjustment, minor repair and torque material. Further supplier sections cover the travel motor, conveyor-screw and scraper-belt motor, and the Bonfiglioli travel gear, including installation, lubrication, maintenance and repair-related information. The manual then closes with hydraulic diagram 2542306 and wiring diagram DE006002 for the BF600C electrical system.
The manual itself notes that its repair instructions are not an updating service and refers users to Technical Service Bulletins for later changes. The hydraulics training material likewise cautions that technical data and machine details can change after the issue date. For serial-sensitive work, match the machine to the cover serial-number ranges and use current service information where later modifications may apply.
Service and Repair Reference for the BF 600 C
The BOMAG BF 600 C Road Finisher Service Manual 008 916 41 – HCE/HCG, HSG/HSE, E/G is built for jobs that require more than a basic maintenance checklist. It supports systematic maintenance, electrical and engine diagnosis, sensor and actuator service, engine-system work, hydraulic troubleshooting, pressure testing, screed and drive adjustment, central-lubrication diagnosis and component repair preparation. Having the correct procedures, test points, specifications, diagrams and tightening information in front of you helps reduce guesswork and gives each repair a defined reference point. Delivery is an instant PDF download after payment – there is no shipping, the file can be viewed on common computers, tablets and phones, and you can print the pages needed at the machine or workbench.
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