Bomag BF300 P Road Finisher Service Manual 00891745
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Comprehensive factory workshop service manual for the Bomag BF300 P Road Finisher (S/N 821837681001 and S/N 821837811001). Covers complete mechanical overhaul, Kubota V 3307 T diesel engine maintenance, electronic ESX controller input codes, closed-loop hydraulics, S340 screed servicing, and full electrical wiring schematics.
Complete Workshop Service & Repair Documentation for Bomag BF300 P Road Finisher
The Bomag BF300 P Road Finisher Service Manual 00891745 provides professional heavy equipment technicians, plant maintenance workshops, and paving field mechanics with an exhaustive, 756-page technical reference. Specifically compiled by BOMAG for wheeled asphalt pavers operating under serial numbers S/N 821 837 68 1001 …. and S/N 821 837 81 1001 …., this manual delivers complete factory-level procedures for machine dismantling, component rebuilding, hydraulic system calibration, electrical troubleshooting, and electronic controller teaching. From testing high-pressure Bosch-Rexroth hydrostatic travel circuits to re-pinning Deutsch electrical connectors and teaching the electronic throttle via dashboard service codes, every mechanical and automated subsystem of the Bomag BF300 P is thoroughly documented.
File Details
Manual Type: Factory Service Manual
Machine Brand: BOMAG (Fayat Group)
Model Coverage: BF 300 P / BF 300_P Road Finisher (equipped with S340 screed variants including S340 VE and S340 TVE)
Serial Number Compatibility: S/N 821 837 68 1001 …. and S/N 821 837 81 1001 ….
Engine Covered: Kubota V 3307 T 4-cylinder water-cooled turbocharged diesel engine
Document / Catalogue Number: 008 917 45
Publication Edition: 08/2012
Language: English
Page Count: 756 pages
File Format: Portable Document Format (PDF)
Chapters Covered
1 General – 1.1 Introduction; 1.2 Safety regulations; 1.3 General repair instructions; 1.4 Tightening torques
2 Technical data – 2.1 Technical data (machine dimensions, weights, operating speeds, hydraulic pump and motor ratings, engine data, capacities)
3 Maintenance – 3.1 General notes on maintenance; 3.2 Fuels and lubricants; 3.3 Running-in instructions
4 E-Plan wiring diagrams – 4.1 Understanding wiring diagrams; 4.2 Circuit symbols in the circuit diagram; 4.3 Identification of switch blocks in the wiring diagram; 4.4 Designation of components in the wiring diagram; 4.5 Terminal designations in wiring diagram
5 Electrics – 5.1 Designation of components; 5.2 Terminal designations; 5.3 Battery ground and analog ground; 5.4 Current and voltage; 5.5 Pulse Width Modulation (PWM); 5.6 Logical base gates; 5.7 Resistance; 5.8 Series/parallel connection; 5.9 Ohm’s law; 5.10 Electrical energy; 5.11 Formula diagram; 5.12 Metrology; 5.13 Diodes, relays, fuses; 5.14 Telemecanique switch; 5.15 Plug connectors; 5.16 Magnetic coil plug; 5.17 Deutsch plug, series DT and DTM; 5.18 Plugs and terminals in spring clamping technology; 5.19 Inductive proximity switches; 5.20 Batteries; 5.21 Battery service, check the main battery switch; 5.22 Starting with jump wires; 5.23 Generator; 5.24 Generator repair; 5.25 Electric starter; 5.26 Repair of starter; 5.27 Engine shut-down solenoid, Y58; 5.28 Camshaft sensor, B92; 5.29 ECOMODE; 5.30 Glow plugs, R81-R84; 5.31 Oil pressure switch (B06); 5.32 Coolant temperature switch (B53); 5.33 Air filter vacuum switch (B03); 5.34 Coolant float switch (B55); 5.35 Charge control light; 5.36 Glow plugs; 5.37 Water separator in fuel filter (B124); 5.38 Level sensor in diesel tank (R03); 5.39 Fuses; 5.40 Component overview; 5.41 Overview of wiring looms; 5.42 Control elements; 5.43 View of operator’s stand; 5.44 Monitoring modules; 5.45 View of outside control stand; 5.46 View of screed control; 5.47 View of electric heating control panel; 5.48 Functional block diagram overview of functions; 5.49 Block diagram components on CAN; 5.50 Block diagram CAN with control elements; 5.51 Block diagram of travel circuit; 5.52 Block diagram material feed; 5.53 Block diagram screed; 5.54 Block diagram screed levelling; 5.55 Block diagram screed heating; 5.56 Functional block diagram monitoring functions; 5.57 Functional block diagram Emergency Stop function; 5.58 Electronic control units; 5.59 Checking the voltage supply for the control unit; 5.60 Diagnostics concept
6 Input codes – 6.1 Input codes – display: Functions and operation; 6.2 Teaching the E-throttle function; 6.3 Teaching the L.C.S. function; 6.4 Travel signal by button for max. screed relief; 6.5 Resetting to factory settings; 6.6 Showing stored faults; 6.7 Showing saved faults with operating hours; 6.8 Deleting the fault log; 6.9 Driving against the closed brake; 6.10 Adapting the engine speed; 6.11 Deactivating / activating the front drive; 6.12 Deactivating / activating the brake pedal switch
7 Replacement of components – 7.1 How to proceed when replacing components (ESX controller, travel pump, E-throttle actuator)
8 Engine – 8.1 Features; 8.2 Cooling system; 8.3 Removing and installing the thermostat; 8.4 Checking the thermostat in disassembled state; 8.5 Check the coolant level; 8.6 Check the anti-freeze concentration; 8.7 Change the coolant; 8.8 Checking radiator hoses and clamps; 8.9 Clean cooling fins; 8.10 Check engine oil level; 8.11 Change engine oil and filter; 8.12 Fuel system; 8.13 Replace fuel filter cartridge; 8.14 Check, clean water separator; 8.15 Replace fuel pre-filter, bleed fuel system; 8.16 Checking fuel lines; 8.17 Checking injection nozzles; 8.18 Check fuel injection timing; 8.19 Check fuel injection pump; 8.20 Checking and tensioning generator V-belt; 8.21 Service combustion air filter; 8.22 Check engine mounts; 8.23 Engine conservation; 8.24 Checking, adjusting valve clearance; 8.25 Engine problems & troubleshooting
9 Material hopper, description – 9.1 Material hopper and transport (hopper wings, folding locks, material flow)
10 Vibrating screed, description – 10.1 Screed (drawing arms, angle of attack, base plates, vibration units, tamper units)
11 Screed heating, repair – 11.1 Removing the screed heating generator; 11.2 Installation of screed heating generator; 11.3 Replace heating elements (base plate and tamper bars)
12 Travel drive, description – 12.1 Travel system
13 Travel drive, repair – 13.1 Check tire pressure; 13.2 Oil level check in front wheel hubs; 13.3 Oil level check in rear differential; 13.4 Oil level check in rear reduction gear; 13.5 Tighten wheel nuts
By delivering the factory table of contents in full technical depth, this manual supplies field technicians and workshop specialists with an unbroken roadmap of all mechanical, fluid, and electronic systems. Rather than generic summaries, the Bomag BF300 P Road Finisher Service Manual equips service personnel with exact manufacturer tolerances, pressure relief settings, diagnostic test pinouts, and component overhaul instructions necessary to return the paver to original factory performance standards.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Bomag BF300 P Road Finisher Service Manual 00891745” are as follows:
+BF 300_Pp. 1
+BF 300_Pp. 1
BF 300_Pp. 1
+S/N 821 837 68 1001 ….p. 1
S/N 821 837 68 1001 ….p. 1
S/N 821 837 81 1001 ….p. 1
Road Finisherp. 1
+1 Generalp. 7
1 Generalp. 7
+1.1 Introductionp. 8
+1.1 Introductionp. 8
This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 8
This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts…p. 8
+Documentationp. 8
Documentationp. 8
For the BOMAG machines described in this manual the following documentation is additionally available:p. 8
+1 Operating and maintenance instructionsp. 8
1 Operating and maintenance instructionsp. 8
2 Spare parts cataloguep. 8
3 Service informationp. 8
Use only genuine BOMAG spare parts.p. 8
Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.p. 8
This manual is not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins".p. 8
In case of a new release all necessary changes will be included.p. 8
In the course of technical development we reserve the right for technical modifications without prior notification.p. 8
Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.p. 8
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 8
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 8
BOMAG GmbHp. 8
Printed in Germanyp. 8
Copyright by BOMAGp. 8
+Generalp. 9
Safety regulationsp. 9
+Important notesp. 9
Important notesp. 9
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 9
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 9
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 9
Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obv…p. 9
This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment.p. 9
+Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 9
+Paragraphs marked like this highlight possible dangers for persons.p. 9
Paragraphs marked like this highlight possible dangers for persons.p. 9
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 9
Observe the regulations for the protection of the environment.p. 9
+Generalp. 9
Generalp. 9
+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
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
+Operation of high-voltage systemsp. 10
Operation of high-voltage systemsp. 10
+The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here.p. 10
The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here.p. 10
+The high-voltage system must only be operated and serviced by qualified and authorized personnel.p. 10
The high-voltage system must only be operated and serviced by qualified and authorized personnel.p. 10
Before starting operation the operator must check the proper condition of the system.p. 10
+Possibility of injury or even death caused by electric shock:p. 10
Possibility of injury or even death caused by electric shock:p. 10
+if persons come into contact with live parts,p. 10
+if persons come into contact with live parts,p. 10
if persons come into contact with live parts,p. 10
+in case of faulty insulation of live parts,p. 10
in case of faulty insulation of live parts,p. 10
+inadequate, unsuitable insulation,p. 10
inadequate, unsuitable insulation,p. 10
+if melted parts flake off in case of short circuits.p. 10
if melted parts flake off in case of short circuits.p. 10
+Old oilsp. 10
Old oilsp. 10
Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appr…p. 10
+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. 11
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 11
+Hydraulicsp. 11
Hydraulicsp. 11
+Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 11
Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 11
Always make sure that all screw fittings have been tightened properly and that hoses and pipes are in mint condition before pressurizing the system again.p. 11
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. 11
Do not step in front of or behind the drums, wheels or crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums, wheels or crawler tracks with wedges.p. 11
Reattach all guards and safety installations after all work has been completed.p. 11
+It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 11
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 11
+Fuelsp. 11
Fuelsp. 11
+Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Follow the valid accident prevention instructions when handling fuels.p. 11
The following notes refer to general safety precautions for danger free handling of fuel.p. 11
Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilution with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop …p. 11
+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. 12
Enginep. 12
+Do not work on the fuel system while the engine is running. (Danger to life!)p. 12
Do not work on the fuel system while the engine is running. (Danger to life!)p. 12
Once the engine has stopped wait approx. 1 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!)p. 12
Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!)p. 12
When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!)p. 12
+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. 12
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. 12
Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/- 0105 Electric precautions against dangerous contact voltages).p. 12
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
Fuel hosesp. 17
Fig. 1p. 17
+All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 17
All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 17
+The values specified in the table apply for screws:p. 17
Gaskets and mating surfacesp. 17
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 17
+Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 17
Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 17
Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 17
Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 17
If necessary remove any old sealing compound before assembling. For this purpose do not use any tools that could damage the sealing surfaces.p. 17
Sealing compound must be applied thin and evenly on the corresponding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores.p. 17
Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone; take care that no grinding dust and dirt enters into tapped bores or enclosed components.p. 17
Blow out lines, ducts and gaps with compressed air, replace any O-rings and seals that have been dislodged by the compressed air.p. 17
Assembly of radial sealsp. 17
Fig. 2p. 17
+Lubricate the sealing lips (2)p. 17
+Lubricate the sealing lips (2)p. 17
(Fig. 2)p. 17
Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 17
+If possible, use an assembly sleeve (1p. 17
+If possible, use an assembly sleeve (1p. 17
(Fig. 2)p. 17
to protect the lip from being damaged by sharp edges, threads or splines.p. 17
+Lubricate the outer rim (arrow 3p. 18
+Lubricate the outer rim (arrow 3p. 18
(Fig. 2)p. 18
Fig. 3p. 18
+Press or knock the seal into the housing, until it is flush with the housing surface.p. 18
Press or knock the seal into the housing, until it is flush with the housing surface.p. 18
+If possible, use a "bell" (1p. 18
+If possible, use a "bell" (1p. 18
(Fig. 3)p. 18
that the seal will not skew.p. 18
If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0,4 mm smaller than the outer diameter of the seal. Use VERY LIGHT blows with the hammer if no press is available.p. 18
+The values specified in the table apply for screws:p. 18
Feather keys and keywaysp. 18
+Feather keys may only be reused if they are free of damage.p. 18
Feather keys may only be reused if they are free of damage.p. 18
Fig. 4p. 18
+Clean and thoroughly examine the feather key.p. 18
Clean and thoroughly examine the feather key.p. 18
Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 18
+The values specified in the table apply for screws:p. 19
Ball and roller bearingsp. 19
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 19
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 19
Fig. 5p. 19
+If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 19
If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 19
Remove any lubricant residues from the ball or roller bearing to be examined by washing it with gasoline or any other appropriate degreasing agent. Ensure strict cleanliness.p. 19
Check balls or rollers, running surfaces, outer faces of outer races and inner faces of inner races for visible damage. Replace the ball or roller bearing if necessary.p. 19
Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 19
Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 19
On greased bearings (e.g. wheel bearings) fill the space between ball or roller bearing and outer seal with the recommended type of grease before assembling the seal.p. 19
Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 19
Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 19
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. 19
Fig. 6p. 19
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 19
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 19
(Fig. 6)p. 19
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 19
+The values specified in the table apply for screws:p. 20
Screws and nutsp. 20
Tightening torquep. 20
+Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 20
Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 20
Damaged screws must under no circumstances be used any longer. Recutting threads with thread cutters or taps adversely affects the strength and leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque value rea…p. 20
Self-locking nuts must generally be replaced after disassembly.p. 20
The use of screws with too high strength can cause damage!p. 20
+Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 20
Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 20
When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque.p. 20
+Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 20
The same applies for self-locking nuts.p. 20
Make sure that no oil or grease will enter into blind tapped bores. The hydraulic power generated when turning in the screw could cause breakage of the effected part.p. 20
Strength classes, metric screwsp. 20
The strength classes (from 3.6 to 12.9) are specified for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw.p. 20
Fig. 7 Identification of screwsp. 20
Example: A screw is identified with 12.9.p. 20
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 20
2p. 20
+The nominal tensile strength is 12 X 100 N/mmp. 20
+The nominal tensile strength is 12 X 100 N/mmp. 20
2p. 20
2p. 20
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 20
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 20
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 20
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 20
+The lower tensile strength is 9/10 X 1200 N/mmp. 20
+The lower tensile strength is 9/10 X 1200 N/mmp. 20
2p. 20
2p. 20
+However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together.p. 20
However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together.p. 20
Strength classes of metric nutsp. 21
Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified.p. 21
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 21
Fig. 8 Identification of nutsp. 21
+In a connection with a screw, these nuts 1p. 21
(Fig. 8)p. 21
Nut height above 0.8 d (d = nominal dimension).p. 21
+Strength class of nutp. 21
Strength class of nutp. 21
+Strength class of associated screwp. 21
Strength class of associated screwp. 21
+4p. 21
4p. 21
+3.6, 4.6, 4.8p. 21
3.6, 4.6, 4.8p. 21
+5p. 21
5p. 21
+3.6, 4.6, 4.8p. 21
3.6, 4.6, 4.8p. 21
5.6, 5.8p. 21
+6p. 21
6p. 21
+6.8p. 21
6.8p. 21
+8p. 21
8p. 21
+8.8p. 21
8.8p. 21
+9p. 21
9p. 21
+9.8p. 21
9.8p. 21
+10p. 21
10p. 21
+10.8p. 21
10.8p. 21
+12p. 21
12p. 21
+12.8p. 21
12.8p. 21
Nuts for screw joints with limited load factor (04, 05)p. 21
+The preceding "0" indicates that, due to their low height, nuts 2p. 21
(Fig. 8)p. 21
Nut height below 0,8 d (d = nominal dimension).p. 21
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 21
+This standard contains strength classes (hardness classes) for nuts 3p. 21
(Fig. 8)p. 21
Nut height below 0,5 d (d = nominal dimension).p. 21
Identification in clock systemp. 21
Fig. 9 Identification of nuts in clock systemp. 21
+For small nutsp. 21
(Fig. 9)p. 21
+The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 21
The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 21
The strength class is identified by a dash (b).p. 21
Identification of UNF-threadsp. 22
Fig. 10p. 22
Screwsp. 22
+The screw head is marked with a stamped in, round cavity 3p. 22
(Fig. 10)p. 22
Nutsp. 22
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 22
Studs and brake rodsp. 22
At the outmost end a short end of the component is reduced to its core diameter (1).p. 22
Cotter pinsp. 22
Fig. 11p. 22
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 22
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 22
+The values specified in the table apply for screws:p. 23
Tightening torquesp. 23
+The values specified in the table apply for screws:p. 23
The values specified in the table apply for screws:p. 23
+black oiledp. 23
black oiledp. 23
with surface protection A4Cp. 23
with surface protection DACROMETp. 23
+DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 23
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 23
+Tightening torques for screws with metric unified threadp. 23
+Tightening torques for screws with metric unified threadp. 23
+Tightening torques for screws with metric unified threadp. 23
+Coefficient of friction m tot. = 0,14p. 23
mp. 23
+Screw dimensionp. 23
Screw dimensionp. 23
+Tightening torques Nmp. 23
Tightening torques Nmp. 23
+8.8p. 23
8.8p. 23
+10.9p. 23
10.9p. 23
+12.9p. 23
12.9p. 23
+M4p. 23
M4p. 23
+3p. 23
3p. 23
+5p. 23
5p. 23
+5p. 23
5p. 23
+M5p. 23
M5p. 23
+6p. 23
6p. 23
+9p. 23
9p. 23
+10p. 23
10p. 23
+M6p. 23
M6p. 23
+10p. 23
10p. 23
+15p. 23
15p. 23
+18p. 23
18p. 23
+M8p. 23
M8p. 23
+25p. 23
25p. 23
+35p. 23
35p. 23
+45p. 23
45p. 23
+M10p. 23
M10p. 23
+50p. 23
50p. 23
+75p. 23
75p. 23
+83p. 23
83p. 23
+M12p. 23
M12p. 23
+88p. 23
88p. 23
+123p. 23
123p. 23
+147p. 23
147p. 23
+M14p. 23
M14p. 23
+137p. 23
137p. 23
+196p. 23
196p. 23
+235p. 23
235p. 23
+M16p. 23
M16p. 23
+211p. 23
211p. 23
+300p. 23
300p. 23
+358p. 23
358p. 23
+M18p. 23
M18p. 23
+290p. 23
290p. 23
+412p. 23
412p. 23
+490p. 23
490p. 23
+M20p. 23
M20p. 23
+412p. 23
412p. 23
+578p. 23
578p. 23
+696p. 23
696p. 23
+M22p. 23
M22p. 23
+560p. 23
560p. 23
+785p. 23
785p. 23
+942p. 23
942p. 23
+M24p. 23
M24p. 23
+711p. 23
711p. 23
+1000p. 23
1000p. 23
+1200p. 23
1200p. 23
+M27p. 23
M27p. 23
+1050p. 23
1050p. 23
+1480p. 23
1480p. 23
+1774p. 23
1774p. 23
+M30p. 23
M30p. 23
+1420p. 23
1420p. 23
+2010p. 23
2010p. 23
+2400p. 23
2400p. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Tightening torques for screws with metric unified fine threadp. 23
+Coefficient of friction m tot. = 0,14p. 23
mp. 23
+Screw dimensionp. 23
Screw dimensionp. 23
+Tightening torques Nmp. 23
Tightening torques Nmp. 23
+8.8p. 23
8.8p. 23
+10.9p. 23
10.9p. 23
+12.9p. 23
12.9p. 23
+M8 x 1p. 23
M8 x 1p. 23
+26p. 23
26p. 23
+37p. 23
37p. 23
+48p. 23
48p. 23
+M10 x 1.25p. 23
M10 x 1.25p. 23
+52p. 23
52p. 23
+76p. 23
76p. 23
+88p. 23
88p. 23
+M12 x 1,25p. 23
M12 x 1,25p. 23
+98p. 23
98p. 23
+137p. 23
137p. 23
+126p. 23
126p. 23
+M12 x 1.5p. 23
M12 x 1.5p. 23
+93p. 23
93p. 23
+127p. 23
127p. 23
+152p. 23
152p. 23
+M14 x 1.5p. 23
M14 x 1.5p. 23
+152p. 23
152p. 23
+216p. 23
216p. 23
+255p. 23
255p. 23
+M16 x 1.5p. 23
M16 x 1.5p. 23
+225p. 23
225p. 23
+318p. 23
318p. 23
+383p. 23
383p. 23
+M18 x 1.5p. 23
M18 x 1.5p. 23
+324p. 23
324p. 23
+466p. 23
466p. 23
+554p. 23
554p. 23
+M20 x 1.5p. 23
M20 x 1.5p. 23
+461p. 23
461p. 23
+628p. 23
628p. 23
+775p. 23
775p. 23
+M22 x 1.5p. 23
M22 x 1.5p. 23
+618p. 23
618p. 23
+863p. 23
863p. 23
+1058p. 23
1058p. 23
+M24 x 2p. 23
M24 x 2p. 23
+780p. 23
780p. 23
+1098p. 23
1098p. 23
+1294p. 23
1294p. 23
+M27 x2p. 23
M27 x2p. 23
+1147p. 23
1147p. 23
+1578p. 23
1578p. 23
+1920p. 23
1920p. 23
+M30 x 2p. 23
M30 x 2p. 23
+1568p. 23
1568p. 23
+2254p. 23
2254p. 23
+2695p. 23
2695p. 23
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 24
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 24
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 24
Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive effects. Prevents seizure and corrosion.p. 24
+Screw dimensionp. 24
Screw dimensionp. 24
+Tightening torques Nmp. 24
Tightening torques Nmp. 24
+8.8p. 24
8.8p. 24
+10.9p. 24
10.9p. 24
+12.9p. 24
12.9p. 24
+M16p. 24
M16p. 24
+169p. 24
169p. 24
+240p. 24
240p. 24
+287p. 24
287p. 24
+M16 x 1.5p. 24
M16 x 1.5p. 24
+180p. 24
180p. 24
+255p. 24
255p. 24
+307p. 24
307p. 24
+M18p. 24
M18p. 24
+232p. 24
232p. 24
+330p. 24
330p. 24
+392p. 24
392p. 24
+M18 x 1.5p. 24
M18 x 1.5p. 24
+260p. 24
260p. 24
+373p. 24
373p. 24
+444p. 24
444p. 24
+M20p. 24
M20p. 24
+330p. 24
330p. 24
+463p. 24
463p. 24
+557p. 24
557p. 24
+M20 x 1.5p. 24
M20 x 1.5p. 24
+369p. 24
369p. 24
+502p. 24
502p. 24
+620p. 24
620p. 24
+M22p. 24
M22p. 24
+448p. 24
448p. 24
+628p. 24
628p. 24
+754p. 24
754p. 24
+M22 x 1.5p. 24
M22 x 1.5p. 24
+495p. 24
495p. 24
+691p. 24
691p. 24
+847p. 24
847p. 24
+M24p. 24
M24p. 24
+569p. 24
569p. 24
+800p. 24
800p. 24
+960p. 24
960p. 24
+M24 x 2p. 24
M24 x 2p. 24
+624p. 24
624p. 24
+879p. 24
879p. 24
+1036p. 24
1036p. 24
+M27p. 24
M27p. 24
+840p. 24
840p. 24
+1184p. 24
1184p. 24
+1520p. 24
1520p. 24
+M27 X 2p. 24
M27 X 2p. 24
+918p. 24
918p. 24
+1263p. 24
1263p. 24
+1536p. 24
1536p. 24
+M30p. 24
M30p. 24
+1136p. 24
1136p. 24
+1608p. 24
1608p. 24
+1920p. 24
1920p. 24
+M30 x 2p. 24
M30 x 2p. 24
+1255p. 24
1255p. 24
+1804p. 24
1804p. 24
+2156p. 24
2156p. 24
+3/4“ – 10 UNCp. 24
3/4“ – 10 UNCp. 24
+276p. 24
276p. 24
+388p. 24
388p. 24
+464p. 24
464p. 24
+3/4“ – 16 UNCp. 24
3/4“ – 16 UNCp. 24
+308p. 24
308p. 24
+432p. 24
432p. 24
+520p. 24
520p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Tightening torques for wheel nuts (fine thread)p. 24
+Coefficient of friction m tot. = 0,14p. 24
mp. 24
These values result in a 90% utilization of the yield pointp. 24
+Thread diameterp. 24
Thread diameterp. 24
+Tightening torques Nmp. 24
Tightening torques Nmp. 24
+10.9p. 24
10.9p. 24
+M12x1.5p. 24
M12x1.5p. 24
+100p. 24
100p. 24
+M14x1.5p. 24
M14x1.5p. 24
+150p. 24
150p. 24
+M18x1.5p. 24
M18x1.5p. 24
+300 – 350p. 24
300 – 350p. 24
+M20x1.5p. 24
M20x1.5p. 24
+400 – 500p. 24
400 – 500p. 24
+M22x1.5p. 24
M22x1.5p. 24
+500 – 600p. 24
500 – 600p. 24
The values specified in the table apply for screws:p. 25
+black oiledp. 25
black oiledp. 25
with surface protection A4Cp. 25
with surface protection DACROMETp. 25
+The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.p. 25
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.p. 25
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 25
+Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 25
+Tightening torques for screws with UNC thread,p. 25
+Tightening torques for screws with UNC thread,p. 25
+Coefficient of friction m tot. = 0,14p. 25
mp. 25
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 25
+Screw dimensionp. 25
Screw dimensionp. 25
+Tightening torques Nmp. 25
Tightening torques Nmp. 25
+8.8p. 25
8.8p. 25
+10.9p. 25
10.9p. 25
+12.9p. 25
12.9p. 25
+1/4“ – 20p. 25
1/4“ – 20p. 25
+11p. 25
11p. 25
+15p. 25
15p. 25
+19p. 25
19p. 25
+5/16“ – 18p. 25
5/16“ – 18p. 25
+23p. 25
23p. 25
+32p. 25
32p. 25
+39p. 25
39p. 25
+3/8“ – 16p. 25
3/8“ – 16p. 25
+39p. 25
39p. 25
+55p. 25
55p. 25
+66p. 25
66p. 25
+7/16“ – 14p. 25
7/16“ – 14p. 25
+62p. 25
62p. 25
+87p. 25
87p. 25
+105p. 25
105p. 25
+1/2“ – 13p. 25
1/2“ – 13p. 25
+96p. 25
96p. 25
+135p. 25
135p. 25
+160p. 25
160p. 25
+9/16“ – 12p. 25
9/16“ – 12p. 25
+140p. 25
140p. 25
+200p. 25
200p. 25
+235p. 25
235p. 25
+5/8“ – 11p. 25
5/8“ – 11p. 25
+195p. 25
195p. 25
+275p. 25
275p. 25
+330p. 25
330p. 25
+3/4“ – 10p. 25
3/4“ – 10p. 25
+345p. 25
345p. 25
+485p. 25
485p. 25
+580p. 25
580p. 25
+7/8“ – 9p. 25
7/8“ – 9p. 25
+560p. 25
560p. 25
+770p. 25
770p. 25
+940p. 25
940p. 25
+1“ – 8p. 25
1“ – 8p. 25
+850p. 25
850p. 25
+1200p. 25
1200p. 25
+1450p. 25
1450p. 25
+1 1/8“ – 7p. 25
1 1/8“ – 7p. 25
+1200p. 25
1200p. 25
+1700p. 25
1700p. 25
+2000p. 25
2000p. 25
+1 1/4“ – 7p. 25
1 1/4“ – 7p. 25
+1700p. 25
1700p. 25
+2400p. 25
2400p. 25
+2900p. 25
2900p. 25
+1 3/8“ – 6p. 25
1 3/8“ – 6p. 25
+2200p. 25
2200p. 25
+3100p. 25
3100p. 25
+3700p. 25
3700p. 25
+1 1/2“ – 6p. 25
1 1/2“ – 6p. 25
+3000p. 25
3000p. 25
+4200p. 25
4200p. 25
+5100p. 25
5100p. 25
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 25
+Tightening torques for screws with UNF thread,p. 25
+Tightening torques for screws with UNF thread,p. 25
+Coefficient of friction m tot. = 0,14p. 26
mp. 26
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 25
+Screw dimensionp. 25
Screw dimensionp. 25
+Tightening torques Nmp. 25
Tightening torques Nmp. 25
+8.8p. 25
8.8p. 25
+10.9p. 25
10.9p. 25
+12.9p. 25
12.9p. 25
+1/4“ – 28p. 25
1/4“ – 28p. 25
+13p. 25
13p. 25
+18p. 25
18p. 25
+22p. 25
22p. 25
+5/16“ – 24p. 25
5/16“ – 24p. 25
+25p. 25
25p. 25
+35p. 25
35p. 25
+42p. 25
42p. 25
+3/8“ – 24p. 25
3/8“ – 24p. 25
+45p. 25
45p. 25
+63p. 25
63p. 25
+76p. 25
76p. 25
+7/16“ – 20p. 25
7/16“ – 20p. 25
+70p. 25
70p. 25
+100p. 25
100p. 25
+120p. 25
120p. 25
+1/2“ – 20p. 25
1/2“ – 20p. 25
+110p. 25
110p. 25
+155p. 25
155p. 25
+185p. 25
185p. 25
+9/16“ – 18p. 25
9/16“ – 18p. 25
+155p. 25
155p. 25
+220p. 25
220p. 25
+260p. 25
260p. 25
+5/8“ – 18p. 25
5/8“ – 18p. 25
+220p. 25
220p. 25
+310p. 25
310p. 25
+370p. 25
370p. 25
+3/4“ – 16p. 25
3/4“ – 16p. 25
+385p. 25
385p. 25
+540p. 25
540p. 25
+650p. 25
650p. 25
+7/8“ -14p. 25
7/8“ -14p. 25
+620p. 25
620p. 25
+870p. 25
870p. 25
+1050p. 25
1050p. 25
+1“ – 12p. 26
1“ – 12p. 26
+930p. 26
930p. 26
+1300p. 26
1300p. 26
+1600p. 26
1600p. 26
+1 1/8“ – 12p. 26
1 1/8“ – 12p. 26
+1350p. 26
1350p. 26
+1900p. 26
1900p. 26
+2300p. 26
2300p. 26
+1 1/4“ – 12p. 26
1 1/4“ – 12p. 26
+1900p. 26
1900p. 26
+2700p. 26
2700p. 26
+3200p. 26
3200p. 26
+1 3/8“ – 12p. 26
1 3/8“ – 12p. 26
+2600p. 26
2600p. 26
+3700p. 26
3700p. 26
+4400p. 26
4400p. 26
+1 1/2“ – 12p. 26
1 1/2“ – 12p. 26
+3300p. 26
3300p. 26
+4600p. 26
4600p. 26
+5600p. 26
5600p. 26
+2 Technical datap. 27
2 Technical datap. 27
Technical datap. 28
Fig. 12p. 28
+Dimensions in mmp. 28
Dimensions in mmp. 28
+Ap. 28
Ap. 28
+Bp. 28
Bp. 28
+Hp. 28
Hp. 28
+H2p. 28
+Hp. 28
2p. 28
+Kp. 28
Kp. 28
+Lp. 28
Lp. 28
+Wp. 28
Wp. 28
+BF 300 P, S340p. 28
BF 300 P, S340p. 28
+2230p. 28
2230p. 28
+1740p. 28
1740p. 28
+3350p. 28
3350p. 28
+2700p. 28
2700p. 28
+170p. 28
170p. 28
+4950p. 28
4950p. 28
+1700p. 28
1700p. 28
+The right for technical modifications remains reservedp. 28
The right for technical modifications remains reservedp. 29
+At a pressure of (166. bar, the valve seat must be fuel leak tightp. 30
At a pressure of (166. bar, the valve seat must be fuel leak tightp. 30
+Travel pumpp. 30
Travel pumpp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bosch-Rexrothp. 30
Bosch-Rexrothp. 30
+Typep. 30
Typep. 30
+A10VGp. 30
A10VGp. 30
+Quantityp. 30
Quantityp. 30
+1p. 30
1p. 30
+Systemp. 30
Systemp. 30
+Axial piston/swash platep. 30
Axial piston/swash platep. 30
+Max. displacementp. 30
Max. displacementp. 30
+cm3/revp. 30
+cmp. 30
3p. 30
+45p. 30
45p. 30
+Max. flow capacityp. 30
Max. flow capacityp. 30
+l/minp. 30
l/minp. 30
+152p. 30
152p. 30
+Maximum pressurep. 30
Maximum pressurep. 30
+barp. 30
barp. 30
+370 – 390p. 30
370 – 390p. 30
+Charge pressurep. 30
Charge pressurep. 30
+barp. 30
barp. 30
+24 – 26p. 30
24 – 26p. 30
+High pressure limitationp. 30
High pressure limitationp. 30
+Pressure override valvep. 30
Pressure override valvep. 30
+Travel motor (rear wheel drive)p. 30
Travel motor (rear wheel drive)p. 30
+Manufacturerp. 30
Manufacturerp. 30
+Sauer Danfossp. 30
Sauer Danfossp. 30
+Typep. 30
Typep. 30
+51Dp. 30
51Dp. 30
+Quantityp. 30
Quantityp. 30
+2p. 30
2p. 30
+Systemp. 30
Systemp. 30
+Axial piston/bent axlep. 30
Axial piston/bent axlep. 30
+Max. displacement (stage 1)p. 30
Max. displacement (stage 1)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+110p. 30
110p. 30
+Min. displacement (stage 2)p. 30
Min. displacement (stage 2)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+69p. 30
69p. 30
+Travel motor (front wheel drive)p. 30
Travel motor (front wheel drive)p. 30
+Manufacturerp. 30
Manufacturerp. 30
+SAI S.p.ap. 30
SAI S.p.ap. 30
+Typep. 30
Typep. 30
+BD1p. 30
BD1p. 30
+Quantityp. 30
Quantityp. 30
+2/4p. 30
2/4p. 30
+Max. displacement (stage 1)p. 30
Max. displacement (stage 1)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+61p. 30
61p. 30
+Min. displacement (stage 2)p. 30
Min. displacement (stage 2)p. 30
+cm3/Up. 30
+cmp. 30
3p. 30
+0p. 30
0p. 30
+Travel gearp. 30
Travel gearp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Officine Mecc. s.r.l.p. 30
Officine Mecc. s.r.l.p. 30
+Typep. 30
Typep. 30
+401-06466Cp. 30
401-06466Cp. 30
+Systemp. 30
Systemp. 30
+Spurwheel gear, shiftable (“high”, “low”)p. 30
Spurwheel gear, shiftable (“high”, “low”)p. 30
+Reduction (“high”)p. 30
Reduction (“high”)p. 30
+3.103:1p. 30
3.103:1p. 30
+Reduction (“low”)p. 30
Reduction (“low”)p. 30
+8.052:1p. 30
8.052:1p. 30
+Reduction gearp. 30
Reduction gearp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bondioli & Pavesip. 30
Bondioli & Pavesip. 30
+Typep. 30
Typep. 30
+S 8341 008 001p. 30
S 8341 008 001p. 30
+Quantityp. 30
Quantityp. 30
+2p. 30
2p. 30
+Systemp. 30
Systemp. 30
+Three-stage spurwheel gear, spur toothedp. 30
Three-stage spurwheel gear, spur toothedp. 30
+Reduction ratiop. 30
Reduction ratiop. 30
+11.908:1p. 30
11.908:1p. 30
+Maximum input speedp. 30
Maximum input speedp. 30
+rpmp. 30
rpmp. 30
+179p. 30
179p. 30
+Service pumpp. 30
Service pumpp. 30
+Manufacturerp. 30
Manufacturerp. 30
+Bosch-Rexrothp. 30
Bosch-Rexrothp. 30
+Typep. 30
Typep. 30
+A10VOp. 30
A10VOp. 30
+Quantityp. 30
Quantityp. 30
+1p. 30
1p. 30
+Systemp. 30
Systemp. 30
+Axial piston/swash platep. 30
Axial piston/swash platep. 30
+Max. displacementp. 31
Max. displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+28p. 31
28p. 31
+Max. flow capacityp. 31
Max. flow capacityp. 31
+l/minp. 31
l/minp. 31
+84p. 31
84p. 31
+Maximum pressurep. 31
Maximum pressurep. 31
+barp. 31
barp. 31
+145 – 155p. 31
145 – 155p. 31
+Charge pressurep. 31
Charge pressurep. 31
+barp. 31
barp. 31
+24 – 26p. 31
24 – 26p. 31
+High pressure limitationp. 31
High pressure limitationp. 31
+Pressure override valvep. 31
Pressure override valvep. 31
+Pump –> tamper and vibration (stage 1)p. 31
Pump –> tamper and vibration (stage 1)p. 31
+Manufacturerp. 31
Manufacturerp. 31
+Haldexp. 31
Haldexp. 31
+Typep. 31
Typep. 31
+WP09p. 31
WP09p. 31
+Systemp. 31
Systemp. 31
+Gear pumpp. 31
Gear pumpp. 31
+Quantityp. 31
Quantityp. 31
+1p. 31
1p. 31
+Displacementp. 31
Displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+190p. 31
190p. 31
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+276p. 31
276p. 31
+Maximum speedp. 31
Maximum speedp. 31
+rpmp. 31
rpmp. 31
+3000p. 31
3000p. 31
+Tamper motorp. 31
Tamper motorp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+SNM2p. 31
SNM2p. 31
+Systemp. 31
Systemp. 31
+Gear motorp. 31
Gear motorp. 31
+Displacementp. 31
Displacementp. 31
+cm3/Up. 31
+cmp. 31
3p. 31
+14.4p. 31
14.4p. 31
+Maximum pressurep. 31
Maximum pressurep. 31
+barp. 31
barp. 31
+280p. 31
280p. 31
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+250p. 31
250p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+1800 – 2000p. 31
1800 – 2000p. 31
+Vibration motorp. 31
Vibration motorp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+SNM2p. 31
SNM2p. 31
+Systemp. 31
Systemp. 31
+Gear motorp. 31
Gear motorp. 31
+Displacementp. 31
Displacementp. 31
+cm3/Up. 31
+cmp. 31
3p. 31
+8.4p. 31
8.4p. 31
+Maximum pressurep. 31
Maximum pressurep. 31
+barp. 31
barp. 31
+280p. 31
280p. 31
+Nominal pressurep. 31
Nominal pressurep. 31
+barp. 31
barp. 31
+250p. 31
250p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+2650 – 2850p. 31
2650 – 2850p. 31
+Pump –> auger drive left (stage 2)p. 31
Pump –> auger drive left (stage 2)p. 31
+Manufacturerp. 31
Manufacturerp. 31
+Haldexp. 31
Haldexp. 31
+Typep. 31
Typep. 31
+WP09p. 31
WP09p. 31
+Systemp. 31
Systemp. 31
+Gear pumpp. 31
Gear pumpp. 31
+Quantityp. 31
Quantityp. 31
+1p. 31
1p. 31
+Displacementp. 31
Displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+80p. 31
80p. 31
+Pressurep. 31
Pressurep. 31
+barp. 31
barp. 31
+230 – 250p. 31
230 – 250p. 31
+Maximum speedp. 31
Maximum speedp. 31
+rpmp. 31
rpmp. 31
+4000p. 31
4000p. 31
+Motor for augersp. 31
Motor for augersp. 31
+Manufacturerp. 31
Manufacturerp. 31
+Sauer Danfossp. 31
Sauer Danfossp. 31
+Typep. 31
Typep. 31
+OMS 160p. 31
OMS 160p. 31
+Systemp. 31
Systemp. 31
+Orbital motorp. 31
Orbital motorp. 31
+Max. displacement.p. 31
Max. displacement.p. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+160p. 31
160p. 31
+Rated speedp. 31
Rated speedp. 31
+rpmp. 31
rpmp. 31
+80 – 84p. 31
80 – 84p. 31
+Quantityp. 31
Quantityp. 31
+2p. 31
2p. 31
+Pump 3-stage (drive of right auger, as well as conveyor belt left & right)p. 31
Pump 3-stage (drive of right auger, as well as conveyor belt left & right)p. 31
+Manufacturerp. 31
Manufacturerp. 31
+Haldexp. 31
Haldexp. 31
+Typep. 31
Typep. 31
+WP09p. 31
WP09p. 31
+Systemp. 31
Systemp. 31
+Gear pumpp. 31
Gear pumpp. 31
+Quantityp. 31
Quantityp. 31
+1p. 31
1p. 31
+Displacementp. 31
Displacementp. 31
+cm3/revp. 31
+cmp. 31
3p. 31
+80p. 31
80p. 31
+Pressurep. 32
Pressurep. 32
+barp. 32
barp. 32
+230 – 250p. 32
230 – 250p. 32
+Maximum speedp. 32
Maximum speedp. 32
+rpmp. 32
rpmp. 32
+4000p. 32
4000p. 32
+Scraper belt motorsp. 32
Scraper belt motorsp. 32
+Manufacturerp. 32
Manufacturerp. 32
+Sauer Danfossp. 32
Sauer Danfossp. 32
+Typep. 32
Typep. 32
+OMS 160p. 32
OMS 160p. 32
+Quantityp. 32
Quantityp. 32
+2p. 32
2p. 32
+Systemp. 32
Systemp. 32
+Orbital motorp. 32
Orbital motorp. 32
+Max. displacement.p. 32
Max. displacement.p. 32
+cm3/revp. 32
+cmp. 32
3p. 32
+160p. 32
160p. 32
+Rated speedp. 32
Rated speedp. 32
+rpmp. 32
rpmp. 32
+60 – 64p. 32
60 – 64p. 32
+Pump for cleaning kitp. 32
Pump for cleaning kitp. 32
+Manufacturerp. 32
Manufacturerp. 32
+Flowjetp. 32
Flowjetp. 32
+Typep. 32
Typep. 32
+Duplex 2 seriesp. 32
Duplex 2 seriesp. 32
+Systemp. 32
Systemp. 32
+Dual piston pumpp. 32
Dual piston pumpp. 32
+Quantityp. 32
Quantityp. 32
+1p. 32
1p. 32
+Displacement (high pressure variant)p. 32
Displacement (high pressure variant)p. 32
+l/minp. 32
l/minp. 32
+8.32p. 32
8.32p. 32
+Displacement (medium and low pressure variant)p. 32
Displacement (medium and low pressure variant)p. 32
+l/minp. 32
l/minp. 32
+6.05p. 32
6.05p. 32
+Maximum pressurep. 32
Maximum pressurep. 32
+barp. 32
barp. 32
+6.8p. 32
6.8p. 32
+Tiresp. 32
Tiresp. 32
+rearp. 32
rearp. 32
+13R22.5p. 32
13R22.5p. 32
+Quantityp. 32
Quantityp. 32
+2p. 32
2p. 32
+frontp. 32
frontp. 32
+Solid rubberp. 32
Solid rubberp. 32
+Quantityp. 32
Quantityp. 32
+4p. 32
4p. 32
+Diameterp. 32
Diameterp. 32
+mmp. 32
mmp. 32
+470p. 32
470p. 32
+Widthp. 32
Widthp. 32
+mmp. 32
mmp. 32
+280p. 32
280p. 32
The following noise and vibration data acc. top. 33
– EC Machine Regulation edition 2006/42/ECp. 33
– the noise regulation 2000/14/EG, noise protection guideline 2003/10/ECp. 33
– Vibration Protection Regulation 2002/44/ECp. 33
were determined during conditions typical for this type of equipment and by application of harmonized standards.p. 33
During operation these values may vary because of the existing operating conditions.p. 33
+Noise valuep. 33
Noise valuep. 33
Sound pressure level on the place of the operator:p. 33
+Lp. 33
pAp. 33
Guaranteed sound power level:p. 33
+Lp. 33
WAp. 33
+Wear your personal noise protection means (ear defenders) before starting operation.p. 33
Wear your personal noise protection means (ear defenders) before starting operation.p. 33
+Vibration valuep. 33
Vibration valuep. 33
Vibration of the entire body (driver’s seat)p. 33
+The weighted effective acceleration value determined acc. to ISO 7096, isp. 33
£p. 33
2p. 33
Hand-arm vibration valuesp. 33
+The weighted effective acceleration value, determined acc. to EN 500/ISO 5349, isp. 33
£p. 33
2p. 33
+3 Maintenancep. 35
3 Maintenancep. 35
+3.1 General notes on maintenancep. 36
3.1 General notes on maintenancep. 36
+When performing maintenance work always comply with the appropriate safety regulations.p. 36
When performing maintenance work always comply with the appropriate safety regulations.p. 36
Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing t…p. 36
The terms right/left correspond with travel direction forward.p. 36
+Always clean machine and engine thoroughly before starting maintenance work.p. 36
Always clean machine and engine thoroughly before starting maintenance work.p. 36
For maintenance work stand the machine on level ground.p. 36
Always remove the main battery switch for all maintenance work.p. 36
Perform maintenance work only with the motor switched off.p. 36
Relieve hydraulic pressures before working on hydraulic lines.p. 36
Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 36
Always ensure sufficient lighting when performing maintenance work.p. 36
+During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.p. 36
During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.p. 36
Keep used filters in a separate waste container and dispose of environmentally.p. 36
Catch biodegradable oils separately.p. 36
+Notes on the fuel systemp. 36
Notes on the fuel systemp. 36
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 36
+Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 36
Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 36
Drums with inside zinc lining are not suitable to store fuel.p. 36
When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.p. 36
Do not let the hose stir up the slurry at the bottom of the drum.p. 36
The fuel drum must rest for a longer period of time before drawing off fuel.p. 36
The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 36
+Notes on the performance of the enginep. 36
Notes on the performance of the enginep. 36
On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.p. 36
If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.p. 36
+Notes on the hydraulic systemp. 36
Notes on the hydraulic systemp. 36
During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles a…p. 36
+If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 36
If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 36
Seal external leaks immediately. If necessary inform the responsible customer service.p. 36
Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes.p. 36
Always use the BOMAG filling unit 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. 36
Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 36
Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 36
+Notes on the cooling systemp. 36
Notes on the cooling systemp. 36
Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 36
The coolant is prepared by mixing a cooling system protection agent (ethylene glycol) into the coolant.p. 36
Mixing with cooling system protection agent is necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.p. 36
+3.2 Fuels and lubricantsp. 37
3.2 Fuels and lubricantsp. 37
+Engine oilp. 37
Engine oilp. 37
Qualityp. 37
Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used.p. 37
+Only engine oils of APIp. 37
American Petroleum Institutep. 37
+Engine oils of API-classification CF-4, CG-4 and CH-4 must not be used.p. 37
Engine oils of API-classification CF-4, CG-4 and CH-4 must not be used.p. 37
Oil viscosityp. 37
Multi-purpose oils should be generally used.p. 37
Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class) .p. 37
Optimal operating conditions can be achieved by using the following oil viscosity chart as a reference.p. 37
+Ambient temperaturep. 37
+Ambient temperaturep. 37
Ambient temperaturep. 37
+Viscosityp. 37
+Viscosityp. 37
Viscosityp. 37
+over 25 °C!p. 37
over 25 °C!p. 37
+SAE 30p. 37
SAE 30p. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
+0°C to 25°Cp. 37
0°C to 25°Cp. 37
+SAE 20p. 37
SAE 20p. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
+below 0 °Cp. 37
below 0 °Cp. 37
+SAE 10p. 37
SAE 10p. 37
SAE 10W-30p. 37
SAE 15W-40p. 37
Oil change intervalsp. 37
The longest permissible time a lubrication oil should remain in an engine is 1 year.p. 37
If the 500 operating hours are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.p. 37
+Fuelsp. 37
Fuelsp. 37
Qualityp. 37
Cetan index number: The recommended minimum index number for the Cetan value is 45. A Cetan index number higher than 50 should preferably be used, especially at ambient temperatures below -20 °C and when working at altitudes of 1500 m and more.p. 37
Diesel fuel specifications: With respect to the percentage (ppm) of sulphur the fuel used in the engine must comply with all relevant exhaust emission regulations in the are of use of the engine.p. 37
It is highly recommended to use a fuel with a sulphur content of less than 0,10 % (1000 ppm).p. 37
When using a diesel fuel with a high sulphur content of 0.50 % (5000 ppm) to 1.0 % (10.000 ppm), the engine oil change intervals must behalved.p. 37
+Do not use any fuels with a sulphur content of more than 1,0 % (10000 ppm).p. 37
Do not use any fuels with a sulphur content of more than 1,0 % (10000 ppm).p. 37
It is recommended to use diesel fuel that complies with the specifications EN590 or ASTM D975.p. 37
Diesel fuel with the designation no. 2-D is a destillate fuel with low volatility, which is especially suitable for industrial engines and heavy-duty commercial vehicles (SAE J313 JUN87).p. 37
As an alternative to no. 2-D you may also use diesel fuel no. 2-D S500 or S15; with ambient temperatures below -10 °C the diesel fuel no. 1-D S500 or S15 should be used fir no. 1-D.p. 37
The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.p. 37
Winter fuelp. 37
+Fire hazard!p. 37
Fire hazard!p. 37
Diesel fuels must never be mixed with gasoline.p. 37
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.p. 37
+Coolantp. 37
Coolantp. 37
Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1.p. 37
Under particularly extreme temperature conditions you should consult the service representation of the engine manufacturer with respect to the anti-freeze agent to be used.p. 37
There are various types of anti-freeze agents available. For this engine you should use ethylene glycol.p. 37
Before filling in the coolant mixed with anti-freeze agent the radiator must be flushed with clean water. This procedure should be repeated two to three times to clean the inside of radiator and engine block.p. 37
Mixing the anti-freeze agent: Prepare a mixture of 50 % anti-freeze agent and 50 % low mineral, clean water. Stirr well before filling it into the radiator. The method for mixing water and anti-freeze agent depends on the brand of the anti-freeze age…p. 38
Add anti-freeze agent: If the coolant level drops because of evaporation,only clean water is to be used for topping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio.p. 38
+Do not mix different coolants and additives of any other kind.p. 38
Do not mix different coolants and additives of any other kind.p. 38
Do not use any radiator cleaning agent after the anti- freeze agent has been mixed in. The anti-freeze agent also contains a corrosion protection agent. If this mixes with cleaning agent it may cause the development of sludge, which could damage the …p. 38
Anti-freeze concentrationp. 38
+50%p. 38
50%p. 38
-37 °Cp. 38
+Coolant must be disposed of environmentally.p. 38
Coolant must be disposed of environmentally.p. 38
+Mineral oil based hydraulic oilp. 38
Mineral oil based hydraulic oilp. 38
+The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mmp. 38
2p. 38
2p. 38
+Gear oilp. 38
Gear oilp. 38
Qualityp. 38
For the gearboxes use only multi-purpose gear oils of API-GL5-class, SAE 80W- 90.p. 38
This is a hypoid lubricant of highest quality class for extremely loaded transmissions.p. 38
The additives in this oil ensure low wear lubrication under all operating conditions.p. 38
+Lubrication greasep. 38
Lubrication greasep. 38
For lubrication use only EP-high pressure grease, lithium saponified (NLGI 3).p. 38
3.3 Running-in instructionsp. 39
+The following maintenance work must be performed when running in new machines or overhauled engines:p. 39
The following maintenance work must be performed when running in new machines or overhauled engines:p. 39
+Up to approx. 250 operating hours check the engine oil level twice every day.p. 39
Up to approx. 250 operating hours check the engine oil level twice every day.p. 39
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. 39
After a running-in time of 30 minutesp. 39
+Retighten the V-beltp. 39
Retighten the V-beltp. 39
After 50 operating hoursp. 39
+Changing engine oil and oil filterp. 39
Changing engine oil and oil filterp. 39
Check the tension of the fan V-beltp. 39
Retighten all wheel fastening screws with the specified tightening torque.p. 39
Oil change in front wheel drive hubsp. 39
Oil change in rear wheel drive differentialp. 39
Oil change in rear wheel drive reduction gearp. 39
Grease the auger drive chainp. 39
Hopper, check scrapers and rubber apronp. 39
After 250 operating hoursp. 39
+Tighten all bolted connections on air intake, exhaust, oil sump and engine mountsp. 39
Tighten all bolted connections on air intake, exhaust, oil sump and engine mountsp. 39
Retighten the bolted connections on the machine.p. 39
Retighten all wheel fastening screws with the specified tightening torque.p. 39
Oil change in front wheel drive hubsp. 39
Oil change in rear wheel drive differentialp. 39
Oil change in rear wheel drive reduction gearp. 39
Grease the auger drive chainp. 39
Hopper, check scrapers and rubber apronp. 39
+4 E-Plan wiring diagramsp. 41
+4 E-Plan wiring diagramsp. 41
4.1 Understanding wiring diagramsp. 42
+Electric circuit diagramsp. 42
Electric circuit diagramsp. 42
+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. 42
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. 42
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 42
+Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 42
Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 42
The sequence in which current flows through the individual elements in the electric circuit.p. 42
Connections between the examined electric circuit and other circuits in the vehicle wiring system.p. 42
Pin assignment of plug-and-socket connections.p. 42
+Structure of a wiring diagramp. 42
Structure of a wiring diagramp. 42
+Cover sheet, see section "Cover sheet"p. 42
Cover sheet, see section "Cover sheet"p. 42
Table of contents, see section "Table of contents"p. 42
Structuring symbol overview, see section "Structuring symbol overview"p. 42
+The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 42
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 42
+Sheets with illustration of function, see section"Sheets with illustration of function"p. 42
Sheets with illustration of function, see section"Sheets with illustration of function"p. 42
List of fuels and lubricants, see "List of fuels and lubricants"p. 42
Terminal strip overview, see section "Terminal strip overview"p. 42
Plug overview, see section "Plug overview"p. 42
Pin overview, see section "Pin overview"p. 42
Cover sheetp. 43
+The cover sheet, see examplep. 43
(Fig. 13)p. 43
Fig. 13 Example: Cover sheetp. 43
Table of contentsp. 44
+The table of contents, see examplep. 44
(Fig. 14)p. 44
Fig. 14 Example: Table of contentsp. 44
Sheets with representations of functionsp. 45
+The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 45
The main reading direction is sheet by sheet, from top to bottom and from left to right.p. 45
All sheets are successively numbered.p. 45
+BOMAG used the resolved type of representation. In this case parts and components with different functions, which belong to the same components (e.g. relay coil and relay contact), can be represented on different sheets. Cross-references, which refer…p. 45
(Fig. 15)p. 45
Fig. 15 Example: Sheet with functionsp. 45
+Current pathsp. 45
+Current pathsp. 45
(Fig. 15)p. 45
+Current paths are successively numbered from 0 to 9.p. 45
Current paths are successively numbered from 0 to 9.p. 45
+Potential cross referencesp. 45
+Potential cross referencesp. 45
(Fig. 15)p. 45
+Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 45
Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 45
+Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current path 1.p. 45
Example: Potential 15_54 +SEAT/16.1p. 45
+SEATp. 45
+Relay cross referencesp. 46
+Relay cross referencesp. 46
(Fig. 15)p. 46
+Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally attach…p. 46
Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally attach…p. 46
+Example: The relay cross-reference (p. 46
Example:p. 46
-K61/4.2p. 46
List of componentp. 47
+The list of components, see examplep. 47
(Fig. 16)p. 47
Fig. 16 Example: List of componentsp. 47
An electric component is a part, assembly or device in an electrical installation.p. 47
+Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the te…p. 47
Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the te…p. 47
The component identifications are alphabetically sorted in the list of components. Each component has the corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which installation location it is assigned to …p. 47
+Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 47
Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 47
Overview of terminal stripsp. 48
+The overview of terminal strips, see axamplep. 48
(Fig. 17)p. 48
Fig. 17 Example: Terminal strip overview X1p. 48
Overview of plugsp. 49
+The overview of plugs, see examplep. 49
(Fig. 18)p. 49
The following information is listed for each plug:p. 49
+Contact numberingp. 49
Contact numberingp. 49
Structuring symbolsp. 49
Function textp. 49
Use in wiring diagram.p. 49
Fig. 18 Example: Plug overview X0p. 49
Overview of pinsp. 50
+The overview of pins, see examplep. 50
(Fig. 19)p. 50
Fig. 19 Example: Overview of pins, control A66p. 50
4.2 Circuit symbols in the circuit diagramp. 51
+Circuit symbolsp. 51
Circuit symbolsp. 51
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. 51
Fig. 20 Example: Circuit symbolp. 51
+1 Current sourcep. 51
1 Current sourcep. 51
2 Conductorp. 51
3 Switchp. 51
4 Groundp. 51
5 Filament lampp. 51
6 Filament lamp with two luminous elementsp. 51
7 Voltmeterp. 51
8 Amperemeterp. 51
9 Resistancep. 51
10 Fusep. 51
11 Terminal stripp. 51
12 Plugp. 51
+Different symbols are used to simplify the differentiation of terminal strips 11p. 51
(Fig. 20)p. 51
+Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug.p. 51
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug.p. 51
Representation of electric devicesp. 52
Electronic devices and components are increasingly used in the construction equipment industry. Controls with software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently used to represent and contro…p. 52
+Black-Box representationp. 52
+Black-Box representationp. 52
(Fig. 21)p. 52
The Black-Box representation shows the device as a Box with the connections required for the machine function. Connections which are not needed do not need to be represented.p. 52
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is available.p. 52
Fig. 21 Example: Central lubrication systemp. 52
+Identification of externally supplied documentationp. 52
(Fig. 22)p. 52
In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the projecting of machines. These systems may be composed of various components and wirings. For easier differentiation of BOMAG designati…p. 52
Fig. 22 Example: Identification of externally supplied documentationp. 52
+PLC representationp. 52
+PLC representationp. 52
(Fig. 23)p. 52
The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections which are not needed do not n…p. 52
Fig. 23 PLC representationp. 53
The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which were specified accordingly, and where information on the assignment of signals is available.p. 53
Identification of similar, adjacent switching symbolsp. 53
In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are arranged just next to each other. In such cases it is common practice to reduce the identification on the subsequent symbol to the criteri…p. 53
+Example: -X0 36 and -X0 37p. 53
(Fig. 23)p. 53
In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol.p. 53
4.3 Identification of switch blocks in the wiring diagramp. 54
+Switches of modular designp. 54
Switches of modular designp. 54
+For normally open contacts the contact symbols "_3/_4" are used.p. 54
For normally open contacts the contact symbols "_3/_4" are used.p. 54
For normally closed contacts the contact symbols "_1/_2" are used.p. 54
In combination with the contact block numbering described above each individual connection is clearly defined.p. 54
Fig. 24p. 54
Example:p. 54
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" / "42" if it is a normally closed contact.p. 54
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it is a normally closed contact.p. 54
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it is a normally closed contact.p. 54
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it is a normally closed contact.p. 54
4.4 Designation of components in the wiring diagramp. 55
+The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 55
The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 55
Control lights, warning buzzer, warning lightp. 55
+Kp. 55
Kp. 55
+Relaysp. 55
Relaysp. 55
+Mp. 55
Mp. 55
+Starter, pumps, motorsp. 55
Starter, pumps, motorsp. 55
+Pp. 55
Pp. 55
+Operating hour meter, general gaugesp. 55
Operating hour meter, general gaugesp. 55
+Rp. 55
Rp. 55
+Transducers, resistorsp. 55
Transducers, resistorsp. 55
+Sp. 55
Sp. 55
+Switches, momentary contact switchesp. 55
Switches, momentary contact switchesp. 55
+Vp. 55
Vp. 55
+Diodep. 55
Diodep. 55
+Xp. 55
Xp. 55
+Terminalp. 55
Terminalp. 55
+Yp. 55
Yp. 55
+Solenoid valvesp. 55
Solenoid valvesp. 55
4.5 Terminal designations in wiring diagramp. 56
+For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 56
+For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 56
For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 56
+Terminal designationp. 56
Terminal designationp. 56
+Meaningp. 56
Meaningp. 56
+15p. 56
15p. 56
+Switch plus (after battery) : Output of ignition switchp. 56
Switch plus (after battery) : Output of ignition switchp. 56
+15ap. 56
15ap. 56
+Output from dropping resistor to ignition coil and starterp. 56
Output from dropping resistor to ignition coil and starterp. 56
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 56
Battery changeover relay 12V / 24V return line to battery 2 minusp. 56
+31bp. 56
31bp. 56
+Return line to battery minus or ground via switch or relay (switched minus)p. 56
Return line to battery minus or ground via switch or relay (switched minus)p. 56
+31cp. 56
31cp. 56
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 56
Battery changeover relay 12V / 24V return line to battery 1 minusp. 56
+49p. 56
49p. 56
+Input flasher relayp. 56
Input flasher relayp. 56
+49ap. 56
49ap. 56
+Output flasher relayp. 56
Output flasher relayp. 56
+49bp. 56
49bp. 56
+Flasher relay output 2nd flasher circuitp. 56
Flasher relay output 2nd flasher circuitp. 56
+49cp. 56
49cp. 56
+Flasher relay output 3rd flasher circuitp. 56
Flasher relay output 3rd flasher circuitp. 56
+50p. 56
50p. 56
+Starter, starter controlp. 56
Starter, starter controlp. 56
+50ap. 56
50ap. 56
+Battery changeover relay, output for starter controlp. 56
Battery changeover relay, output for starter controlp. 56
+53p. 56
53p. 56
+Wiper motor input (+)p. 56
Wiper motor input (+)p. 56
+53ap. 56
53ap. 56
+Wiper motor (+) end limit shut downp. 56
Wiper motor (+) end limit shut downp. 56
+53bp. 56
53bp. 56
+Wiper shunt windingp. 56
Wiper shunt windingp. 56
+56p. 56
56p. 56
+Head lightp. 56
Head lightp. 56
+56ap. 56
56ap. 56
+Head light, travel light and travel light controlp. 56
Head light, travel light and travel light controlp. 56
+56bp. 56
56bp. 56
+Head lights, dimmed head lightp. 56
Head lights, dimmed head lightp. 56
+56dp. 56
56dp. 56
+Head lights, flash lightp. 56
Head lights, flash lightp. 56
+57p. 56
57p. 56
+Parking light for motor cycles (abroad also for cars and trucks)p. 56
Parking light for motor cycles (abroad also for cars and trucks)p. 56
+57ap. 56
57ap. 56
+Parking lightp. 56
Parking lightp. 56
+57Lp. 56
57Lp. 56
+Parking light leftp. 56
Parking light leftp. 56
+57Rp. 56
57Rp. 56
+Parking light rightp. 56
Parking light rightp. 56
+58p. 56
58p. 56
+Side lights, tail light, number plate light, dashboard lightp. 56
Side lights, tail light, number plate light, dashboard lightp. 56
+58bp. 56
58bp. 56
+Tail light changeover for single axle trailersp. 56
Tail light changeover for single axle trailersp. 56
+58cp. 56
58cp. 56
+Trailer plug for single core wired and trailer fused tail lightp. 56
Trailer plug for single core wired and trailer fused tail lightp. 56
+58dp. 56
58dp. 56
+Adjustable dashboard light, tail light and side lightp. 56
Adjustable dashboard light, tail light and side lightp. 56
+58Lp. 56
58Lp. 56
+Side light, leftp. 56
Side light, leftp. 56
+58Rp. 56
58Rp. 56
+Side light, rightp. 56
Side light, rightp. 56
+61p. 56
61p. 56
+Generator controlp. 56
Generator controlp. 56
+75p. 56
75p. 56
+Radio, cigarette lighterp. 56
Radio, cigarette lighterp. 56
+76p. 56
76p. 56
+Loudspeakerp. 56
Loudspeakerp. 56
+87p. 56
87p. 56
+Relay contact on breaker and two-way contact, inputp. 56
Relay contact on breaker and two-way contact, inputp. 56
+87ap. 57
87ap. 57
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 57
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 57
+87bp. 57
87bp. 57
+Relay contact on breaker and two-way contact, output 2p. 57
Relay contact on breaker and two-way contact, output 2p. 57
+87cp. 57
87cp. 57
+Relay contact on breaker and two-way contact, output 3p. 57
Relay contact on breaker and two-way contact, output 3p. 57
+87zp. 57
87zp. 57
+Relay contact on breaker and two-way contact, input 1p. 57
Relay contact on breaker and two-way contact, input 1p. 57
+87yp. 57
87yp. 57
+Relay contact on breaker and two-way contact, input 2p. 57
Relay contact on breaker and two-way contact, input 2p. 57
+87xp. 57
87xp. 57
+Relay contact on breaker and two-way contact, input 3p. 57
Relay contact on breaker and two-way contact, input 3p. 57
+88p. 57
88p. 57
+Relay contact for makerp. 57
Relay contact for makerp. 57
+88ap. 57
88ap. 57
+Relay contact on maker and two-way contact, (maker side) output 1p. 57
Relay contact on maker and two-way contact, (maker side) output 1p. 57
+88bp. 57
88bp. 57
+Relay contact on maker and two-way contact, (maker side) output 2p. 57
Relay contact on maker and two-way contact, (maker side) output 2p. 57
+88cp. 57
88cp. 57
+Relay contact on maker and two-way contact, (maker side) output 3p. 57
Relay contact on maker and two-way contact, (maker side) output 3p. 57
+88zp. 57
88zp. 57
+Relay contact on maker, input 1p. 57
Relay contact on maker, input 1p. 57
+88yp. 57
88yp. 57
+Relay contact on maker, input 2p. 57
Relay contact on maker, input 2p. 57
+88xp. 57
88xp. 57
+Relay contact on maker, input 3p. 57
Relay contact on maker, input 3p. 57
+B+p. 57
B+p. 57
+Battery positivep. 57
Battery positivep. 57
+B-p. 57
B-p. 57
+Battery minusp. 57
Battery minusp. 57
+D+p. 57
D+p. 57
+Dynamo Plusp. 57
Dynamo Plusp. 57
+D-p. 57
D-p. 57
+Dynamo Minusp. 57
Dynamo Minusp. 57
+DFp. 57
DFp. 57
+Dynamo field (generator excitation current)p. 57
Dynamo field (generator excitation current)p. 57
+DF1p. 57
DF1p. 57
+Dynamo field 1 (generator excitation current)p. 57
Dynamo field 1 (generator excitation current)p. 57
+DF2p. 57
DF2p. 57
+Dynamo field 2 (generator excitation current)p. 57
Dynamo field 2 (generator excitation current)p. 57
+5 Electricsp. 59
+5 Electricsp. 59
5.1 Designation of components in the wiring diagramp. 60
+The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 60
The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table.p. 60
Control lights, warning buzzer, warning lightp. 60
+Kp. 60
Kp. 60
+Relaysp. 60
Relaysp. 60
+Mp. 60
Mp. 60
+Starter, pumps, motorsp. 60
Starter, pumps, motorsp. 60
+Pp. 60
Pp. 60
+Operating hour meter, general gaugesp. 60
Operating hour meter, general gaugesp. 60
+Rp. 60
Rp. 60
+Transducers, resistorsp. 60
Transducers, resistorsp. 60
+Sp. 60
Sp. 60
+Switches, momentary contact switchesp. 60
Switches, momentary contact switchesp. 60
+Vp. 60
Vp. 60
+Diodep. 60
Diodep. 60
+Xp. 60
Xp. 60
+Terminalp. 60
Terminalp. 60
+Yp. 60
Yp. 60
+Solenoid valvesp. 60
Solenoid valvesp. 60
5.2 Terminal designations in wiring diagramp. 61
+For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 61
+For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 61
For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ta…p. 61
+Terminal designationp. 61
Terminal designationp. 61
+Meaningp. 61
Meaningp. 61
+15p. 61
15p. 61
+Switch plus (after battery) : Output of ignition switchp. 61
Switch plus (after battery) : Output of ignition switchp. 61
+15ap. 61
15ap. 61
+Output from dropping resistor to ignition coil and starterp. 61
Output from dropping resistor to ignition coil and starterp. 61
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 61
Battery changeover relay 12V / 24V return line to battery 2 minusp. 61
+31bp. 61
31bp. 61
+Return line to battery minus or ground via switch or relay (switched minus)p. 61
Return line to battery minus or ground via switch or relay (switched minus)p. 61
+31cp. 61
31cp. 61
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 61
Battery changeover relay 12V / 24V return line to battery 1 minusp. 61
+49p. 61
49p. 61
+Input flasher relayp. 61
Input flasher relayp. 61
+49ap. 61
49ap. 61
+Output flasher relayp. 61
Output flasher relayp. 61
+49bp. 61
49bp. 61
+Flasher relay output 2nd flasher circuitp. 61
Flasher relay output 2nd flasher circuitp. 61
+49cp. 61
49cp. 61
+Flasher relay output 3rd flasher circuitp. 61
Flasher relay output 3rd flasher circuitp. 61
+50p. 61
50p. 61
+Starter, starter controlp. 61
Starter, starter controlp. 61
+50ap. 61
50ap. 61
+Battery changeover relay, output for starter controlp. 61
Battery changeover relay, output for starter controlp. 61
+53p. 61
53p. 61
+Wiper motor input (+)p. 61
Wiper motor input (+)p. 61
+53ap. 61
53ap. 61
+Wiper motor (+) end limit shut downp. 61
Wiper motor (+) end limit shut downp. 61
+53bp. 61
53bp. 61
+Wiper shunt windingp. 61
Wiper shunt windingp. 61
+56p. 61
56p. 61
+Head lightp. 61
Head lightp. 61
+56ap. 61
56ap. 61
+Head light, travel light and travel light controlp. 61
Head light, travel light and travel light controlp. 61
+56bp. 61
56bp. 61
+Head lights, dimmed head lightp. 61
Head lights, dimmed head lightp. 61
+56dp. 61
56dp. 61
+Head lights, flash lightp. 61
Head lights, flash lightp. 61
+57p. 61
57p. 61
+Parking light for motor cycles (abroad also for cars and trucks)p. 61
Parking light for motor cycles (abroad also for cars and trucks)p. 61
+57ap. 61
57ap. 61
+Parking lightp. 61
Parking lightp. 61
+57Lp. 61
57Lp. 61
+Parking light leftp. 61
Parking light leftp. 61
+57Rp. 61
57Rp. 61
+Parking light rightp. 61
Parking light rightp. 61
+58p. 61
58p. 61
+Side lights, tail light, number plate light, dashboard lightp. 61
Side lights, tail light, number plate light, dashboard lightp. 61
+58bp. 61
58bp. 61
+Tail light changeover for single axle trailersp. 61
Tail light changeover for single axle trailersp. 61
+58cp. 61
58cp. 61
+Trailer plug for single core wired and trailer fused tail lightp. 61
Trailer plug for single core wired and trailer fused tail lightp. 61
+58dp. 61
58dp. 61
+Adjustable dashboard light, tail light and side lightp. 61
Adjustable dashboard light, tail light and side lightp. 61
+58Lp. 61
58Lp. 61
+Side light, leftp. 61
Side light, leftp. 61
+58Rp. 61
58Rp. 61
+Side light, rightp. 61
Side light, rightp. 61
+61p. 61
61p. 61
+Generator controlp. 61
Generator controlp. 61
+75p. 61
75p. 61
+Radio, cigarette lighterp. 61
Radio, cigarette lighterp. 61
+76p. 61
76p. 61
+Loudspeakerp. 61
Loudspeakerp. 61
+87p. 61
87p. 61
+Relay contact on breaker and two-way contact, inputp. 61
Relay contact on breaker and two-way contact, inputp. 61
+87ap. 62
87ap. 62
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 62
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 62
+87bp. 62
87bp. 62
+Relay contact on breaker and two-way contact, output 2p. 62
Relay contact on breaker and two-way contact, output 2p. 62
+87cp. 62
87cp. 62
+Relay contact on breaker and two-way contact, output 3p. 62
Relay contact on breaker and two-way contact, output 3p. 62
+87zp. 62
87zp. 62
+Relay contact on breaker and two-way contact, input 1p. 62
Relay contact on breaker and two-way contact, input 1p. 62
+87yp. 62
87yp. 62
+Relay contact on breaker and two-way contact, input 2p. 62
Relay contact on breaker and two-way contact, input 2p. 62
+87xp. 62
87xp. 62
+Relay contact on breaker and two-way contact, input 3p. 62
Relay contact on breaker and two-way contact, input 3p. 62
+88p. 62
88p. 62
+Relay contact for makerp. 62
Relay contact for makerp. 62
+88ap. 62
88ap. 62
+Relay contact on maker and two-way contact, (maker side) output 1p. 62
Relay contact on maker and two-way contact, (maker side) output 1p. 62
+88bp. 62
88bp. 62
+Relay contact on maker and two-way contact, (maker side) output 2p. 62
Relay contact on maker and two-way contact, (maker side) output 2p. 62
+88cp. 62
88cp. 62
+Relay contact on maker and two-way contact, (maker side) output 3p. 62
Relay contact on maker and two-way contact, (maker side) output 3p. 62
+88zp. 62
88zp. 62
+Relay contact on maker, input 1p. 62
Relay contact on maker, input 1p. 62
+88yp. 62
88yp. 62
+Relay contact on maker, input 2p. 62
Relay contact on maker, input 2p. 62
+88xp. 62
88xp. 62
+Relay contact on maker, input 3p. 62
Relay contact on maker, input 3p. 62
+B+p. 62
B+p. 62
+Battery positivep. 62
Battery positivep. 62
+B-p. 62
B-p. 62
+Battery minusp. 62
Battery minusp. 62
+D+p. 62
D+p. 62
+Dynamo Plusp. 62
Dynamo Plusp. 62
+D-p. 62
D-p. 62
+Dynamo Minusp. 62
Dynamo Minusp. 62
+DFp. 62
DFp. 62
+Dynamo field (generator excitation current)p. 62
Dynamo field (generator excitation current)p. 62
+DF1p. 62
DF1p. 62
+Dynamo field 1 (generator excitation current)p. 62
Dynamo field 1 (generator excitation current)p. 62
+DF2p. 62
DF2p. 62
+Dynamo field 2 (generator excitation current)p. 62
Dynamo field 2 (generator excitation current)p. 62
+DTM Seriesp. 63
5.3 Battery ground and analog groundp. 63
+GND, battery groundp. 63
GND, battery groundp. 63
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. 63
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. 63
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. 63
Terminal designation for GND = terminale 31p. 63
+AGND, analog groundp. 63
AGND, analog groundp. 63
Apart from the "normal" battery ground there is also the analog ground, which is solely reserved for sensors.p. 63
+DTM Seriesp. 63
5.4 Current and voltagep. 63
+Generalp. 63
Generalp. 63
If one wants to describe electric current, this can most simply be accomplished by means of a comparison:p. 63
One simply compares electric current with water.p. 63
+Voltagep. 63
Voltagep. 63
Fig. 1p. 63
+1 (Fig. 1) Chargep. 63
+1 (Fig. 1) Chargep. 63
1 (Fig. 1)p. 63
2 Voltagep. 63
3 Currentp. 63
+The equalization attempt between different electric charges is referred to as electric voltage.p. 63
The equalization attempt between different electric charges is referred to as electric voltage.p. 63
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. 63
Fig. 2p. 63
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.p. 63
Plus pole= lack of electronsp. 63
Minus pole = excess of electronsp. 63
The following statements concerning electric voltage can be madep. 64
+electric voltage is the pressure or force applied to free electrons.p. 64
electric voltage is the pressure or force applied to free electrons.p. 64
the electric voltage is the cause of electric currentp. 64
electric voltage is a result of the equalization attempt of electric charges.p. 64
Voltage is measured with a Voltmeter.p. 64
Unit, Voltp. 64
The electric voltage (U) is measured in Volt (V).p. 64
Currentp. 64
+Electric current generally describes the directed movement of charge carriers.p. 64
Electric current generally describes the directed movement of charge carriers.p. 64
+The charge carriers may either be electrons or ions.p. 64
The charge carriers may either be electrons or ions.p. 64
Electric current can only flow if there is a sufficient amount of free moving charge carriers.p. 64
The higher the number of electrons flowing through a conductor per second, the higher the amperage.p. 64
Current is measured with an ammeter.p. 64
Unit, Amperep. 64
The electric amperage (I) is measured in Ampere (A).p. 64
The technical flow direction is specified from PLUS to MINUS.p. 64
+Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 64
Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 64
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. 64
+Circuitp. 64
Circuitp. 64
Fig. 3 Circuitp. 64
+A simple circuit consists of a current source 1p. 64
(Fig. 3)p. 64
When the circuit is closed, current can flow.p. 64
The circuit can be interrupted or closed with a switch (2).p. 64
The system is protected by a fuse (4).p. 64
Types of currentp. 65
+Direct current (D.C.)p. 65
Direct current (D.C.)p. 65
Fig. 1 Direct current (D.C.)p. 65
Direct current flows with steady voltage and amperage from the plus to the minus pole.p. 65
Pure D.C.-voltages are only delivered by accumulators or batteries.p. 65
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. 65
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off.p. 65
+Alternating current (A.C.)p. 65
Alternating current (A.C.)p. 65
Fig. 2 Alternating current (A.C.)p. 65
Alternating current not only changes its direction, but also its amperage.p. 65
+DTM Seriesp. 66
5.5 Pulse Width Modulation (PWM)p. 66
+Pulse width modulation (PWM)p. 66
Pulse width modulation (PWM)p. 66
PWM is the abbreviation for Pulse Width Modulation, frequently also referred to as "Pulse Pause Modulation" (PPM). It is used in the field of controls for mobile and robust applications, mainly to control proportional valves (PWM-valves).p. 66
The following applies:p. 66
+The signal voltage cannot be measured.p. 66
The signal voltage cannot be measured.p. 66
The current can be measured.p. 66
+PWM-solenoid valves must not be interference suppressed with suppressor diodes.p. 66
PWM-solenoid valves must not be interference suppressed with suppressor diodes.p. 66
What does a PWM-output do?p. 66
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 quick sequence of many square-wave p…p. 66
Fig. 1p. 66
+(Fig. 1)Course of PWM-voltage U and coil current I at 10 % duty cycle The effective coil current Ieff is also 10 %.p. 66
(Fig. 1)p. 66
Fig. 1p. 66
+(Fig. 1) Course of PWM-voltage U and coil current I at 50 % duty cycle The effective coil current Ieff is also 50 %.p. 66
(Fig. 1)p. 66
Fig. 1p. 67
+(Fig. 1) Course of PWM-voltage U and coil current I at 100 % duty cycle The effective coil current Ieff is also 100 %.p. 67
(Fig. 1)p. 67
+What does Dither mean?p. 67
What does Dither mean?p. 67
When a proportional hydraulic valve is triggered, its spool will not move immediately and at the beginning it will also not move proportionally to the coil current. Due to this "Slip-Stick effect" – a kine of "breakaway torque" – the valve right at t…p. 67
Engineering tackles this problem by subjecting the valve spool to an almost insignificant shuttle movement (the dither). The piston thereby permanently performs a shuttle movement and can therefore not "stick". Even very small position changes now ta…p. 67
Advantage: The hydraulic cylinder actuated this way can be controlled with a much higher sensitivity.p. 67
Disadvantage: With dither the valves becomes noticeably warmer, because the valve spool is permanently in action.p. 67
+DTM Seriesp. 68
5.6 Logical base gatesp. 68
+Generalp. 68
Generalp. 68
+In modern electronics links (logic base gates) are used for data processing and digitizing.p. 68
In modern electronics links (logic base gates) are used for data processing and digitizing.p. 68
They arrange the vast variety of entered signals according to certain established mathematical rules. They thereby "set the points" for all incoming signals.p. 68
Links enable certain computing operations, such as addition, subtraction, multiplication, etc.p. 68
In digital technology circuits are today generally bulit up with electronic components: resistors, diodes, transistors, capacitors, etc.p. 68
This enables clear circuits with all components. Assemblies are also replaced by simplified circuit symbols.p. 68
+Truth tablep. 68
Truth tablep. 68
The truth table is a tabular representation of events for logic links, as used in boolean algebra. Truth tables are created for the logic links AND gate, OR gate, NOT gate etc., for flip-flops and for extensive logic circuits, under due consideration…p. 68
+AND / Conjunctionp. 68
AND / Conjunctionp. 68
+AND is called a conjunction.p. 68
AND is called a conjunction.p. 68
AND is a basic gate working on the principle that the result is true, if two states or statements are true:p. 68
If A and B, then…p. 68
Fig. 1 AND gatep. 68
Truth table AND gatep. 68
Output Q is always 1, if the inputs A and B are equal 1.p. 68
+Ap. 68
Ap. 68
+Bp. 68
Bp. 68
+Qp. 68
Qp. 68
+0p. 68
0p. 68
+0p. 68
0p. 68
+0p. 68
0p. 68
+0p. 68
0p. 68
+1p. 68
1p. 68
+0p. 68
0p. 68
+1p. 68
1p. 68
+0p. 68
0p. 68
+0p. 68
0p. 68
+1p. 68
1p. 68
+1p. 68
1p. 68
+1p. 68
1p. 68
This logic gate is also known as AND gate. Any circuit corresponding with the truth table is an AND gate.p. 68
The following rules apply:p. 68
Output Q is only 1, if all inputs are 1.p. 68
Output Q is 0, if at least one input is 0.p. 68
Substitute circuit with relayp. 68
Fig. 2 AND relay circuitp. 68
+OR / Disjunctionp. 68
OR / Disjunctionp. 68
OR is called a disjunction.p. 68
OR is a base gate working on the principle that the result is true, if one or the other condition or one or the other statement is true:p. 68
If A or B, then…p. 68
Fig. 3 OR gatep. 69
Truth table OR gatep. 69
Output Q is always 1, if the inputs A or B are equal 1.p. 69
+Ap. 69
Ap. 69
+Bp. 69
Bp. 69
+Qp. 69
Qp. 69
+0p. 69
0p. 69
+0p. 69
0p. 69
+0p. 69
0p. 69
+0p. 69
0p. 69
+1p. 69
1p. 69
+1p. 69
1p. 69
+1p. 69
1p. 69
+0p. 69
0p. 69
+1p. 69
1p. 69
+1p. 69
1p. 69
+1p. 69
1p. 69
+1p. 69
1p. 69
This logic gate is also known as OR gate. Any circuit corresponding with the truth table is an OR gate.p. 69
The following rules apply:p. 69
Output Q is 1, if at least one input is 1.p. 69
Output Q is only 0, if all inputs are 0.p. 69
Substitute circuit with relayp. 69
Fig. 4 OR relay circuitp. 69
+NOT / Negationp. 69
NOT / Negationp. 69
A negation or Not-function is given if one or several functions or conditions lead to the fact, that the result is NOT true. NOT is a base gate working on the principle that the result is NOT true, if one and/or several condition(s) or one/several st…p. 69
If A or B, then not…p. 69
The negation can obviously also be linked with an AND or OR gate. The results are then: NOT-, NAND- , NOR-Gate:p. 69
NOT-Gatep. 69
Fig. 5 NOT-Gatep. 69
Truth table NOT gatep. 69
Output Y is 0, if input A is equal 1.p. 69
+Ap. 69
Ap. 69
+Yp. 69
Yp. 69
+1p. 69
1p. 69
+0p. 69
0p. 69
+0p. 69
0p. 69
+1p. 69
1p. 69
Fig. 6 NOT relay circuitp. 69
NAND-Gatep. 70
Fig. 7 NAND-Gatep. 70
Truth table NAND gatep. 70
Output Y is 0, if the inputs A and B are equal 1.p. 70
+Ap. 70
Ap. 70
+Bp. 70
Bp. 70
+Yp. 70
Yp. 70
+0p. 70
0p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+1p. 70
1p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+1p. 70
1p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
Fig. 8 NAND-relay circuitp. 70
NOR-Gatep. 70
Fig. 9 NOR-Gatep. 70
Truth table NOR gatep. 70
Output Y is 0, if input A or input B is equal 1.p. 70
+Ap. 70
Ap. 70
+Bp. 70
Bp. 70
+Yp. 70
Yp. 70
+0p. 70
0p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
+0p. 70
0p. 70
+1p. 70
1p. 70
+1p. 70
1p. 70
+0p. 70
0p. 70
Substitute circuit with relayp. 70
Fig. 10 NOR-relay circuitp. 70
+DTM Seriesp. 71
5.7 Resistancep. 71
+Resistance and voltage dropp. 71
Resistance and voltage dropp. 71
+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. 71
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. 71
Fig. 1 Various size resistorsp. 71
+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. 71
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. 71
The resistance can only be measured with a Multimeter.p. 71
Symbol, Rp. 71
+Unit, Ohmp. 71
Wp. 71
+The electric resistance (R) is measured in Ohmp. 71
Wp. 71
Rule of thumb:p. 71
+The thicker the cable cross-section, the lower the voltage loss.p. 71
The thicker the cable cross-section, the lower the voltage loss.p. 71
The shorter the cable, the better the current.p. 71
The cleaner the contacts, the better the current.p. 71
The quality of the ground cable is of the same importance as the supply line.p. 71
+Unnecessary resistancesp. 71
Unnecessary resistancesp. 71
+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. 71
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. 71
Badp. 71
Fig. 1 Screw-type terminalsp. 71
Copper wires are squashed and thus become faulty.p. 71
+Betterp. 71
Betterp. 71
Fig. 2 Spring clampsp. 71
Connecting clamps for flexible conductorsp. 71
BOMAG No. 057 565 72p. 71
Ampacity up to 20 Amp.p. 71
Cable cross-section 0.08 to 2.5 qmmp. 71
Fig. 3p. 72
+In many cases it is better to replace the contact. Soiled or oxidized contacts should be cleaned with Ballistolp. 72
(Fig. 4)p. 72
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. 72
Fig. 4 Balistol oilp. 72
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. 72
Fig. 5p. 72
Hint for practice:p. 72
A tool you cannot buy. The pliers were converted, the nail is permanently present.p. 72
+DTM Seriesp. 73
5.8 Series / parallel connectionp. 73
+Series connectionp. 73
Series connectionp. 73
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. 73
Fig. 1 Series connectionp. 73
Currentp. 73
In series connection the current is identical at every point.p. 73
Itotal = I1 = I2 = I3p. 73
Voltagep. 73
The sum of all partial voltages is identical with the total voltage.p. 73
Utotal = U1 + U2 + U3p. 73
Resistancep. 73
The sum of all partial resistances is identical with the total resistance.p. 73
Rtotal = R1 + R2 + R3p. 73
+Series connection of batteriesp. 73
Series connection of batteriesp. 73
Fig. 2p. 73
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. 73
+In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 73
In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 73
The sum of all individual voltages is applied to the free poles.p. 73
The total capacity (Ah) is identical with the capacity of the individual battery.p. 73
+Parallel connection of batteriesp. 74
Parallel connectionp. 74
In parallel connection all resistances (consumers) are connected between feed and return line.p. 74
+All resistances (consumers) are supplied with the same voltage.p. 74
All resistances (consumers) are supplied with the same voltage.p. 74
Each of the resistances (consumers) draws as much current as required.p. 74
Fig. 3 Parallel connectionp. 74
Currentp. 74
The total current is the sum of all currents.p. 74
Itotal = I1 + I2 + I3p. 74
Voltagep. 74
The voltage values are identical at every resistance (consumer).p. 74
Utotal = U1 = U2 = U3p. 74
Resistancep. 74
The total resistance is less than the lowest individual resistance.p. 74
+Parallel connection of batteriesp. 74
Parallel connection of batteriesp. 74
Fig. 4p. 74
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. 74
+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. 74
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. 74
Plus and minus poles have the voltage of the single battery applied.p. 74
The total capacity (Ah) is identical with the sum of all battery capacities.p. 74
The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of charging.p. 74
+DTM Seriesp. 75
5.9 Ohm's lawp. 75
+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. 75
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. 75
Fig. 1p. 75
+According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohmp. 75
Wp. 75
Advicep. 75
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. 75
Voltage U = I multiplied with Rp. 75
Resistance R = U divided by Ip. 75
Amperage I = U divided by Rp. 75
U = Voltage in Voltp. 75
I = Current in Amperep. 75
+R = Resistance in OHMp. 75
Wp. 75
+DTM Seriesp. 75
5.10 Electrical energyp. 75
Fig. 1p. 75
In a closed electric circuit current and voltage generate energy.p. 75
If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced.p. 75
Advicep. 75
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. 75
Energy P = I multiplied with Up. 75
Amperage I = P divided by Up. 75
Voltage U = P divided by Ip. 75
U = Voltage in Voltp. 75
I = Current in Amperep. 75
P = Power in Wattp. 75
+DTM Seriesp. 76
5.11 Formula diagramp. 76
+Description:p. 76
Description:p. 76
+Select the desired value from the inner circle.p. 76
Select the desired value from the inner circle.p. 76
Determine the formula variables in the quarter circlep. 76
Calculatep. 76
Example:p. 76
P = 150 Wattp. 76
U = 24 Voltp. 76
Sought for = Current in Amperep. 76
I = P : U = 150 W : 24 Volt = 6.25 Amperep. 76
Fig. 1 Formula diagramp. 76
+Resistance, R Ohmp. 76
Wp. 76
Voltage, U Voltp. 76
Current, I Amperep. 76
Power, P Wattp. 76
+DTM Seriesp. 77
5.12 Metrologyp. 77
+Test lampsp. 77
Test lampsp. 77
+Test lampp. 77
Test lampp. 77
Fig. 1 Test lampp. 77
+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. 77
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. 77
+Diode test lampp. 77
Diode test lampp. 77
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. 77
Fig. 2 Diode test lampp. 77
If voltage is present, the corresponding light emitting diode will light up.p. 77
Multimeterp. 77
+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. 77
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. 77
Fig. 1 Multimeterp. 77
In order to avoid damage:p. 77
+the range selector switch must be correctly set for the corresponding measurement.p. 77
the range selector switch must be correctly set for the corresponding measurement.p. 77
the test cable must be plugged into the correct socket.p. 77
the voltage type (AC/DC) must be set.p. 77
In case of direct voltage the correct polarity must be assured.p. 77
the measuring range should be chosen higher at the beginning of the test.p. 77
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. 77
Resistance and continuity measurement with multimeterp. 78
Fig. 2p. 78
The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points.p. 78
Fig. 3p. 78
The following information should be observed when measuring resistance and continuity:p. 78
+The component to be measured must not be connected to the power supply during the measurement.p. 78
The component to be measured must not be connected to the power supply during the measurement.p. 78
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. 78
Polarity is of no significance.p. 78
Voltage and voltage drop measurement with multimeterp. 78
Fig. 4 Measuring voltagep. 78
+Measurement at the voltage source measures the currently available Voltage.p. 78
Measurement at the voltage source measures the currently available Voltage.p. 78
The meter is always connected parallel to consumer, component or power source.p. 78
Fig. 5 Voltage measurementp. 78
+A measurement at the consumer measures the voltage drop at this component.p. 78
A measurement at the consumer measures the voltage drop at this component.p. 78
Current measurement with the multimeterp. 79
Fig. 6 Measuring currentp. 79
+The meter is connected in series with the consumer.p. 79
The meter is connected in series with the consumer.p. 79
During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened.p. 79
Fig. 7 Current measurementp. 79
Advicep. 79
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. 79
The current value can then be calculated with the help of Ohm's law.p. 79
Clip-on measuring instrumentp. 79
+The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 79
The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 79
Fig. 1 Clip-on measuring instrumentp. 79
Fig. 2p. 79
+For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 79
For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 79
Magnet testerp. 80
Fig. 1 Magnet testerp. 80
The magnet tester is used to test solenoid valves and magnetic coils.p. 80
The test lamp responds to the magnetic fields of A.C- voltage, D.C.-voltage and permanent magnets.p. 80
+The component to be tested does not need to be removed.p. 80
The component to be tested does not need to be removed.p. 80
The magnetic coil can also be tested under a protective cap.p. 80
Power measurementp. 80
The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage.p. 80
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. 80
Fig. 2p. 80
+DTM Seriesp. 81
5.13 Diodes, relays, fusesp. 81
+Diodesp. 81
Diodesp. 81
Fig. 1p. 81
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. 81
Plus-voltage on diode:p. 81
+At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 81
At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 81
Negative voltage on diode:p. 81
+The diode does not allow current to pass through.p. 81
The diode does not allow current to pass through.p. 81
Fig. 2 Marking of the cathodep. 81
Diodes are used:p. 81
+For rectifying A.C. voltage.p. 81
For rectifying A.C. voltage.p. 81
For absorbing voltage peaks (free-wheeling diode).p. 81
For construction of logical circuits.p. 81
+Diode logics and free-wheeling diodep. 81
Diode logics and free-wheeling diodep. 81
Fig. 3 Diode circuitryp. 81
+The solenoid valve Y48p. 81
+The solenoid valve Y48p. 81
(Fig. 3)p. 81
Solenoid valve Y20 is supplied, if the switch is in position "1".p. 81
Solenoid valve Y21 is supplied, if the switch is in position "2".p. 81
The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.p. 81
+Light emitting diodesp. 82
Light emitting diodesp. 82
Fig. 4 LEDp. 82
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. 82
Relaysp. 82
Fig. 1 Relaysp. 82
Relays are commonly used to realize switching processes.p. 82
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. 82
With the possibility of using breaker – maker contacts the effect of an information can be reversed.p. 82
Fig. 2 Relay circuitryp. 82
+The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric currentp. 82
(Fig. 2)p. 82
86 = Positive supply for coilp. 82
85 = Ground supply for coilp. 83
30 = Supply voltagep. 83
87 = Normally open contactp. 83
87a= Normally closed contactp. 83
Fusesp. 83
Fig. 1p. 83
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. 83
+Fuses must not be repaired or bridged.p. 83
Fuses must not be repaired or bridged.p. 83
The melting time at 23 °C is:p. 83
+approx. 1 hour with 1.5 times the rated currentp. 83
approx. 1 hour with 1.5 times the rated currentp. 83
approx. 1 minute with 2.5 times the rated current.p. 83
A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours.p. 83
Yellow = 5 Ap. 83
Brown = 7.5 Ap. 83
White = 8 Ap. 83
Red = 16 Ap. 83
Blue = 25 Ap. 83
+DTM Seriesp. 84
5.14 Telemecanique switchp. 84
+Disassemblyp. 84
Disassemblyp. 84
Fig. 1 Disassemblyp. 84
+Lift up the interlock (5).p. 84
Lift up the interlock (5).p. 84
Fig. 2 Folding down the switch blockp. 84
+Fold down the switch block (4).p. 84
Fold down the switch block (4).p. 84
Loosen screw (1).p. 84
Fig. 3 Pulling out the front elementp. 84
+Lift up the interlock (2) and pull out the front element (3).p. 84
Lift up the interlock (2) and pull out the front element (3).p. 84
Assemblyp. 85
Fig. 4 Assemblyp. 85
+Insert the front element (3) into the bore in the control panel.p. 85
Insert the front element (3) into the bore in the control panel.p. 85
Fig. 5 Observe the marks.p. 85
+Clip the fastening adapter (6) onto the front element (3).p. 85
Clip the fastening adapter (6) onto the front element (3).p. 85
+Watch the marls on front elementp. 85
+Watch the marls on front elementp. 85
(Fig. 5)p. 85
+Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 85
Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 85
Fig. 6 Assemble the switch blockp. 85
+Clip on the switch block (4).p. 85
Clip on the switch block (4).p. 85
+Hook in the switch block at the bottom firstp. 85
+Hook in the switch block at the bottom firstp. 85
(Fig. 6)p. 85
+DTM Seriesp. 86
5.15 Plug connectorsp. 86
+Duties and requirementsp. 86
Duties and requirementsp. 86
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. 86
+Examples for these loads are:p. 86
Examples for these loads are:p. 86
+Vibration accelerationp. 86
Vibration accelerationp. 86
Temperature fluctuations, high and low temperaturesp. 86
Dampnessp. 86
Micro movements of the contact with resulting friction corrosion.p. 86
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. 86
+Low transition resistances of the conductive parts.p. 86
Low transition resistances of the conductive parts.p. 86
High insulation strength between conductive parts with different voltage potentials.p. 86
Excellent leak tightness against water and moisture.p. 86
+DTM Seriesp. 86
5.16 Magnetic coil plugp. 86
+Magnetic coil plug with LED and suppressor diodep. 86
Magnetic coil plug with LED and suppressor diodep. 86
The plug is equipped with a polarized function display and a suppressor diode as protection against overvoltages.p. 86
Fig. 7p. 86
The plug is reverse polarity protected, it does not matter whether Pin1 or Pin 2 is supplied with current, Pin 3 is not used. The LED lights if voltage is applied to the solenoid valve.p. 86
Fig. 8p. 86
Fig. 9 Switching symbol in circuit diagramp. 86
+Magnetic coil plug without LED and without supressor diodep. 86
Magnetic coil plug without LED and without supressor diodep. 86
The plug has no LED and no suppressor diode as protection against overvoltages.p. 86
+Assembly of magnetic coil plugsp. 87
Assembly of magnetic coil plugsp. 87
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. 87
Fig. 10 Solenoid valve plug with pointed cablep. 87
Fig. 11p. 87
+Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 87
Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 87
Fig. 12p. 87
+Fasten the screw with a suitable screwdriver.p. 87
Fasten the screw with a suitable screwdriver.p. 87
Fig. 13p. 87
+Press the plug firmly on again.p. 87
Press the plug firmly on again.p. 87
Fig. 14p. 87
+Retighten the screw.p. 87
Retighten the screw.p. 87
Fig. 15p. 88
+There should be no gap between plug and solenoid coil!p. 88
There should be no gap between plug and solenoid coil!p. 88
Fig. 16 Correctly installed plug without gapp. 88
+DTM Seriesp. 88
5.17 Deutsch plug, series DT and DTMp. 88
+Generalp. 88
Generalp. 88
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. 88
Fig. 17 Crimp connectionsp. 88
+Do not crimp more than one lead per pin or per socket.p. 88
Do not crimp more than one lead per pin or per socket.p. 88
Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics).p. 88
When connecting sockets and plugs these must engage with a noticeable click when both halves interlock.p. 88
The plug connection should not be separable (without loosening the interlock).p. 88
Pulling testp. 88
This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing.p. 88
+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. 88
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. 88
+DT Seriesp. 89
DT Seriesp. 89
Fig. 1 DT plug connectionp. 89
Fig. 2 DT Seriesp. 89
Fig. 3 Sectional drawingp. 89
+DTM Seriesp. 90
DT Seriesp. 90
+Installing DT contactsp. 90
Installing DT contactsp. 90
Fig. 4p. 90
+Insert the contacts through the rubber grommet until they click into place.p. 90
Insert the contacts through the rubber grommet until they click into place.p. 90
Insert the orange wedge in direction of arrow.p. 90
+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. 90
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. 90
+Use the same method when assembling the socket.p. 90
Use the same method when assembling the socket.p. 90
+Disassembling DT contactsp. 90
Disassembling DT contactsp. 90
Fig. 5p. 90
+Pull the orange wedge out with long nose pliers.p. 90
Pull the orange wedge out with long nose pliers.p. 90
Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 90
Pull the contact out of the socket.p. 90
+Use the same method when assembling the socket.p. 90
Use the same method when assembling the socket.p. 90
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 90
+DTM Seriesp. 91
DTM Seriesp. 91
Fig. 6 DTM Seriesp. 91
Fig. 7 Sectional drawingp. 91
+Installing DTM contactsp. 91
Installing DTM contactsp. 91
Fig. 8p. 91
+Insert the contacts through the rubber grommet until they click into place.p. 91
Insert the contacts through the rubber grommet until they click into place.p. 91
Insert the orange wedge, until it clicks into place.p. 91
+Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 92
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 92
+Use the same method when assembling the socket.p. 92
Use the same method when assembling the socket.p. 92
+Removing DTM contactsp. 92
Removing DTM contactsp. 92
Fig. 9p. 92
+Pull the orange wedge (interlock) out with long nose pliers.p. 92
Pull the orange wedge (interlock) out with long nose pliers.p. 92
Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 92
Pull the contact out of the socket.p. 92
+Use the same method when assembling the socket.p. 92
Use the same method when assembling the socket.p. 92
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 92
+5.21 Battery service, check the main battery switchp. 93
5.18 Plugs and terminals in spring clamping technologyp. 93
+Generalp. 93
Generalp. 93
Fig. 1p. 93
+The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 93
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 93
+Spring clamp technologyp. 93
(Fig. 1)p. 93
+Connecting terminal for quick repairsp. 93
Connecting terminal for quick repairsp. 93
Fig. 2 That's how it worksp. 93
BOMAG part-no.: 057 565 72p. 93
+The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mmp. 93
2p. 93
2p. 93
2p. 93
(Fig. 2)p. 93
That's how it worksp. 93
+Strip 9-10 mm of the lead.p. 93
Strip 9-10 mm of the lead.p. 93
Open the actuating lever and insert the strand.p. 93
Return the actuating lever to initial position.p. 93
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 93
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 93
+X-COM plug clampp. 94
Series clampp. 94
Fig. 3 That's how it worksp. 94
That's how it worksp. 94
+Insert a screw driver into the actuating opening until it bottoms.p. 94
Insert a screw driver into the actuating opening until it bottoms.p. 94
Strip 9-10 mm of the lead and insert it into the clamp.p. 94
Pull out the screw driver.p. 94
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 94
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 94
Measuring signalsp. 94
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. 94
Fig. 4 Test adapterp. 94
+X-COM plug clampp. 95
X-COM Systemp. 95
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. 95
+X-COM plug clampp. 95
X-COM plug clampp. 95
Fig. 5 That's how it worksp. 95
That's how it worksp. 95
+Insert a screw driver into the actuating opening until it bottoms.p. 95
Insert a screw driver into the actuating opening until it bottoms.p. 95
Strip 9-10 mm of the lead and insert it into the plug.p. 95
Pull out the screw driver.p. 95
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 95
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 95
Fig. 6 X-COM plug with measuring cablep. 95
+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. 95
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. 95
Measuring signalsp. 96
Fig. 7 X-COM plug plugged onto the series clampp. 96
+5.21 Battery service, check the main battery switchp. 97
5.19 Inductive proximity switchesp. 97
+Generalp. 97
Generalp. 97
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. 97
+Working principlep. 97
Working principlep. 97
Fig. 8p. 97
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. 97
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. 97
+PNP circuitryp. 97
PNP circuitryp. 97
Fig. 9 PNP circuitryp. 97
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. 97
+NPN circuitryp. 97
NPN circuitryp. 97
Fig. 10 NPN circuitryp. 97
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. 97
+Breaking and making contactsp. 97
Breaking and making contactsp. 97
Fig. 11p. 97
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. 97
+The LEDp. 97
(Fig. 11)p. 97
Fig. 12 Circuit diagram, making contactp. 98
+The circuit diagramp. 98
(Fig. 12)p. 98
Brown = voltage supplyp. 98
Blue = ground supplyp. 98
Black = switching outputp. 98
The initiator switches the relay (K05)p. 98
+5.21 Battery service, check the main battery switchp. 98
5.20 Batteriesp. 98
+Battery – accumulatorp. 98
Battery – accumulatorp. 98
Fig. 1p. 98
In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries.p. 98
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.p. 98
The basic element of a lead accumulator is the cell. It contains the plate blocks consisting of positive and negative plates. These plates are separated from each other by separators.p. 98
All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.p. 98
Fig. 2p. 98
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.p. 98
Capacityp. 98
is a synonym for the amount of current taken up and discharged by a battery over a specified period of time.p. 98
+Battery maintenancep. 99
Battery maintenancep. 99
+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. 99
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. 99
If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself.p. 99
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. 99
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.p. 99
The following therefore applies for longer downtimes:p. 99
+Remove the battery and store it in a cool, dry and frost protected room.p. 99
Remove the battery and store it in a cool, dry and frost protected room.p. 99
Check the open circuit voltage on the battery at regular intervals (at least once every month).p. 99
Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).p. 99
+The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 99
The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 99
+Battery test in generalp. 99
Battery test in generalp. 99
+Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 99
Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 99
Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar.p. 99
+5.21 Battery service, check the main battery switchp. 99
Batteries with screw plugsp. 99
+Checking the electrolyte levelp. 99
Checking the electrolyte levelp. 99
Fig. 3p. 99
+1 Upper filling level markp. 99
1 Upper filling level markp. 99
2 Lower filling level markp. 99
+If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 99
If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells.p. 99
Checking the electrolyte densityp. 100
Fig. 4p. 100
+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. 100
3p. 100
3p. 100
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. 100
Fig. 5 Checking the electrolyte density:p. 100
1) correctp. 100
2) poorp. 100
3) poorp. 100
+(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 100
(Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte.p. 100
Do not draw too much electrolyte into the pipe.p. 100
Make sure that the float is not obstructed in its movement and hold the electrolyte tester at eye level.p. 100
The electrolyte tester must be read at the highest electrolyte level.p. 100
+If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 100
+If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formulap. 100
(reference)p. 100
Referencep. 100
The specific weight varies slightly with temperature. To be exact, the specific weight drops by 0.0007 per 1 °C temperature increase (by 0.0004 per 1 °F) and increases by 0,0007 per 1 °C temperature reduction (by 0,0004 per 1 °F) . If e.g. a temp…p. 100
+Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 100
Specific weight at 20 °C = measuring value + 0,0007 × (electrolyte temperature: 20 °C)p. 100
Specific weight at 68 °F = measuring value + 0,0004 × (electrolyte temperature: 68 °F)p. 100
+Acid density at 27 °C in kg/dmp. 100
3p. 100
+1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 100
1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.p. 100
1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary.p. 100
1.19 and less, open circuit voltage less than 12.3 Volt. Battery is insufficiently charged. The battery needs to be recharged immediately.p. 100
If there is a deviation of the specific weight of more than 0.05 between any of the cells, the battery needs to be replaced.p. 100
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. 100
+5.21 Battery service, check the main battery switchp. 101
Testing batteries without screw plugsp. 101
On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:p. 101
Fig. 6 Battery and generator testerp. 101
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. 101
+Before testing clean the poles and ensure good connection between clamps and poles.p. 101
Before testing clean the poles and ensure good connection between clamps and poles.p. 101
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. 101
The starting power can exceed 100%.p. 101
5.21 Battery service, check the main battery switchp. 101
+5.21 Battery service, check the main battery switchp. 102
5.21 Battery service, check the main battery switchp. 102
+Danger of cauterisation ! Danger of explosion!p. 102
+Danger of cauterisation ! Danger of explosion!p. 102
Danger of cauterisation ! Danger of explosion!p. 102
When working on the battery do not use open fire, do not smoke!p. 102
The battery contains acid. Do not let acid come in contact with skin or clothes!p. 102
Wear protective clothing!p. 102
Do not lay any tools on the battery!p. 102
For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.p. 102
+Dispose of the old batteries environmentally.p. 102
Dispose of the old batteries environmentally.p. 102
+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. 102
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. 102
The following therefore applies for the service life:p. 102
+Switch off all consumers (e.g. ignition, light, inside light, radio).p. 102
Switch off all consumers (e.g. ignition, light, inside light, radio).p. 102
Check open-circuit voltage of the battery at regular intervals. At least once per month.p. 102
Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.p. 102
+Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 102
Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 102
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.p. 102
+After each charging process allow the battery to rest for one hour before taking it into service.p. 102
After each charging process allow the battery to rest for one hour before taking it into service.p. 102
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. 102
+Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty!p. 102
Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty!p. 102
+Move the driver's platform fully to the right and open the cover.p. 102
Move the driver's platform fully to the right and open the cover.p. 102
Fig. 7p. 102
+Remove the batteryp. 102
+Remove the batteryp. 102
(Fig. 7)p. 102
Clean the outside of the battery.p. 102
Clean battery poles and pole clamps and grease them with pole grease (Vaseline).p. 102
Check the fastening of the battery.p. 102
On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.p. 102
+Checking the main battery switchp. 102
Checking the main battery switchp. 102
Fig. 8p. 102
+Turn the main battery switchp. 102
+Turn the main battery switchp. 102
(Fig. 8)p. 102
+5.22 Starting with jump wiresp. 103
5.22 Starting with jump wiresp. 103
+A wrong connection will cause severe damage in the electric system.p. 103
+A wrong connection will cause severe damage in the electric system.p. 103
A wrong connection will cause severe damage in the electric system.p. 103
Only use a 12 V battery to bridge the machine.p. 103
Fig. 9p. 103
+When jump starting with an external battery connect both plus poles first.p. 103
When jump starting with an external battery connect both plus poles first.p. 103
+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. 103
+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. 103
(Fig. 9)p. 103
Start as described under "Starting the engine".p. 103
+Once the engine is running switch on a powerful consumer (working light, etc.).p. 103
Once the engine is running switch on a powerful consumer (working light, etc.).p. 103
+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. 103
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. 103
+After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 103
After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 103
Switch off the consumer.p. 103
5.23 Generatorp. 103
+Generalp. 103
Generalp. 103
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. 103
Terminal designationsp. 103
+B61, L = charge controlp. 103
B61, L = charge controlp. 103
B+, B = battery plus, also with the designation "30"p. 103
B- = battery minus, also with the designation "31"p. 103
D+ = dynamo plus corresponds with terminal "61" and "L"p. 103
D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed)p. 103
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. 103
DF1 = dynamo field 1p. 103
DF2 = dynamo field 2p. 103
IG = "15" ignition switchp. 103
Three-phase generatorp. 104
+The AC-generator first of all produces AC-voltage / AC-current.p. 104
The AC-generator first of all produces AC-voltage / AC-current.p. 104
Why does AC-current need to be rectified?p. 104
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. 104
This includes :p. 104
+Incandescent lampsp. 104
Incandescent lampsp. 104
Fluorescent lampsp. 104
Glow lampsp. 104
Electric heating elements.p. 104
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. 104
This includes :p. 104
+Electric motorsp. 104
Electric motorsp. 104
Relays.p. 104
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.p. 104
This includes :p. 104
+Accumulatorsp. 104
Accumulatorsp. 104
Control unitsp. 104
All electronicsp. 104
Communication equipment.p. 104
+Design and functionp. 104
Design and functionp. 104
Fig. 10p. 104
+1 Fanp. 104
1 Fanp. 104
2 Holding platep. 104
3 Stator corep. 104
4 Stator windingp. 104
5 Brushp. 104
6 Brush holderp. 104
7 Rectifierp. 104
8 Bearing coverp. 104
9 Rotor windingp. 104
10 Rotorp. 104
11 V-belt pulleyp. 104
Fig. 11 Rotor with claw polesp. 104
+In the generator the armature windings are located inside the stationary statorp. 104
(Fig. 12)p. 104
(Fig. 11)p. 104
Fig. 12 Statorp. 104
+The three stator windingsp. 104
(Fig. 12)p. 104
Fig. 13 3-phase currentp. 105
+The wiring diagramp. 105
(Fig. 13)p. 105
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. 105
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. 105
Charge control lightp. 105
The charge control light has two duties:p. 105
+Indication of the correct generator functionp. 105
Indication of the correct generator functionp. 105
External excitation of the generator during the starting phasep. 105
Fig. 14 plus controlled charging regulatorp. 105
+(Fig. 14) shows the current flow with the ignition switched on, engine stopped.p. 105
(Fig. 14)p. 105
Fig. 15 plus controlled charging regulatorp. 105
+(Fig. 15) shows the current flow with the ignition switched on, engine running.p. 105
(Fig. 15)p. 105
+1 Batteryp. 105
1 Batteryp. 105
2 Charge controllerp. 105
3 Ignition switchp. 105
4 Charge control lightp. 105
5 Rectifierp. 105
6 Rotorp. 105
7 Sliprings / carbon brushp. 105
8 Auxiliary rectifierp. 105
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. 105
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. 106
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. 106
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. 106
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. 106
Charge controllerp. 106
The charge controller has the following functionsp. 106
+To regulate the voltage generated by the generatorp. 106
To regulate the voltage generated by the generatorp. 106
To protect against overloads caused by too high output currentp. 106
Protection against reverse currentp. 106
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. 106
+Electronic charge regulatorp. 106
Electronic charge regulatorp. 106
Fig. 16 Regulator, Kubota enginep. 106
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. 106
Checking the generatorp. 107
+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. 107
+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. 107
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. 107
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. 107
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. 107
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. 107
Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle.p. 107
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. 107
+First one must check whether the generator is actually defective.p. 107
First one must check whether the generator is actually defective.p. 107
+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. 107
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. 107
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. 107
The following points allow to contain faults in the voltage supply within certain limits.p. 107
+Cable connections on the generator OK?p. 107
Cable connections on the generator OK?p. 107
V-belt OK?p. 107
Generator ground (engine ground) OK?p. 107
Pre-excitation from vehicle electronics OK?p. 107
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. 107
5.24 Generator repairp. 108
+Dismantling and assemblingp. 108
Dismantling and assemblingp. 108
+Front housing flangep. 108
Front housing flangep. 108
Fig. 1p. 108
+1 Front housing flangep. 108
1 Front housing flangep. 108
2 Rear housing flangep. 108
3 (Screwp. 108
+Unscrew screws (3).p. 108
Unscrew screws (3).p. 108
Separate front (1) and rear housing flanges (2).p. 108
+V-belt pulleyp. 108
V-belt pulleyp. 108
Fig. 2p. 108
+Carefully clamp the claw-type rotor in a vice.p. 108
Carefully clamp the claw-type rotor in a vice.p. 108
Loosen the nut with a size 24 ring spanner.p. 108
+V-belt pulley tightening torque 58.4 to 78.9 Nm.p. 108
V-belt pulley tightening torque 58.4 to 78.9 Nm.p. 108
+Rotorp. 108
Rotorp. 108
Fig. 3p. 108
+Unscrew 4 screws and take off the bearing cover.p. 108
Unscrew 4 screws and take off the bearing cover.p. 108
Temporarily screw the V-belt pulley nut on the rotor shaft and knock the rotor out.p. 108
+Brushesp. 108
Brushesp. 108
Fig. 4p. 108
+After the rotor has been taken out one can see 2 carbon brushes protruding into the shaft bore.p. 108
After the rotor has been taken out one can see 2 carbon brushes protruding into the shaft bore.p. 108
+Assembling the brushesp. 108
Assembling the brushesp. 108
Fig. 5p. 108
+Insert the brushes with their sliding side in clockwise direction when viewed from the front.p. 108
Insert the brushes with their sliding side in clockwise direction when viewed from the front.p. 108
Fig. 6p. 109
+Both brushes must be deep in the brush holder. Otherwise both rotor and rear housing flange cannot be correctly positioned.p. 109
Both brushes must be deep in the brush holder. Otherwise both rotor and rear housing flange cannot be correctly positioned.p. 109
Use a hexagon key (4.0 mm) to push the brushes to furthest rear position.p. 109
Use a pointed (2.0 mm) punch or nail to secure the brushes against popping out, as shown in the illustration.p. 109
Fig. 7p. 109
+Align the marking lines (arrows) on front and rear housing flange to each other.p. 109
Align the marking lines (arrows) on front and rear housing flange to each other.p. 109
Tighten 4 screws and pull the pointed punch out of the brush holder.p. 109
+Bearing on slipring sidep. 109
Bearing on slipring sidep. 109
Fig. 8p. 109
+1 Rotorp. 109
1 Rotorp. 109
2 Bearingp. 109
3 Pullerp. 109
+Slightly clamp the rotors (1) in a vice to protect it against being damaged and disassemble the bearing (2) with a puller (3).p. 109
Slightly clamp the rotors (1) in a vice to protect it against being damaged and disassemble the bearing (2) with a puller (3).p. 109
Checkp. 110
+Bearingp. 110
Bearingp. 110
Fig. 1p. 110
+Check whether the bearing rotates without obstruction.p. 110
Check whether the bearing rotates without obstruction.p. 110
Replace the bearing if it does not rotate properly.p. 110
Statorp. 110
Fig. 2p. 110
+Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 110
Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 110
If the measuring value does not comply with the factory specification, replace the stator.p. 110
Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core.p. 110
Replace the stator if no infinite value is indicated.p. 110
+Factory specification for resistance: Less than 1p. 110
+Factory specification for resistance: Less than 1p. 110
Wp. 110
Rotorp. 111
Fig. 3p. 111
+Measure the resistance between the sliprings.p. 111
Measure the resistance between the sliprings.p. 111
If the resistance does not comply with the factory specification, replace the rotor.p. 111
Use the resistance range of the continuity tester to check the continuity between slipring and core.p. 111
Replace the rotor if no infinite value is indicated.p. 111
+Factory specification for resistance: 2.8 to 3.3p. 111
+Factory specification for resistance: 2.8 to 3.3p. 111
Wp. 111
Slipringp. 111
Fig. 4p. 111
+Check the slipring for score marks.p. 111
Check the slipring for score marks.p. 111
If score marks are found rework the slipring with emery cloth or on a lathe.p. 111
Measure the outer diameter of the slipring with a vernier caliper.p. 111
Replace if the measuring value is below the permissible limit.p. 111
+Outer slipring diameter: 22.7 mm.p. 111
Outer slipring diameter: 22.7 mm.p. 111
Permissible limit: 22.1 mm.p. 111
Wear on carbon brushesp. 112
Fig. 5p. 112
+Measure the brush length with a vernier caliper.p. 112
Measure the brush length with a vernier caliper.p. 112
Replace if the measuring value is below the permissible limit.p. 112
Make sure that the brush is light moving.p. 112
A defective carbon brush must be replaced.p. 112
+Brush: 18.5 mm.p. 112
Brush: 18.5 mm.p. 112
Permissible limit: 5.0 mm.p. 112
5.25 Electric starterp. 112
+Generalp. 112
Generalp. 112
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. 112
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. 112
Duties of the starter:p. 112
+to accelerate the combustion engine to start speed with lowest possible current consumption.p. 112
to accelerate the combustion engine to start speed with lowest possible current consumption.p. 112
establish the gear connection between starter and combustion engine.p. 112
to maintain this connection.p. 112
to switch on the starter current.p. 112
After starting the engine:p. 112
+to return the starter pinion to initial position.p. 112
to return the starter pinion to initial position.p. 112
to switch off the starter current.p. 112
Directly acting electric starterp. 113
+This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 113
This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 113
Fig. 6p. 113
+1 Magnetic switchp. 113
1 Magnetic switchp. 113
2 Armaturep. 113
3 Actuating leverp. 113
4 Freewheeling clutchp. 113
5 Resetting springp. 113
6 Brushp. 113
7 Exciting windingp. 113
8 Armaturep. 113
9 Collectorp. 113
+Ignition switch in position "START"p. 113
Ignition switch in position "START"p. 113
Fig. 7 Magnetic switch openp. 113
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. 113
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. 113
+1 Armaturep. 113
1 Armaturep. 113
2 Holding windingp. 113
3 Pick-up windingp. 113
4 Magnetic switchp. 113
5 Ignition switchp. 113
6 Actuating leverp. 113
7 Ring gearp. 113
8 Pinionp. 113
9 Freewheeling clutchp. 113
10 (Batteryp. 113
+Pinion meshes with the ring gearp. 113
Pinion meshes with the ring gearp. 113
Fig. 8 Magnetic switch closedp. 113
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. 113
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. 113
+1 Pick-up windingp. 113
1 Pick-up windingp. 113
2 Magnetic switchp. 113
3 Pinionp. 113
4 Ring gearp. 113
5 Armaturep. 113
6 Exciting windingp. 113
7 Batteryp. 113
+Engine runningp. 114
Engine runningp. 114
Fig. 9p. 114
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. 114
+1 Pinionp. 114
1 Pinionp. 114
2 (Ring gearp. 114
3 Freewheeling clutchp. 114
4 Armaturep. 114
+Ignition switch releasedp. 114
Ignition switch releasedp. 114
Fig. 10p. 114
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. 114
This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops.p. 114
+1 Armaturep. 114
1 Armaturep. 114
2 Holding windingp. 114
3 Pick-up windingp. 114
4 Resetting springp. 114
5 Magnetic switchp. 114
6 Ignition switchp. 114
7 Pinionp. 114
8 Ring gearp. 114
9 Batteryp. 114
Starter with planetary gearp. 115
The reduction gear is a planetary gear which reduces the speed of the armature shaft (9) at the drive shaft in the ratio of approx. 1:5.p. 115
The actuator lever (2) forces the pinion (4) with the freewheeling clutch (5) against the ring gear.p. 115
Fig. 11 with planetary gearp. 115
The working principle of this starter is the same as with the "direct acting electric starter".p. 115
+1 Holding platep. 115
1 Holding platep. 115
2 Actuating leverp. 115
3 Magnetic switchp. 115
4 Pinionp. 115
5 Freewheeling clutchp. 115
6 Output shaftp. 115
7 Transmissionp. 115
8 (8) Pinionp. 115
9 (9) Armature shaftp. 115
Magnetic switchp. 115
Fig. 12 Direct acting electric motorp. 115
Fig. 13 Geared motorp. 115
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. 115
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. 115
+1 Holding windingp. 115
1 Holding windingp. 115
2 Pick-up windingp. 115
3 Contact platep. 115
4 Armaturep. 115
5 Resetting springp. 115
6 Armature guidep. 115
Freewheeling clutchp. 116
Fig. 14 Freewheeling clutchp. 116
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. 116
This makes sure that the armature will only drive the ring gear, but can never be driven by the engine.p. 116
+1 Freewheeling ringp. 116
1 Freewheeling ringp. 116
2 Rollerp. 116
3 Roller springp. 116
4 Splined shaftp. 116
5 Pinionp. 116
6 Pinionp. 116
Trouble shooting "Starter"p. 116
+The most frequent fault is definitely a fully discharged battery.p. 116
+The most frequent fault is definitely a fully discharged battery.p. 116
The most frequent fault is definitely a fully discharged battery.p. 116
+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. 116
If the starter rotates too slowlyp. 116
+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. 116
If the starter only emits a clicking soundp. 116
Frequently a jammed return mechanism is the reason for a starter failure.p. 116
Occasionally worn contacts are found on the magnetic return switchp. 116
Defects on the actual starter motor including pinion and carbon brushes are very rare.p. 116
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. 116
+Immobilizer deactivated?p. 116
Immobilizer deactivated?p. 116
Ignition switch OK?p. 116
Travel lever in correct position?p. 116
Emergency stop not actuated?p. 116
Battery sufficiently charged?p. 116
Battery poles OK?p. 116
Main battery fuse OK?p. 116
Main battery switch closed?p. 116
Main starter cable (terminal 30) OK?p. 116
Starter control cable (terminal 50) OK, voltage drop?p. 116
Ground cable OK?p. 116
Switching of magnetic switches OK?p. 116
The sequence of these tests is generally of no significance. It mainly depends on:p. 116
+the experience of the specialistp. 116
the experience of the specialistp. 116
the failure probability of the component to be tested and the testing effort for the respective part.p. 116
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. 116
Testing and measuring the starterp. 117
+Function control with the starter removedp. 117
Function control with the starter removedp. 117
+Fasten the starter to make sure that it will not come loose during the test.p. 117
Fasten the starter to make sure that it will not come loose during the test.p. 117
Fig. 15p. 117
+Connect a jumper lead between start terminal (1) and battery plus (2).p. 117
Connect a jumper lead between start terminal (1) and battery plus (2).p. 117
Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 117
+If the motor does not start, the starter is defective. Repair or replace the starter.p. 117
If the motor does not start, the starter is defective. Repair or replace the starter.p. 117
+Checking the magnetic switchp. 117
Checking the magnetic switchp. 117
Fig. 16p. 117
+Connect a jumper lead between start terminal (1) and battery plus (2).p. 117
Connect a jumper lead between start terminal (1) and battery plus (2).p. 117
Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 117
+If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 117
If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 117
+Continuity test for the magnetic switchp. 117
Continuity test for the magnetic switchp. 117
Fig. 17p. 117
+Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 117
Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 117
Replace the magnetic switch if no continuity is detected.p. 117
Repair of starterp. 118
+Dismantling and assemblingp. 118
Dismantling and assemblingp. 118
Fig. 1p. 118
+1 Gearp. 118
+1 Gearp. 118
1 Gearp. 118
2 Front bracketp. 118
3 Magnetic switchp. 118
4 Freewheeling clutchp. 118
5 Inner gearp. 118
6 Planet gearsp. 118
7 Ball bearingp. 118
8 Seal kitp. 118
9 Through boltp. 118
10 Armaturep. 118
11 Standp. 118
12 Brush holderp. 118
13 Rear bearing platep. 118
Dismantlingp. 118
+Disconnect the magnetic switch (3).p. 118
Disconnect the magnetic switch (3).p. 118
Remove both through bolts (9) and 2 brush holder fastening screws. Remove the rear bearing plate (13) and take out the brush holder (12).p. 118
Separate the armature (10) from the frame (11). Remove also the ball bearing (7) from the tip of the armature.p. 118
Remove seal kit (8), 4 planet wheels (6) and the other seal.p. 118
Take out the shaft assembly. Make a note of the lever position.p. 118
+Before separating the frame (11) mark both the frame (11) and the front bracket (2).p. 118
Before separating the frame (11) mark both the frame (11) and the front bracket (2).p. 118
Record the position of the seal kit (8) and the screw.p. 118
Do not damage carbon bushes or collector.p. 118
Assemblyp. 118
+Apply some grease to the parts marked in the illustration.p. 118
Apply some grease to the parts marked in the illustration.p. 118
Tightening torque fastening nut for starter terminal B: 9.8 to 11.0 Nmp. 118
Checkp. 119
+Freewheelp. 119
Freewheelp. 119
Fig. 1p. 119
+Check the pinion for wear or damage.p. 119
Check the pinion for wear or damage.p. 119
Replace the freewheeling assembly if found defectivep. 119
Make sure that the pinion rotates freely in the freewheeling direction and does not slip in starting direction.p. 119
If the pinion slips or does not rotate to both directions, replace the freewheel assembly.p. 119
+Do not wash the grease in the freewheel out with chemicals or oils.p. 119
Do not wash the grease in the freewheel out with chemicals or oils.p. 119
Collector and mica capacitorp. 119
Fig. 2p. 119
+Check the contact surface of the collector for wear and rework it with sanding paper if it is slightly worn.p. 119
Check the contact surface of the collector for wear and rework it with sanding paper if it is slightly worn.p. 119
Fig. 3p. 119
+Measure the outer diameter of the collector at several points with an outside micrometer.p. 119
Measure the outer diameter of the collector at several points with an outside micrometer.p. 119
If the smallest outside diameter is below the permissible limit, the rotor must be replaced.p. 119
+Use a continuity tester to check the continuity between brush holder and holder carrier.p. 121
Use a continuity tester to check the continuity between brush holder and holder carrier.p. 121
If continuity is found replace the brush holder.p. 121
Armature coilp. 121
Fig. 7p. 121
+Use the resistance range of the continuity tester to check the continuity between collector and armature coil.p. 121
Use the resistance range of the continuity tester to check the continuity between collector and armature coil.p. 121
If continuity is found replace the armature.p. 121
Fig. 8p. 121
+Use the resistance range of the continuity tester to check the continuity between the collector segments.p. 121
Use the resistance range of the continuity tester to check the continuity between the collector segments.p. 121
If no continuity is found replace the armature.p. 121
Field coilp. 122
Fig. 9p. 122
+1 Replace thep. 122
1 Replace thep. 122
2 Brushp. 122
3 Statorp. 122
+Use the continuity tester to check the continuity between line (1) and brush (2).p. 122
Use the continuity tester to check the continuity between line (1) and brush (2).p. 122
If no continuity is found replace the stator frame.p. 122
Fig. 10p. 122
+Use the continuity tester to check the continuity between brush (2) and stator (3).p. 122
Use the continuity tester to check the continuity between brush (2) and stator (3).p. 122
If continuity is found replace the stator frame.p. 122
Engine shut-down solenoid, Y58p. 123
+Shut-down magnetp. 123
Shut-down magnetp. 123
Fig. 11 Engine shut-down solenoid on ijection pump, Y58p. 123
+Testing the shut-off solenoidp. 123
Testing the shut-off solenoidp. 123
Fig. 12p. 123
+1 Plugp. 123
1 Plugp. 123
2 Batteryp. 123
3 Switch for holding winding (H)p. 123
4 Switch for pick-up winding (P)p. 123
Testing the functionp. 124
+Danger of burning!p. 124
Danger of burning!p. 124
The shut-down solenoid gets very hot during the stating process.p. 124
+For inspection do not apply current to the pick-up winding for longer than two seconds.p. 124
For inspection do not apply current to the pick-up winding for longer than two seconds.p. 124
Fig. 13p. 124
+Remove the shut-down solenoid, leave the plug on the solenoid.p. 124
Remove the shut-down solenoid, leave the plug on the solenoid.p. 124
Connect the housing of the solenoid to engine ground (ground supply).p. 124
Start the engine for a moment.p. 124
+During the starting process the pin is retracted and it extends again when the ignition is switched off.p. 124
During the starting process the pin is retracted and it extends again when the ignition is switched off.p. 124
+P: Terminal for pick-up winding, resistance approx. 0.38p. 124
+P: Terminal for pick-up winding, resistance approx. 0.38p. 124
Wp. 124
+H: Terminal for holding winding, resistance approx. 16p. 124
Wp. 124
+Disassemble the shut-down solenoid.p. 124
Disassemble the shut-down solenoid.p. 124
+Connect bridging cables between terminal P of the pick-up winding and switch 4p. 124
(Fig. 11)p. 124
Connect bridging cables between terminal H of the holding winding and switch (3), as well as between switch (3) and battery plus.p. 124
Connect a bridging cable between the housing of the shut-off solenoid and battery minus (ground supply).p. 124
Switch the switch (4) on and off.p. 124
+When switching the switch (4) on the pin is retracted and it moves out again when the switch (4) is switched off.p. 124
When switching the switch (4) on the pin is retracted and it moves out again when the switch (4) is switched off.p. 124
+Switch the switch (3) on first and switch (4) after -the pin is retracted into the body of the solenoid and remains in this position when switch (4) is switched off.p. 124
Switch the switch (3) on first and switch (4) after -the pin is retracted into the body of the solenoid and remains in this position when switch (4) is switched off.p. 124
Camshaft sensor, B92
Fig. 1p. 125
Fig. 2p. 125
+The camshaft sensor 1p. 125
(Fig. 2)p. 125
ECOMODE
Fig. 1p. 126
The standard BOMAG ECOMODE ensures a clean environmental balance. Due to the active engine management power is made available for the driver when it is needed and is reduced again when permitted by the application. Intelligent sensors in connection w…p. 126
Fig. 2p. 127
+The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 127
+The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 127
The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"p. 127
+The actuator M39 acts directly on the motor power leverp. 127
(Fig. 1)p. 127
+The motor is a permanently controlled DC-motor, which is triggered by the ESX-control A34 via the changeover relay K176 (1)p. 127
(Fig. 3)p. 127
The position of the drive axle is detected by an integrated potentiometer. The potentiometer is positively connected with the drive shaft of the control element and serves the purpose of feeding back the output shaft position.p. 127
The gearbox has been designed with three stages. Internal stops protect the gearbox against damage. The gear on the drive shaft is a toothed segment which determines the internal mechanical stops. The defined limitation of adjusting speed contributes…p. 127
Functional principle of ECO modep. 127
The ESX-control (A34) regulates the control command in dependence onp. 127
The following settings result in an increase in engine speed:p. 127
+Switching on the screed heatingp. 127
Switching on the screed heatingp. 127
Activating the load functionp. 127
Extending/retracting the extendable screed left/ rightp. 127
Manual operation of the scraper belt left/right in forwardp. 127
Manual operation of the auger left/right in forwardp. 127
Opening/closing the hopper wings left/right.p. 127
Fig. 3p. 128
Fig. 4p. 128
5.30 Glow plugs, R81-R84p. 129
+During the pre-heating and starting process the glow plugs are energized through relay K14.p. 129
During the pre-heating and starting process the glow plugs are energized through relay K14.p. 129
During the preheating process the control lamp is switched on for 10 seconds and switched off again when starting.p. 129
Fig. 5p. 129
+1 Glow plugsp. 129
1 Glow plugsp. 129
2 Glow plug cablep. 129
+Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 129
Continuity testp. 129
+Remove the glow plug.p. 129
Remove the glow plug.p. 129
Fig. 6p. 129
+Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 129
+Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 129
Use a continuity tester to measure the resistance between glow plug connection and glow plug housing.p. 129
+If the measured value does not correspond with the factory specification, the glow plug (29p. 129
(Fig. 6)p. 129
+Factory specification for resistance approx. 0.95 Ohm in cold condition.p. 129
Factory specification for resistance approx. 0.95 Ohm in cold condition.p. 129
Assemblyp. 129
+Align the recess to the connecting side when assembling the seal (1)p. 129
+Align the recess to the connecting side when assembling the seal (1)p. 129
(Fig. 6)p. 129
Tightening torque: 7.7 to 9.3 Nm.p. 129
5.31 Oil pressure switch (B06)p. 130
Fig. 1p. 130
The oil pressure switch is mounted on the cylinder block and is connected to the lubrication oil channel.p. 130
+At a pressure of less than 0.4 bar the oil pressure switch switches to motor ground.p. 130
At a pressure of less than 0.4 bar the oil pressure switch switches to motor ground.p. 130
Fig. 1p. 130
+n redp. 130
+n redp. 130
np. 130
Engine oil pressure too low, engine is shut down after 10 seconds.p. 130
5.32 Coolant temperature switch (B53)p. 130
Fig. 1p. 130
The temperature switch is arranged in the coolant circuit of the engine in such a way, that its tip is surrounded by coolant.p. 130
+Should the engine overheat, the temperature switch will switch to engine ground.p. 130
Should the engine overheat, the temperature switch will switch to engine ground.p. 130
Fig. 1p. 130
+b redp. 130
+b redp. 130
bp. 130
lights if engine overheats. After 8 seconds the warning buzzer will sound, vibration will be switched off and the travel speed reduced.p. 130
5.33 Air filter vacuum switch (B03)p. 131
Fig. 1 Vacuum switchp. 131
+The vacuum switch 1p. 131
+The vacuum switch 1p. 131
(Fig. 1)p. 131
Fig. 1p. 131
+a yellowp. 131
+a yellowp. 131
ap. 131
lights if combustion air filter cartridge is soiled, clean or replace if necessary.p. 131
5.34 Coolant float switch (B55)p. 131
Fig. 1p. 131
+In case of a too low coolant level the float switch will switch to ground.p. 131
In case of a too low coolant level the float switch will switch to ground.p. 131
Fig. 1p. 131
+o redp. 131
+o redp. 131
op. 131
flashes when the coolant (filling) level is too low. Engine is shut down after 10 seconds.p. 131
5.35 Charge control lightp. 132
Fig. 1p. 132
+The control lamp lights up if a ground signal is applied to the generator terminal (L).p. 132
The control lamp lights up if a ground signal is applied to the generator terminal (L).p. 132
Fig. 1p. 132
+p yellowp. 132
+p yellowp. 132
pp. 132
Charge control lamp, lights if the battery is not being charged. Check the V-belt, if necessary repair the generator.p. 132
5.36 Glow plugsp. 132
Fig. 1p. 132
During the preheating process the control lamp is switched on for 10 seconds and switched off again when starting.p. 132
Fig. 1p. 132
+l yellowp. 132
+l yellowp. 132
lp. 132
lights during preheating (for cold starting).p. 132
5.37 Water separator in fuel filter (B124))p. 133
Fig. 1p. 133
+With water in the filter the sensor will switch to ground.p. 133
With water in the filter the sensor will switch to ground.p. 133
Fig. 1p. 133
+k yellowp. 133
+k yellowp. 133
kp. 133
lights when the water proportion in the transparent section of the fuel pre-filter reaches the contacts.p. 133
5.38 Level sensor in diesel tank (R03)p. 133
Fig. 1p. 133
+The analog level switch is a variable resistance to ground.p. 133
The analog level switch is a variable resistance to ground.p. 133
Fig. 1p. 133
+sp. 133
+sp. 133
sp. 133
Fuel level gaugep. 133
Fig. 2p. 133
Main battery switchp. 133
+Position "I"p. 133
Position "I"p. 133
Normal position, operationp. 133
Position "II"p. 134
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. 134
+Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 134
Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency.p. 134
5.39 Fusesp. 134
Fig. 3p. 134
+No. 1 = Fusesp. 134
No. 1 = Fusesp. 134
+Fire hazard!p. 134
Fire hazard!p. 134
Do not use fuses with higher ampere ratings and do not bridge fuses.p. 134
The fuse box is located on the right hand side under the driver's platform.p. 134
Move the driver's platform fully to the left to access the fuse box. Remove the cover from the fuse box.p. 134
+5.40 Component overviewp. 135
+5.40 Component overviewp. 135
Fig. 4p. 135
+Pos.p. 135
Pos.p. 135
+Descriptionp. 135
Descriptionp. 135
+1p. 135
1p. 135
+E-throttle actuatorp. 135
E-throttle actuatorp. 135
+2p. 135
2p. 135
+Charge pressure filterp. 135
Charge pressure filterp. 135
+3p. 135
3p. 135
+Main fusesp. 135
Main fusesp. 135
+4p. 135
4p. 135
+Batteriesp. 135
Batteriesp. 135
+5p. 135
5p. 135
+Control panel with switches, warning lights, potentiometers, travel lever and multi-function displaysp. 135
Control panel with switches, warning lights, potentiometers, travel lever and multi-function displaysp. 135
+6p. 135
6p. 135
+Brake releasing valvep. 135
Brake releasing valvep. 135
+7p. 135
7p. 135
+Generatorp. 135
Generatorp. 135
Fig. 5p. 136
+Pos.p. 136
Pos.p. 136
+Descriptionp. 136
Descriptionp. 136
+8p. 136
8p. 136
+Screed heating control panel and Load Control System (LCS)p. 136
Screed heating control panel and Load Control System (LCS)p. 136
+9p. 136
9p. 136
+Working hydraulics (valves, etc.)p. 136
Working hydraulics (valves, etc.)p. 136
+10p. 136
10p. 136
+Fuel pre-filterp. 136
Fuel pre-filterp. 136
+11p. 136
11p. 136
+Water separatorp. 136
Water separatorp. 136
+12p. 136
12p. 136
+Fuel pumpp. 136
Fuel pumpp. 136
+13p. 136
13p. 136
+Hydraulic oil tankp. 136
Hydraulic oil tankp. 136
+14p. 136
14p. 136
+Travel pumpsp. 136
Travel pumpsp. 136
+15p. 136
15p. 136
+Service pumpp. 136
Service pumpp. 136
+16p. 136
16p. 136
+Central electrics with fuse boxp. 136
Central electrics with fuse boxp. 136
+17p. 136
17p. 136
+Travel motorp. 136
Travel motorp. 136
+18p. 136
18p. 136
+Valve block for hydraulic crown adjustmentp. 136
Valve block for hydraulic crown adjustmentp. 136
+19p. 136
19p. 136
+Valve block for vibrationp. 136
Valve block for vibrationp. 136
+20p. 136
20p. 136
+Valve block for tampingp. 136
Valve block for tampingp. 136
+21p. 136
21p. 136
+Valve block to extend and retract the mobile sectionsp. 136
Valve block to extend and retract the mobile sectionsp. 136
+5.43 View of operator's standp. 138
Overview of wiring loomsp. 138
+1 Wiring loom, engine BF300p. 138
+1 Wiring loom, engine BF300p. 138
1 Wiring loom, engine BF300p. 138
1 Battery cable, red 35mmp. 139
+1 Battery cable, red 35mmp. 139
+1 Battery cable, red 35mmp. 139
+1 Battery cable, red 35mmp. 139
2p. 139
+2 Battery cable, black 70mmp. 139
2p. 139
+3 Battery cable, red 70mmp. 139
2p. 139
1 Wiring loom BF300 — pre-heating systemp. 140
+1 Wiring loom BF300 — pre-heating systemp. 140
+1 Wiring loom BF300 — pre-heating systemp. 140
1 Wiring loom BF300 — pre-heating systemp. 140
1 Battery cable, red 35mmp. 141
+1 Battery cable, red 35mmp. 141
+1 Battery cable, red 35mmp. 141
+1 Battery cable, red 35mmp. 141
2p. 141
+2 Battery cable, black 35mmp. 141
2p. 141
+3 Battery cable, red 70mmp. 141
2p. 141
+4 Battery cable, black 70mmp. 141
2p. 141
+5 Battery cable, black 70mmp. 141
2p. 141
1 Wiring loom BF300p. 142
+1 Wiring loom BF300p. 142
+1 Wiring loom BF300p. 142
1 Wiring loom BF300p. 142
1 Wiring loom BF300, hydraulic valvesp. 143
+1 Wiring loom BF300, hydraulic valvesp. 143
+1 Wiring loom BF300, hydraulic valvesp. 143
1 Wiring loom BF300, hydraulic valvesp. 143
1 Wiring loom BF300, hydraulic valves on screedp. 144
+1 Wiring loom BF300, hydraulic valves on screedp. 144
+1 Wiring loom BF300, hydraulic valves on screedp. 144
1 Wiring loom BF300, hydraulic valves on screedp. 144
1 Wiring loom BF300, screed control panelsp. 145
+1 Wiring loom BF300, screed control panelsp. 145
+1 Wiring loom BF300, screed control panelsp. 145
1 Wiring loom BF300, screed control panelsp. 145
+5.43 View of operator's standp. 146
5.42 Control elementsp. 146
+5.43 View of operator's standp. 147
5.43 View of operator's standp. 147
Fig. 6p. 147
+1p. 147
1p. 147
+A15 Instrument clusterp. 147
+A15 Instrument clusterp. 147
A15p. 147
+16p. 147
16p. 147
+S225, S226, S227Conveyor belt control panelp. 147
+S225, S226, S227Conveyor belt control panelp. 147
S225, S226, S227p. 147
+2p. 147
2p. 147
+Tire spraying unitp. 147
+Tire spraying unitp. 147
Optional equipmentp. 147
+17p. 147
17p. 147
+S222, S223 Material hopper control panelp. 147
+S222, S223 Material hopper control panelp. 147
S222, S223p. 147
+3p. 147
3p. 147
+S197 Asphalt fume extractionp. 147
+S197 Asphalt fume extractionp. 147
S197p. 147
Optional equipmentp. 147
+18p. 147
18p. 147
+R07 Rotary switch for working speedp. 147
+R07 Rotary switch for working speedp. 147
R07p. 147
+4p. 147
4p. 147
+S225 Switch to reverse the conveyor beltp. 147
+S225 Switch to reverse the conveyor beltp. 147
S225p. 147
+19p. 147
19p. 147
+S217 Operating mode switch transport/workp. 147
+S217 Operating mode switch transport/workp. 147
S217p. 147
+5p. 147
5p. 147
+A81 Display and warning elementsp. 147
+A81 Display and warning elementsp. 147
A81p. 147
+20p. 147
20p. 147
+S03 Warning hornp. 147
+S03 Warning hornp. 147
S03p. 147
+6p. 147
6p. 147
+S236 Switch for auger height adjustmentp. 147
+S236 Switch for auger height adjustmentp. 147
S236p. 147
+21p. 147
21p. 147
+S14 Hazard light switchp. 147
+S14 Hazard light switchp. 147
S14p. 147
+7p. 147
7p. 147
+S15 StVZO lightingp. 147
+S15 StVZO lightingp. 147
S15p. 147
+22p. 147
22p. 147
+S04, Push button for parking brakep. 147
+S04, Push button for parking brakep. 147
S04p. 147
+8p. 147
8p. 147
+S16 Rotary switch for working lights, frontp. 147
+S16 Rotary switch for working lights, frontp. 147
S16p. 147
+23p. 147
23p. 147
+S120 Rotary switch for engine speed/ ECO-modep. 147
+S120 Rotary switch for engine speed/ ECO-modep. 147
S120p. 147
+9p. 147
9p. 147
+S26 Rear working lightp. 147
+S26 Rear working lightp. 147
S26p. 147
+24p. 147
24p. 147
+S216, S219, S220 Travel system control panelp. 147
+S216, S219, S220 Travel system control panelp. 147
S216, S219, S220p. 147
+10p. 147
10p. 147
+S37 Travel direction indicator (flasher)p. 147
+S37 Travel direction indicator (flasher)p. 147
S37p. 147
+25p. 147
25p. 147
+S243, S244 Control panel for levellingp. 147
+S243, S244 Control panel for levellingp. 147
S243, S244p. 147
+11p. 147
11p. 147
+Push button for electro-hydraulicsp. 147
Push button for electro-hydraulicsp. 147
+26p. 147
26p. 147
+S215 Front wheel drive control panelp. 147
+S215 Front wheel drive control panelp. 147
S215p. 147
+12p. 147
12p. 147
+S01 Emergency stop switchp. 147
+S01 Emergency stop switchp. 147
S01p. 147
+27p. 147
27p. 147
+Dashboard lightp. 147
Dashboard lightp. 147
+13p. 147
13p. 147
+S250 Push button for partial screed load reliefp. 147
+S250 Push button for partial screed load reliefp. 147
S250p. 147
+28p. 147
28p. 147
+S237, S238, S239, S240 Screed width control panelp. 147
+S237, S238, S239, S240 Screed width control panelp. 147
+Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i…p. 164
Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i…p. 164
Control units generally work according to the IPO- principle. IPO stands for Input-Processing-Output. Sensors are available for input. Sensors determine a physical characteristic like e.g. rotary speed, pressure, temperature, etc. This value is compa…p. 164
Fig. 1 Electronic control (ESX)p. 164
In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units exchange information about operating states and other relevant data in vehicle across the system. Furthermore, the on-board diagnostic or the d…p. 164
Modulesp. 164
+In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists of a programmable microprocessor with additional circuitry for inputs and outputs.p. 164
In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists of a programmable microprocessor with additional circuitry for inputs and outputs.p. 164
Fig. 2 Modulep. 164
The modules have control lights on inputs and outputs to monitor the applied signals.p. 164
Signalsp. 165
+Analog signalsp. 165
Analog signalsp. 165
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. 165
+Binary signalsp. 165
Binary signalsp. 165
Process states are bivalent (binary) if they have only 2 possible states of truth, such as e.g. button pressed/ not pressed, object present/not present. The two states of truth are mapped by means of defined states of an information carrier, e.g. 'no…p. 165
CAN-bus, Controller Area Networkp. 165
+created by Bosch at the end of the eighties for automobile applications.p. 165
created by Bosch at the end of the eighties for automobile applications.p. 165
Development objectives:p. 165
Real-time critical, robust and low price communication of control units, such as transmission and engine control, but also less time critical applications in the field of convenience electronics, such as air conditioning.p. 165
Fig. 3p. 165
Why CAN?p. 165
+Networking of control units for the realization of complex functions.p. 165
+Networking of control units for the realization of complex functions.p. 165
Networking of control units for the realization of complex functions.p. 165
Reduction of the extend of wiring and plug connections.p. 165
+It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 165
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 165
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur simultaneously in both lines, the software is thus able to filter out interfering signals more easily.p. 165
Wire (+) = cable colour bluep. 165
Wire (-) = cable colour yellowp. 165
+Measuring on the CANp. 165
Measuring on the CANp. 165
Signals transmitted through the bus line can generally not be measured with simple measuring instruments. Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means of a continuity test. BOMAG displa…p. 165
5.59 Checking the voltage supply for the control unitp. 166
+Power supply for a control unit, generalp. 166
Power supply for a control unit, generalp. 166
All electronic switching and control units require an electric power supply to be able to work. If the plus or minus supply is faulty, the control unit will work incorrectly or fail.p. 166
+The following describes the electric power supply for the ESX-control.p. 166
The following describes the electric power supply for the ESX-control.p. 166
+(Fig. 4) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete representation can be found in the wiring diagram of the machine.p. 166
(Fig. 4)p. 166
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the procedures for line testing are generally the same.p. 166
Fig. 4 Circuitry examplep. 166
+1p. 166
1p. 166
Engine blockp. 166
+ESXp. 166
ESXp. 166
Control unitp. 166
+F00p. 166
F00p. 166
Main fusep. 166
+Fx,Fxxp. 166
Fx,Fxxp. 166
Fuses potential 30p. 166
+Fxxxp. 166
Fxxxp. 166
Fuses potential 15p. 166
+Gp. 166
Gp. 166
Generatorp. 166
+G01p. 166
G01p. 166
Batteryp. 166
+GNDp. 166
GNDp. 166
Housing earthp. 166
+H08p. 166
H08p. 166
Charge control lightp. 166
+S00p. 166
S00p. 166
Ignition switchp. 166
+S01p. 166
S01p. 166
Emergency stop switchp. 166
+Pin 28p. 166
Pin 28p. 166
Voltage supply for controlp. 166
+Pin 54p. 166
Pin 54p. 166
if the signal (12/24 Volt) is applied, the control is switched onp. 166
+Pin 55p. 166
Pin 55p. 166
Ground supply for controlp. 166
+Pin 56 to 60p. 166
Pin 56 to 60p. 166
Voltage supply for outputsp. 166
+GNDp. 166
GNDp. 166
Housing earthp. 166
Fault in current supply, generalp. 167
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides of control units are in most cases connected to the vehicle mains supply via several cables, so that several parallel current branches ex…p. 167
Fig. 5 Circuitry examplep. 167
The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply voltage.p. 167
The following faults may occur:p. 167
+Line interruption in a plus supply linep. 167
Line interruption in a plus supply linep. 167
high voltage drop in a plus supply linep. 167
line interruption on the minus sidep. 167
Measuring principle for line testingp. 168
+When a line conducts an electric current, a voltage drop will occur in the line (Up. 168
Vp. 168
Vp. 168
+the available amperage (I) andp. 168
the available amperage (I) andp. 168
+the electric resistance (Rp. 168
linep. 168
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Identical marginal conditions are therefore used in all of the following examples:p. 168
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.p. 168
12 V / 21 W – lamp as load in a 12 Volt vehicle network.p. 168
24 V / 21 W – lamp as load in a 24 Volt vehicle network.p. 168
+Test stepsp. 168
Test stepsp. 168
1. Switch off the ignition.p. 168
2. Unplug the control unit from wiring loom.p. 168
+3. If available connect the Pinboxp. 168
(Fig. 6)p. 168
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as necessary. Repeat the measurement.p. 168
+The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 168
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug.p. 168
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.p. 168
Fig. 6 Pinbox for 68 pole ESX controlp. 168
General measuring setup to check a supply line (plus side)p. 169
Fig. 7 Measuring arrangement 12 Voltp. 169
+1p. 169
1p. 169
Supply line, plus sidep. 169
+2p. 169
2p. 169
+Plug contact in wiring loom plug on control or Pinboxp. 169
(Fig. 6)p. 169
+Ep. 169
Ep. 169
Lamp, 12V / 21 Wattp. 169
+Pp. 169
Pp. 169
Multimeterp. 169
+G01p. 169
G01p. 169
Battery as voltage source, 12Vp. 169
+Up. 169
+Up. 169
Vp. 169
Voltage drop caused by the lamp currentp. 169
Setpointp. 169
+The voltage drop Up. 169
Vp. 169
Setpointp. 169
£p. 169
General measuring setup to check a return line (minus side)p. 170
Fig. 8 Measuring arrangement 12 Voltp. 170
+1p. 170
1p. 170
Return line, minus sidep. 170
+2p. 170
2p. 170
+Plug contact in wiring loom plug on control or Pinboxp. 170
(Fig. 6)p. 170
+Ep. 170
Ep. 170
Lamp, 12V / 21 Wattp. 170
+Pp. 170
Pp. 170
Multimeterp. 170
+G01p. 170
G01p. 170
Battery as voltage source, 12Vp. 170
+Up. 170
+Up. 170
Vp. 170
Voltage drop caused by the lamp currentp. 170
Setpointp. 170
+The voltage drop Up. 170
Vp. 170
Setpointp. 170
£p. 170
Connection example to check the plus line between battery and plug pin 28p. 171
Fig. 9p. 171
+Xp. 171
Xp. 171
+Wiring loom plug disconnected from control unit or Pinboxp. 171
(Fig. 6)p. 171
+Pp. 171
Pp. 171
Multimeterp. 171
+S00p. 171
S00p. 171
+Ignition switched on. Setpoint : E is bright. Up. 171
Vp. 171
+S00p. 171
S00p. 171
+Ignition switched off. Setpoint : E is dark. Up. 171
Vp. 171
Connection example to check the minus line between battery and plug pin 55p. 172
Fig. 10p. 172
+Pp. 172
Pp. 172
Multimeterp. 172
+Xp. 172
Xp. 172
+Wiring loom plug disconnected from control unit or Pinboxp. 172
(Fig. 6)p. 172
+Ep. 172
Ep. 172
+Setpoint : E is bright. Up. 172
Vp. 172
Test protocol for ESXp. 173
+E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 173
E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 173
E lamp 24V / 21W in 24V vehicle network, to load the current branches.p. 173
G01, batteryp. 173
P multimeter, measuring range: DCp. 173
+Plug pinp. 173
Plug pinp. 173
+Notep. 173
Notep. 173
+Setpointsp. 173
Setpointsp. 173
+28p. 173
28p. 173
+Ignition ONp. 173
Ignition ONp. 173
E between plug pin 28 and battery minusp. 173
P between battery plus and plug pin 28p. 173
E is bright,p. 173
+Up. 173
Vp. 173
+28p. 173
28p. 173
+Ignition OFFp. 173
Ignition OFFp. 173
E between plug pin 28 and battery plusp. 173
P between battery minus and plug pin 28p. 173
E is dark,p. 173
+Up. 173
Vp. 173
+54p. 173
54p. 173
+Ignition OFF, emergency stop not operatedp. 173
Ignition OFF, emergency stop not operatedp. 173
E between plug pin 54 and battery minusp. 173
P between battery plus and plug pin 54p. 173
E is bright,p. 173
+Up. 173
Vp. 173
+54p. 173
54p. 173
+Ignition OFF, emergency stop operatedp. 173
Ignition OFF, emergency stop operatedp. 173
E between plug pin 54 and battery minusp. 173
P between battery plus and plug pin 54p. 173
E is dark,p. 173
+Up. 173
Vp. 173
+55p. 173
55p. 173
+Ignition OFFp. 173
Ignition OFFp. 173
E between plug pin 55 and battery minusp. 173
P between battery plus and plug pin 55p. 173
E is bright,p. 173
+Up. 173
Vp. 173
+56, 57, 58, 59, 60p. 173
56, 57, 58, 59, 60p. 173
+Ignition OFFp. 173
Ignition OFFp. 173
E between plug pin 56, 57, 58, 59, 60 and battery minusp. 173
P between battery plus and plug pin 56, 57, 58, 59, 60p. 173
E is bright,p. 173
+Up. 173
Vp. 173
+If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 173
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 173
Example 1:p. 173
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons. Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.p. 173
Example 2:p. 173
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch and the corresponding plug pin.p. 173
5.60 Diagnostics conceptp. 174
+Introductionp. 174
Introductionp. 174
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble shooting proce…p. 174
+Fault description and questioning of the customerp. 174
Fault description and questioning of the customerp. 174
After the customer has explained his complaint(s) the engineer has to ask further questions to track down the cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examination and a possible test d…p. 174
Fig. 11p. 174
+(1) Fault memorized in error logp. 174
(1) Fault memorized in error logp. 174
+Clear cause?p. 174
Clear cause?p. 174
+If the fault message leaves no doubt, repair work may be started immediately.p. 174
If the fault message leaves no doubt, repair work may be started immediately.p. 174
+(2) No fault memorized in the error log at the time of initial questioningp. 174
(2) No fault memorized in the error log at the time of initial questioningp. 174
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even gets worse …p. 174
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming sensor information and outgoing command values on a control unit. This requires profound knowledge of system and components.p. 174
+Consideration, if the error log has not recorded a faultp. 174
Consideration, if the error log has not recorded a faultp. 174
+What could be the cause of the complaint?p. 174
What could be the cause of the complaint?p. 174
Which measuring possibilities are available?p. 174
Localizing faultsp. 175
+Line or component?p. 175
Line or component?p. 175
Fig. 12p. 175
+In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the c…p. 175
In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the c…p. 175
Checking the voltage supply for the control unitp. 175
Checking the sensor linesp. 175
Checking the actor linesp. 175
Sequence after the fault is foundp. 176
Fig. 13p. 176
+6 Input codesp. 177
+6 Input codesp. 177
Input codes — display: Functions and operationp. 178
+Display functions and operationp. 178
Display functions and operationp. 178
+The main LC-displayp. 178
(Fig. 14)p. 178
+Display of operating hours as well as error and input codes (1)p. 178
Display of operating hours as well as error and input codes (1)p. 178
Button right (2)p. 178
Button left (3)p. 178
Tool symbol (4) (only visible in Service mode)p. 178
Fig. 14 LC-Displayp. 178
Input of codes (input codes)p. 178
+The brake needs to be activated to be able to access input mode!p. 178
The brake needs to be activated to be able to access input mode!p. 178
+Calling up input modep. 178
Calling up input modep. 178
+Actionp. 178
Actionp. 178
+Resultp. 178
Resultp. 178
+— Press button left and button right at the same time for at least two seconds.p. 178
+— Press button left and button rightp. 178
at the same timep. 178
twop. 178
+— The display shows "0000"p. 178
+— The display showsp. 178
"0000"p. 178
+— The leftp. 178
"0"p. 178
+One can change the numerical value of the display by using the buttons one after the other:p. 178
One can change the numerical value of the display by using the buttons one after the other:p. 178
The left hand button to change the numbers in ascending mode (0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 0, …).p. 178
+The right hand button to move on to the next digit (p. 178
0p. 178
0p. 178
0p. 178
0p. 178
0p. 178
+Calling up service modep. 178
Calling up service modep. 178
+Actionp. 178
Actionp. 178
+Resultp. 178
Resultp. 178
+— Enter code 0001.p. 178
+— Enter codep. 178
0001p. 178
+— The system changes to service mode.p. 178
— The system changes to service mode.p. 178
— The display shows the tool symbol.p. 178
+6.2 Teaching the E-throttle function:p. 179
Teaching the E-throttle functionp. 179
+Take notice of the section "Input codes Display General"!p. 179
Take notice of the section "Input codes Display General"!p. 179
+Teaching the E-throttle function:p. 179
Teaching the E-throttle function:p. 179
+Actionp. 179
+Actionp. 179
Actionp. 179
+Resultp. 179
+Resultp. 179
Resultp. 179
+— Switch on the ignition.p. 179
— Switch on the ignition.p. 179
+Note: Dop. 179
Note:p. 179
notp. 179
+— Enter code 0001.p. 179
+— Enter codep. 179
0001p. 179
+— The system changes to service mode.p. 179
— The system changes to service mode.p. 179
— The display shows the tool symbol.p. 179
+— Enter code 5038.p. 179
+— Enter codep. 179
5038p. 179
+— The teach function "Teach E-throttle function" is activated.p. 179
— The teach function "Teach E-throttle function" is activated.p. 179
+— Enter code 5039.p. 179
+— Enter codep. 179
5039p. 179
+— The function E-throttle lower value is activated.p. 179
+— The function E-throttlep. 179
lower valuep. 179
+— The E-throttle actuator in the engine compartmentp. 179
clicksp. 179
+Note: This clicking sound indicates that the coupling of the actuator has been opened.p. 179
Note:p. 179
— The corresponding position value appears in the display.p. 179
+Note: The value must be lower than 500. Otherwise you must adjust the lever of the `E-throttle actuator.p. 179
Note:p. 179
+— Shift the lever of the injection pump fully to min (idle speed) and hold it in this position.p. 179
+— Shift the lever of the injection pump fully top. 179
min (idle speed)p. 179
+Note: This makes sure that the lever is actually in position "min".p. 179
Note:p. 179
+— The E-throttle actuator in the engine compartment clicks.p. 179
+— The E-throttle actuator in the engine compartmentp. 179
clicksp. 179
— A valid value has been taught.p. 179
+— Enter code 5040.p. 179
+— Enter codep. 179
5040p. 179
+— The function E-throttle upper value is activated.p. 179
+— The function E-throttlep. 179
upper valuep. 179
+— The E-throttle actuator in the engine compartmentp. 179
clicksp. 179
+Note: This clicking sound indicates that the coupling of the actuator has been opened.p. 179
Note:p. 179
— The corresponding position value appears in the display.p. 179
+— Shift the lever of the injection pump fully to maximum (full speed) and hold it in this position.p. 179
+— Shift the lever of the injection pump fully top. 179
maximum (full speed)p. 179
+— The E-throttle actuator in the engine compartment clicks.p. 179
+— The E-throttle actuator in the engine compartmentp. 179
clicksp. 179
— A valid value has been taught.p. 179
+— Enter code 5041.p. 179
+— Enter codep. 179
5041p. 179
+— The E-throttle function is terminated.p. 179
— The E-throttle function is terminated.p. 179
— END.p. 179
+6.3 Teaching the L.C.S. functionp. 180
Teaching the LCS functionp. 180
+The L.C.S. Control panelp. 180
(Fig. 15)p. 180
+Work potentiometer (1)p. 180
Work potentiometer (1)p. 180
Stop potentiometer (2)p. 180
Timer potentiometer (3)p. 180
Fig. 15 LCS operationp. 180
Fig. 16 Screed adjustmentp. 180
+Lower the screed to be able to teach the L.C.S. function.p. 180
Lower the screed to be able to teach the L.C.S. function.p. 180
+The switch “a”p. 180
(Fig. 16)p. 180
+Take notice of the section "Input codes Display General"!p. 180
Take notice of the section "Input codes Display General"!p. 180
+During this teach function the travel lever mustp. 180
+During this teach function the travel lever mustp. 180
alwaysp. 180
+Teaching the LCS function:p. 181
Teaching the LCS function:p. 181
+Actionp. 181
+Actionp. 181
Actionp. 181
+Resultp. 181
+Resultp. 181
Resultp. 181
+— Start the engine.p. 181
— Start the engine.p. 181
+— Turn all potentiometers on the LCS control panel to "min".p. 181
— Turn all potentiometers on the LCS control panel to "min".p. 181
+— Enter code 0001.p. 181
+— Enter codep. 181
0001p. 181
+— The system changes to service mode.p. 181
— The system changes to service mode.p. 181
— The display shows the tool symbol.p. 181
+— Enter code 3006.p. 181
+— Enter codep. 181
3006p. 181
+— The teach function "Teach LCS" is activated.p. 181
— The teach function "Teach LCS" is activated.p. 181
— The display shows "0 0 0 0".p. 181
+— Enter code 3007.p. 181
+— Enter codep. 181
3007p. 181
+— The function LCS maximum work pressure is activated.p. 181
+— The function LCSp. 181
maximum work pressurep. 181
— The display shows "4 4 4 4 4".p. 181
+— Set the work potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 181
— Set the work potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 181
+— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 181
— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 181
+— Turn the timer potentiometer from "min" to "max" and back to "min".p. 181
— Turn the timer potentiometer from "min" to "max" and back to "min".p. 181
+— The display shows "1 1 1 1 1".p. 181
— The display shows "1 1 1 1 1".p. 181
— This is followed by "3 3 3 3 3".p. 181
+— Turn the work potentiometer to "min".p. 181
— Turn the work potentiometer to "min".p. 181
+— The display shows "2 2 2 2 2".p. 181
— The display shows "2 2 2 2 2".p. 181
— This is followed by "0 0 0 0".p. 181
+— Enter code 3008.p. 181
+— Enter codep. 181
3008p. 181
+— The function LCS maximum stop pressure is activated.p. 181
+— The function LCSp. 181
maximum stop pressurep. 181
+— Set the stop potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 181
— Set the stop potentiometer to the desired pressure (read pressure on pressure gauge of LCS control panel).p. 181
+— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 181
— The display shows the current position of the potentiometer for informative reasons (value between "0" and "1000").p. 181
+— Turn the timer potentiometer from "min" to "max" and back to "min".p. 181
— Turn the timer potentiometer from "min" to "max" and back to "min".p. 181
+— The display shows "1 1 1 1 1".p. 181
— The display shows "1 1 1 1 1".p. 181
— This is followed by "3 3 3 3 3".p. 181
+— Turn the stop potentiometer to "min".p. 181
— Turn the stop potentiometer to "min".p. 181
+— The display shows "2 2 2 2 2".p. 181
— The display shows "2 2 2 2 2".p. 181
— This is followed by "0 0 0 0".p. 181
+— Enter code 0000.p. 181
+— Enter codep. 181
0000p. 181
+— This quits the service mode.p. 181
— This quits the service mode.p. 181
— END.p. 181
+6.4 Travel signal by button for max. screed reliefp. 182
+This function is a so-calledp. 182
+This function is a so-calledp. 182
limp home functionp. 182
As long as the function "Travel signal by push button for maximum screed relief" is activated, the button for maximum screed relief is not available to the operator! However, the Load Control System (LCS) does still work.p. 182
Fig. 17 Push button for maximum screed reliefp. 182
+Take notice of the section "Input codes Display General"!p. 182
Take notice of the section "Input codes Display General"!p. 182
+Activation of the function "Travel signal by push button for maximum screed relief":p. 182
Activation of the function "Travel signal by push button for maximum screed relief":p. 182
+Actionp. 182
+Actionp. 182
Actionp. 182
+Resultp. 182
+Resultp. 182
Resultp. 182
+— Switch on the ignition.p. 182
— Switch on the ignition.p. 182
+Note: Dop. 182
Note:p. 182
notp. 182
+— Enter code 0001.p. 182
+— Enter codep. 182
0001p. 182
+— The system changes to service mode.p. 182
— The system changes to service mode.p. 182
— The display shows the tool symbol.p. 182
+— Enter code 1100.p. 182
+— Enter codep. 182
1100p. 182
+— Changes to the travel system parameters are now possible.p. 182
— Changes to the travel system parameters are now possible.p. 182
+— Enter code 1121.p. 182
+— Enter codep. 182
1121p. 182
+— The function "Travel signal by push button for maximum screed relief" is activated.p. 182
— The function "Travel signal by push button for maximum screed relief" is activated.p. 182
+To drive the machine the operator must now:p. 182
To drive the machine the operator must now:p. 182
– Shift both travel control lever forward (or backward).p. 182
+–p. 182
At the same timep. 182
(Fig. 17)p. 182
+– Travel lever in "Neutral" stops the machine.p. 183
– Travel lever in "Neutral" stops the machine.p. 183
+Once the fault(s) no longer exist (e.g. after a repair) this functionp. 183
+Once the fault(s) no longer exist (e.g. after a repair) this functionp. 183
deactivatesp. 183
automaticallyp. 183
There is also the possibility to switch off this function manually.p. 183
+Deactivation of the function "Travel signal by push button for maximum screed relief":p. 183
Deactivation of the function "Travel signal by push button for maximum screed relief":p. 183
+Actionp. 183
+Actionp. 183
Actionp. 183
+Resultp. 183
+Resultp. 183
Resultp. 183
+— Switch on the ignition.p. 183
— Switch on the ignition.p. 183
+Note: Dop. 183
Note:p. 183
notp. 183
+— Enter code 0001.p. 183
+— Enter codep. 183
0001p. 183
+— The system changes to service mode.p. 183
— The system changes to service mode.p. 183
— The display shows the tool symbol.p. 183
+— Enter code 1100.p. 183
+— Enter codep. 183
1100p. 183
+— Changes to the travel system parameters are now possible.p. 183
— Changes to the travel system parameters are now possible.p. 183
+— Enter code 1122.p. 183
+— Enter codep. 183
1122p. 183
+— The function "Travel signal by push button for maximum screed relief" is deactivated.p. 183
— The function "Travel signal by push button for maximum screed relief" is deactivated.p. 183
+6.5 Resetting to factory settingsp. 184
+Take notice of the section "Input codes Display General"!p. 184
Take notice of the section "Input codes Display General"!p. 184
+The machine will not move as long as the code "7860" is displayed.p. 184
The machine will not move as long as the code "7860" is displayed.p. 184
+Resetting to factory settings:p. 184
Resetting to factory settings:p. 184
+Actionp. 184
+Actionp. 184
Actionp. 184
+Resultp. 184
+Resultp. 184
Resultp. 184
+— Switch on the ignition.p. 184
— Switch on the ignition.p. 184
+Note: Dop. 184
Note:p. 184
notp. 184
+— Enter code 0001.p. 184
+— Enter codep. 184
0001p. 184
+— The system changes to service mode.p. 184
— The system changes to service mode.p. 184
— The display shows the tool symbol.p. 184
+— Enter code 7010.p. 184
+— Enter codep. 184
7010p. 184
+— The display shows "7 8 6 0".p. 184
— The display shows "7 8 6 0".p. 184
+— Press the right button to confirm "7860".p. 184
— Press the right button to confirm "7860".p. 184
+— The ESX runs a reset.p. 184
— The ESX runs a reset.p. 184
+— Switch off the ignition.p. 184
— Switch off the ignition.p. 184
— Switch on the ignition.p. 184
+— The display shows "7 8 6 0".p. 184
— The display shows "7 8 6 0".p. 184
+— Enter code 0001.p. 184
+— Enter codep. 184
0001p. 184
+— The system changes to service mode.p. 184
— The system changes to service mode.p. 184
— The display shows the tool symbol.p. 184
+— Enter code 7010.p. 184
+— Enter codep. 184
7010p. 184
+— Use the left hand button to select code 7861.p. 184
+— Use the left hand button to select codep. 184
7861p. 184
— Press the right button to confirm.p. 184
+— The ESX runs another reset.p. 184
— The ESX runs another reset.p. 184
+— Switch off the ignition.p. 184
— Switch off the ignition.p. 184
— Switch on the ignition.p. 184
+— The display shows "7 8 6 1".p. 184
— The display shows "7 8 6 1".p. 184
+— Enter code 0000.p. 184
+— Enter codep. 184
0000p. 184
+— This quits the service mode.p. 184
— This quits the service mode.p. 184
— END.p. 184
+6.6 Showing stored faultsp. 185
+This function can only be activated / deactivated if the parking brake has been activated!p. 185
This function can only be activated / deactivated if the parking brake has been activated!p. 185
+Dop. 185
notp. 185
+Display of logged errors:p. 185
Display of logged errors:p. 185
+Actionp. 185
+Actionp. 185
Actionp. 185
+Resultp. 185
+Resultp. 185
Resultp. 185
+— Switch on the ignition.p. 185
— Switch on the ignition.p. 185
+Note: Dop. 185
Note:p. 185
notp. 185
+— Enter code 0700.p. 185
+— Enter codep. 185
0700p. 185
+— The system changes to the mode "Show logged errors".p. 185
— The system changes to the mode "Show logged errors".p. 185
— The error codes logged in the ESX appear flashing in the display.p. 185
Note:p. 185
+If more than only one error codes has been logged, these codes are displayed inp. 185
three secondp. 185
+If there arep. 185
nop. 185
– – – – –p. 185
+— Enter code 0701.p. 185
+— Enter codep. 185
0701p. 185
+— The mode "Show logged errors" is terminated.p. 185
— The mode "Show logged errors" is terminated.p. 185
+Apart from the logged error codes the current faults (if present) are also displayed.p. 185
Apart from the logged error codes the current faults (if present) are also displayed.p. 185
+6.7 Showing saved faults with operating hoursp. 186
+This function can only be activated / deactivated if the parking brake has been activated!p. 186
This function can only be activated / deactivated if the parking brake has been activated!p. 186
+Dop. 186
notp. 186
+Display of logged errors:p. 186
Display of logged errors:p. 186
+Actionp. 186
+Actionp. 186
Actionp. 186
+Resultp. 186
+Resultp. 186
Resultp. 186
+— Switch on the ignition.p. 186
— Switch on the ignition.p. 186
+Note: Dop. 186
Note:p. 186
notp. 186
+— Enter code 0705.p. 186
+— Enter codep. 186
0705p. 186
+— The system changes to the mode "Show logged errors with operating hours".p. 186
— The system changes to the mode "Show logged errors with operating hours".p. 186
— The error codes logged in the ESX appear flashing in the display.p. 186
+— Press the left hand button.p. 186
— Press the left hand button.p. 186
Attention: three possible options!p. 186
+— Option 1: No error code logged in the ESX:p. 186
+—p. 186
Option 1p. 186
+–> The display shows "p. 186
– – – – –p. 186
+—p. 186
Option 2p. 186
–> The display shows the error code. Continue with "One error code".p. 186
+—p. 186
Option 3p. 186
–> The display first shows only one error code. Continue with "Several error codes".p. 186
+One error code:p. 186
One error code:p. 186
— Press the left hand button again.p. 186
+— The display does not change, the logged error code flashes. Continue with "Show operating hours of error code".p. 186
— The display does not change, the logged error code flashes. Continue with "Show operating hours of error code".p. 186
+Several error codes:p. 186
Several error codes:p. 186
— Press the left hand button again.p. 186
+— The display changes. Each actuation of the left hand button brings you to the next error code, until the first one appears again. Continue with "Show operating hours of error code".p. 186
— The display changes. Each actuation of the left hand button brings you to the next error code, until the first one appears again. Continue with "Show operating hours of error code".p. 186
+Showing the operating hours for the error code:p. 186
Showing the operating hours for the error code:p. 186
— Press the right hand button.p. 186
+— The operating hours at which the corresponding error code has been logged are displayed. ("When did the error occur the last time?")p. 186
— The operating hours at which the corresponding error code has been logged are displayed. ("When did the error occur the last time?")p. 186
+Showing the number of occurrence of this error:p. 186
Showing the number of occurrence of this error:p. 186
— Press the right hand button again.p. 186
+The display shows the number of occurrence of the corresponding error since the error log had been deleted the last time. ("How often has the error been detected?")p. 186
The display shows the number of occurrence of the corresponding error since the error log had been deleted the last time. ("How often has the error been detected?")p. 186
+— Enter code 0706.p. 186
+— Enter codep. 186
0706p. 186
+— The mode "Show logged errors with operating hours" is terminated.p. 186
— The mode "Show logged errors with operating hours" is terminated.p. 186
+Apart from the logged error codes the current faults (if present) are also displayed.p. 186
Apart from the logged error codes the current faults (if present) are also displayed.p. 186
+6.8 Deleting the fault logp. 187
+This function can only be activated / deactivated if the parking brake has been activated!p. 187
This function can only be activated / deactivated if the parking brake has been activated!p. 187
+Dop. 187
notp. 187
+Deleting logged errors:p. 187
Deleting logged errors:p. 187
+Actionp. 187
+Actionp. 187
Actionp. 187
+Resultp. 187
+Resultp. 187
Resultp. 187
+— Switch on the ignition.p. 187
— Switch on the ignition.p. 187
+Note: Dop. 187
Note:p. 187
notp. 187
+— Enter code 0710.p. 187
+— Enter codep. 187
0710p. 187
+— Switch off the ignition.p. 187
— Switch off the ignition.p. 187
— Switch on the ignition.p. 187
+— All logged error codes have been deleted.p. 187
— All logged error codes have been deleted.p. 187
+6.9 Driving against the closed brakep. 188
+Activation of this mode is only possible from software version 0.21!p. 188
Activation of this mode is only possible from software version 0.21!p. 188
+Activate function "Driving against the closed brake":p. 188
Activate function "Driving against the closed brake":p. 188
+Actionp. 188
+Actionp. 188
Actionp. 188
+Resultp. 188
+Resultp. 188
Resultp. 188
+— Start the engine.p. 188
— Start the engine.p. 188
— Shift the travel lever to "Neutral"p. 188
+— Enter code 0001.p. 188
+— Enter codep. 188
0001p. 188
+— The system changes to service mode.p. 188
— The system changes to service mode.p. 188
— The display shows the tool symbol.p. 188
+— Enter code 0500.p. 188
+— Enter codep. 188
0500p. 188
+— The mode "Driving against the closed brake" is activated.p. 188
— The mode "Driving against the closed brake" is activated.p. 188
+— The LED for brakep. 188
flashesp. 188
+— Shift the travel lever to "forward" ("reverse").p. 188
— Shift the travel lever to "forward" ("reverse").p. 188
— Set the speed potentiometer to "> 0".p. 188
+— The display shows "0 0 0 0".p. 188
— The display shows "0 0 0 0".p. 188
+— Shift the travel lever to "Neutral"p. 188
— Shift the travel lever to "Neutral"p. 188
— Set the speed potentiometer to "> 0".p. 188
+— The display shows "0 0 0 0".p. 188
— The display shows "0 0 0 0".p. 188
+— Enter code 0501.p. 188
+— Enter codep. 188
0501p. 188
+— The mode "Driving against the closed brake" is deactivated.p. 188
— The mode "Driving against the closed brake" is deactivated.p. 188
+— The LED for brakep. 188
lightsp. 188
— The display shows "0 0 0 0".p. 188
+— Enter code 0000.p. 188
+— Enter codep. 188
0000p. 188
+— This quits the service mode.p. 188
— This quits the service mode.p. 188
— END.p. 188
+6.10 Adapting the engine speedp. 189
+On the finisher BF300 the transmission ratio of the belt drive for the generator (power generation for screed heating) was adapted from a certain serial number. The diameter of the generator V-belt pulley was thereby changed. In the software versionp. 189
+On the finisher BF300 the transmission ratio of the belt drive for the generator (power generation for screed heating) was adapted from a certain serial number. The diameter of the generator V-belt pulley was thereby changed. In the software versionp. 189
v0.27p. 189
+Serial numbers, from which the changed V-belt drive has been installed:p. 189
Serial numbers, from which the changed V-belt drive has been installed:p. 189
+BF300_P – S340 VE : 821837681008 – …p. 189
BF300_P – S340 VE : 821837681008 – …p. 189
BF300_P – S340 TVE : 821837811013 – …p. 189
BF300_C – S340 TVE : 821837821017 – …p. 189
+The engine speedp. 189
+The engine speedp. 189
mustp. 189
v0.27p. 189
+Take notice of the section "Input codes Display General"!p. 189
Take notice of the section "Input codes Display General"!p. 189
+Adapting the engine speed:p. 189
Adapting the engine speed:p. 189
+Actionp. 189
+Actionp. 189
Actionp. 189
+Resultp. 189
+Resultp. 189
Resultp. 189
+— Switch on the ignition.p. 189
— Switch on the ignition.p. 189
+Note: Dop. 189
Note:p. 189
notp. 189
+— Enter code 0001.p. 189
+— Enter codep. 189
0001p. 189
+— The system changes to service mode.p. 189
— The system changes to service mode.p. 189
— The display shows the tool symbol.p. 189
+— Enter code 5046.p. 189
+— Enter codep. 189
5046p. 189
+— The engine speed is adapted to the original settings (old generator).p. 189
— The engine speed is adapted to the original settings (old generator).p. 189
+— Enter code 0000.p. 189
+— Enter codep. 189
0000p. 189
+— This quits the service mode.p. 189
— This quits the service mode.p. 189
— END.p. 189
+6.11 Deactivating / activating the front drivep. 190
+The front drive is a special feature available for the wheel version of the BF300 finisher.p. 190
The front drive is a special feature available for the wheel version of the BF300 finisher.p. 190
+On machines which are only equipped with rear wheel drive, the front drive must bep. 190
deactivatedp. 190
+If the front drive isp. 190
+If the front drive isp. 190
notp. 190
+1029p. 190
1029p. 190
1030p. 190
1140p. 190
1143p. 190
1150p. 190
+Take notice of the section "Input codes Display General"!p. 190
Take notice of the section "Input codes Display General"!p. 190
+Deactivating the front drive:p. 190
Deactivating the front drive:p. 190
+Actionp. 190
+Actionp. 190
Actionp. 190
+Resultp. 190
+Resultp. 190
Resultp. 190
+— Switch on the ignition.p. 190
— Switch on the ignition.p. 190
+Note: Dop. 190
Note:p. 190
notp. 190
+— Enter code 0001.p. 190
+— Enter codep. 190
0001p. 190
+— The system changes to service mode.p. 190
— The system changes to service mode.p. 190
— The display shows the tool symbol.p. 190
+— Enter code 1100.p. 190
+— Enter codep. 190
1100p. 190
+— The function "Setting the machine type code" is activated.p. 190
— The function "Setting the machine type code" is activated.p. 190
+— Enter code 1102.p. 190
+— Enter codep. 190
1102p. 190
+— The front drive is deactivated.p. 190
+— The front drive isp. 190
deactivatedp. 190
+— Switch off the ignition.p. 190
— Switch off the ignition.p. 190
+— END.p. 190
— END.p. 190
+Activating the front drive:p. 190
Activating the front drive:p. 190
+Actionp. 190
+Actionp. 190
Actionp. 190
+Resultp. 190
+Resultp. 190
Resultp. 190
+— Switch on the ignition.p. 190
— Switch on the ignition.p. 190
+Note: Dop. 190
Note:p. 190
notp. 190
+— Enter code 0001.p. 190
+— Enter codep. 190
0001p. 190
+— The system changes to service mode.p. 190
— The system changes to service mode.p. 190
— The display shows the tool symbol.p. 190
+— Enter code 1100.p. 190
+— Enter codep. 190
1100p. 190
+— The function "Setting the machine type code" is activated.p. 190
— The function "Setting the machine type code" is activated.p. 190
+— Enter code 1101.p. 190
+— Enter codep. 190
1101p. 190
+— The front drive is activated.p. 190
+— The front drive isp. 190
activatedp. 190
+— Switch off the ignition.p. 190
— Switch off the ignition.p. 190
+— END.p. 190
— END.p. 190
+6.12 Deactivating / activating the brake pedal switchp. 191
+6.12 Deactivating / activating the brake pedal switchp. 191
+With a defective brake pedal switch the machine can no longer be moved correctly.p. 191
With a defective brake pedal switch the machine can no longer be moved correctly.p. 191
The brake pedal switch can therefore be deactivated.p. 191
+With a deactivated brake pedal switch the braking effect kicks in with a delay. Adapt your travel performance!p. 191
With a deactivated brake pedal switch the braking effect kicks in with a delay. Adapt your travel performance!p. 191
The display shows the error code 1005.p. 191
+Take notice of the section "Input codes Display General"!p. 191
Take notice of the section "Input codes Display General"!p. 191
+Deactivating the brake pedal switch:p. 191
Deactivating the brake pedal switch:p. 191
+Actionp. 191
+Actionp. 191
Actionp. 191
+Resultp. 191
+Resultp. 191
Resultp. 191
+— Switch on the ignition.p. 191
— Switch on the ignition.p. 191
+Note: Dop. 191
Note:p. 191
notp. 191
+— Enter code 0001.p. 191
+— Enter codep. 191
0001p. 191
+— The system changes to service mode.p. 191
— The system changes to service mode.p. 191
— The display shows the tool symbol.p. 191
+— Enter code 1100.p. 191
+— Enter codep. 191
1100p. 191
+— The function "Setting the machine type code" is activated.p. 191
— The function "Setting the machine type code" is activated.p. 191
+— Enter code 1104.p. 191
+— Enter codep. 191
1104p. 191
+— The brake pedal switch is deactivated.p. 191
+— The brake pedal switch isp. 191
deactivatedp. 191
+— Switch off the ignition.p. 191
— Switch off the ignition.p. 191
+— END.p. 191
— END.p. 191
+Once the brake pedal switch has been repaired, it must be activated again.p. 191
Once the brake pedal switch has been repaired, it must be activated again.p. 191
+Activating the brake pedal switch:p. 191
Activating the brake pedal switch:p. 191
+Actionp. 191
+Actionp. 191
Actionp. 191
+Resultp. 191
+Resultp. 191
Resultp. 191
+— Switch on the ignition.p. 191
— Switch on the ignition.p. 191
+Note: Dop. 191
Note:p. 191
notp. 191
+— Enter code 0001.p. 191
+— Enter codep. 191
0001p. 191
+— The system changes to service mode.p. 191
— The system changes to service mode.p. 191
— The display shows the tool symbol.p. 191
+— Enter code 1100.p. 191
+— Enter codep. 191
1100p. 191
+— The function "Setting the machine type code" is activated.p. 191
— The function "Setting the machine type code" is activated.p. 191
+— Enter code 1103.p. 191
+— Enter codep. 191
1103p. 191
+— The brake pedal switch is activated.p. 191
+— The brake pedal switch isp. 191
activatedp. 191
+— Switch off the ignition.p. 191
— Switch off the ignition.p. 191
+— END.p. 191
— END.p. 191
+7 Replacement of componentsp. 193
+7 Replacement of componentsp. 193
How to proceed when replacing components?p. 194
+Forewordp. 194
Forewordp. 194
Each machine is adjusted individually ex factory. Should the replacement of machine parts become necessary during the operating period of the machine, there is always a possibility to repeat these adjustments.p. 194
BOMAG thereby does without any expensive special tools, but gives the service personnel the possibility tom make adjustments and settings easily and simply by just using the display on the machine. The chapter "Electrics finisher input codes" contain…p. 194
+Replacing the contgrol (ESX)p. 194
Replacing the contgrol (ESX)p. 194
Since the central control (ESX) saves all data and values, all teach procedures listed in the chapter "Electrics finisher input codes" must be carried out.p. 194
+Compliance with the specified sequence of procedures is mandatory!p. 194
Compliance with the specified sequence of procedures is mandatory!p. 194
Carry out the following teach procedure(s):p. 194
+Input codes — reset to factory settings (Code:p. 194
+Input codes — reset to factory settings (Code:p. 194
7861p. 194
Pp. 194
7865p. 194
Cp. 194
+Input codes – automatic calibration of currents for travel system (p. 194
onlyp. 194
Cp. 194
+If necessary: Input codes – manual calibration of currents for travel system (p. 194
onlyp. 194
Cp. 194
Input codes — teaching E-throttle functionp. 194
If necessary: Input codes – adapt engine speed.p. 194
+Replacement of travel pump(s)p. 194
Replacement of travel pump(s)p. 194
Carry out the following teach procedure(s):p. 194
+Input codes – automatic calibration of currents for travel system (p. 194
+Input codes – automatic calibration of currents for travel system (p. 194
onlyp. 194
Cp. 194
+If necessary: Input codes – manual calibration of currents for travel system (p. 194
onlyp. 194
Cp. 194
+Replacement of E-throttle actuatorp. 194
Replacement of E-throttle actuatorp. 194
Carry out the following teach procedure(s):p. 194
+Input codes — teaching E-throttle functionp. 194
Input codes — teaching E-throttle functionp. 194
+The following components can be replaced without a subsequent teach procedure:p. 194
The following components can be replaced without a subsequent teach procedure:p. 194
+The displayp. 194
The displayp. 194
+The diesel engine (p. 194
Attention:p. 194
All switches in the instrument panel and the lateral contro, panels.p. 194
+8 Enginep. 195
8 Enginep. 195
+8.5 Check the coolant levelp. 196
8.1 Featuresp. 196
+Generalp. 196
Generalp. 196
All BOMAG finishers BF300 are powered by powerful 4-cylinder KUBOTA engines with direct fuel injection, turbocharger and 4-valve technology. Engines which impress by their homogeneous development of power with low fuel consumption and low CO2 emissio…p. 196
Fig. 18p. 196
The standard BOMAG ECOMODE ensures a clean environmental balance. Due to the active engine management power is made available for the driver when it is needed and is reduced again when permitted by the application. Intelligent sensors in connection w…p. 196
Engine blockp. 196
Fig. 19 Engine blockp. 196
+1 Crankcase 1p. 196
1 Crankcase 1p. 196
2 Crankcase 2p. 196
+The engine has two separate crankcases – crankcase 1p. 196
(Fig. 19)p. 196
The cylinders are designed without liners, which ensures excellent cooling, lower tensions and good abrasion resistance.p. 196
Semi-floating valve coverp. 197
A recessed rubber seal ensures a distance of approx. 0.5 mm between valve cover and cylinder head. This reduces the development of noise on the cylinder head.p. 197
Fig. 20p. 197
+1 Valve coverp. 197
1 Valve coverp. 197
2 Rubber sealp. 197
Cylinder headp. 197
The engine has a 4-valve system with one cylinder head, which is designed with dual intake channels.p. 197
Fig. 21p. 197
+1 Intakep. 197
1 Intakep. 197
2 Exhaustp. 197
Central Direct Injection System (E-CDIS)p. 198
The engines are equipped with the central direct injection system (E-CDIS = Center Direct Injection System) with the injection nozzle arranged vertically in the centre of the cylinder.p. 198
The system injects the fuel directly into the centre of the cylinder.p. 198
Fig. 22p. 198
+1 Exhaust valvesp. 198
1 Exhaust valvesp. 198
2 Pistonp. 198
3 Injection nozzlep. 198
4 Intake valvesp. 198
+8.5 Check the coolant levelp. 198
8.2 Cooling systemp. 198
+Thermostatp. 198
Thermostatp. 198
Conventional thermostat valves (type outlet water temperature) open against the coolant flow. In this design the pressure (steam pressure + water pump output pressure) influences the opening/closing performance of the valve.p. 198
The valve could thus be delayed at a specified opening temperature and then suddenly open above the specified temperature. This is referred to as overshoot phenomenon. The overshoot problem also leads to a subharmonic phenomenon. Too much water coole…p. 198
A repetitive cycle of such overshoot and subharmonic phenomena is referred to as water temperature hunting. This overshoot problem not only adversely affects the cooling system components, but also the engine and related components.p. 198
+In order to tackle this problem the V3 is equipped with a flow control thermostat. The valve is provided with a recess 4p. 198
(Fig. 24)p. 198
Fig. 23p. 198
+1 Coolant temperaturep. 198
1 Coolant temperaturep. 198
2 Timep. 198
3 Overshootingp. 198
+4 (Fig. 24) Recessp. 198
4 (Fig. 24)p. 198
Fig. 24p. 199
Lower bypassp. 199
+The engines of series V3 are designed with lower bypass, which ensures better cooling performance of the radiator. At low coolant temperature in the engine the thermostat 1p. 199
(Fig. 25)p. 199
Fig. 25 Bypass closedp. 199
+If the temperature exceeds the thermostat opening temperature, the thermostat 1p. 199
(Fig. 26)p. 199
This enhances the cooling power of the radiator.p. 199
Fig. 26 Bypass openp. 199
+8.5 Check the coolant levelp. 200
8.3 Removing and installing the thermostatp. 200
Fig. 1p. 200
+1 Thermostat coverp. 200
1 Thermostat coverp. 200
2 Thermostat cover sealp. 200
3 Thermostatp. 200
4 Borep. 200
+Unscrew the thermostat cover fastening screws and take off the thermostat cover (1)p. 200
+Unscrew the thermostat cover fastening screws and take off the thermostat cover (1)p. 200
(Fig. 1)p. 200
Remove the thermostat (3).p. 200
For assemblyp. 200
+Assemble the thermostat cover (3) with the hole (4) facing towards the front cover side.p. 200
Assemble the thermostat cover (3) with the hole (4) facing towards the front cover side.p. 200
+8.5 Check the coolant levelp. 200
8.4 Checking the thermostat in disassembled statep. 200
+The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 74,5°C to 78,5°C the thermostat is…p. 200
The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 74,5°C to 78,5°C the thermostat is…p. 200
Fig. 1p. 200
+Measure and write down the measurement "a" on the thermostatp. 200
+Measure and write down the measurement "a" on the thermostatp. 200
(Fig. 1)p. 200
+"a" = beginning of stroke at approx. 74.5°C to 78.5°C (T1)p. 200
"a" = beginning of stroke at approx. 74.5°C to 78.5°C (T1)p. 200
"b" = end of stroke at approx. 90 °C (T2)p. 200
Fig. 2p. 200
+Warm up the thermostat in a water bathp. 200
+Warm up the thermostat in a water bathp. 200
(Fig. 2)p. 200
+In order to determine the exact start of opening the temperature should be measured as close to the thermostat as possible, but without touching it.p. 200
In order to determine the exact start of opening the temperature should be measured as close to the thermostat as possible, but without touching it.p. 200
The water must thereby be stirred continuously, to ensure even temperature distribution.p. 200
The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.p. 201
Fig. 3p. 201
+Measure and write down the measurement "b" on the thermostat .p. 201
+Measure and write down the measurement "b" on the thermostat .p. 201
(Fig. 3)p. 201
Calculate the stroke.p. 201
Stroke = b – ap. 201
+The stroke at the given temperature (T2) should be approx. 8 mm.p. 201
The stroke at the given temperature (T2) should be approx. 8 mm.p. 201
+8.5 Check the coolant levelp. 201
8.5 Check the coolant levelp. 201
+Danger of scalding!p. 201
+Danger of scalding!p. 201
Danger of scalding!p. 201
Fill up coolant only when the engine is cold.p. 201
+If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 201
If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 201
+Open the engine flap and secure it.p. 201
Open the engine flap and secure it.p. 201
Fig. 4p. 201
+Check the coolant levelp. 201
+Check the coolant levelp. 201
(Fig. 4)p. 201
+Top up coolant, if necessary.p. 201
Top up coolant, if necessary.p. 201
For quality of coolant refer to the chapter 5.2, fuels and lubricants.p. 201
+8.6 Check the anti-freeze concentration and the condition of the coolantp. 202
8.6 Check the anti-freeze concentration and the condition of the coolantp. 202
+Danger of scalding!p. 202
+Danger of scalding!p. 202
Danger of scalding!p. 202
Check the anti-freeze concentration only when the engine is cold.p. 202
+In order to avoid damage to the engine (e.g. by corrosion, cavitation and freezing), particular attention must be paid to the inspection of the coolant.p. 202
In order to avoid damage to the engine (e.g. by corrosion, cavitation and freezing), particular attention must be paid to the inspection of the coolant.p. 202
For coolant quality refer to the "table of fuels and lubricants".p. 202
Do not mix different coolants and additives, see section "Fuelds and Lubricants – Coolant".p. 202
If the coolant is contaminated by corrosion residues or other suspended matter, flush the cooling system, see section "Changing the coolant".p. 202
+Catch coolant and dispose of environmentally.p. 202
Catch coolant and dispose of environmentally.p. 202
Fig. 5p. 202
+Unscrew the radiator capp. 202
+Unscrew the radiator capp. 202
(Fig. 5)p. 202
Check the condition of the coolant.p. 202
Screw the cover back on again.p. 202
+8.7 Change the coolantp. 202
8.7 Change the coolantp. 202
+Danger of scalding!p. 202
+Danger of scalding!p. 202
Danger of scalding!p. 202
Do not remove the cap from the compensation tank when the engine is still hot.p. 202
Change the coolant only when the engine is cold.p. 202
+Do not start the engine after draining off the coolant.p. 202
Do not start the engine after draining off the coolant.p. 202
Thoroughly flush the engine if the coolant is contaminated by corrosion residues or other suspended matter.p. 202
When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.p. 202
Do not mix different coolants and additives of any other kind.p. 202
Change the coolant at the latest after two years.p. 202
For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 202
+Catch coolant and dispose of environmentally.p. 202
Catch coolant and dispose of environmentally.p. 202
Fig. 6p. 202
+Unscrew the capp. 202
+Unscrew the capp. 202
(Fig. 6)p. 202
Fig. 7p. 203
+Unscrew the plug, let the coolant run out and catch itp. 203
+Unscrew the plug, let the coolant run out and catch itp. 203
(Fig. 7)p. 203
Screw the plug back in once all coolant has run out.p. 203
Check the condition of the coolant.p. 203
Thoroughly flush the engine if the coolant is contaminated by corrosion residues or other suspended matter.p. 203
Fill in clean water.p. 203
Start the engine and flush the cooling system out for a short while.p. 203
Drain all water off.p. 203
Fig. 8p. 203
+Fill in coolant up to theMAX markp. 203
+Fill in coolant up to theMAX markp. 203
(Fig. 8)p. 203
Start the diesel engine and run it warm to operating temperature.p. 203
Let the engine cool down and check the coolant level again, top up if necessary.p. 203
+8.8 Checking radiator hoses and hose clampsp. 203
8.8 Checking radiator hoses and hose clampsp. 203
+Danger of burning!p. 203
+Danger of burning!p. 203
Danger of burning!p. 203
Perform inspection work only after the engine has cooled down and with the engine stopped.p. 203
+If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately.p. 203
If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately.p. 203
Take care that no contaminants enter into the air intake system, since this could damage the engine!p. 203
Fig. 9p. 203
+Check the condition and tight fit of all radiator hoses and hose clampsp. 203
+Check the condition and tight fit of all radiator hoses and hose clampsp. 203
(Fig. 9)p. 203
+Check the condition and tight fit of all air intake lines and hose clamps.p. 203
Check the condition and tight fit of all air intake lines and hose clamps.p. 203
+8.9 Clean the cooling fins on engine and hydraulic oil coolerp. 204
8.9 Clean the cooling fins on engine and hydraulic oil coolerp. 204
+Danger of injury!p. 204
+Danger of injury!p. 204
Danger of injury!p. 204
Perform cleaning work only after the engine has cooled down and with the engine stopped.p. 204
+Do not damage any cooling fins on the cooler core when cleaning.p. 204
Do not damage any cooling fins on the cooler core when cleaning.p. 204
+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. 204
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. 204
+Cleaning with compressed airp. 204
Cleaning with compressed airp. 204
+Start to blow out from the exhaust side.p. 204
Start to blow out from the exhaust side.p. 204
Fig. 10p. 204
+Blow the coolerp. 204
+Blow the coolerp. 204
(Fig. 10)p. 204
+Cleaning with cold cleansing agentp. 204
Cleaning with cold cleansing agentp. 204
+Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 204
Protect electrical equipment such as generator, regulator and starter against the direct water jet.p. 204
+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. 204
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. 204
Run the engine warm for a while to avoid corrosion.p. 204
+8.10 Check the engine oil levelp. 204
8.10 Check the engine oil levelp. 204
+The machine must be in horizontal position. When the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.p. 204
+The machine must be in horizontal position. When the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.p. 204
The machine must be in horizontal position. When the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.p. 204
+Danger of squashing!p. 204
Danger of squashing!p. 204
Always support the engine hood when it is open.p. 204
+Open and support the engine hood.p. 204
Open and support the engine hood.p. 204
Fig. 11p. 204
+Pull the dipstickp. 204
+Pull the dipstickp. 204
(Fig. 11)p. 204
Pull the dipstick back out.p. 204
The oil level must always be between the "MIN"- and "MAX"-marks.p. 204
+If the oil level is too low top up oil immediately.p. 204
If the oil level is too low top up oil immediately.p. 204
If the oil level is too high, determine the cause and drain the oil off.p. 204
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 204
+8.11 Change engine oil and oil filter cartridgep. 205
8.11 Change engine oil and oil filter cartridgep. 205
+Danger of scalding!p. 205
+Danger of scalding!p. 205
Danger of scalding!p. 205
When draining off hot oil.p. 205
By hot oil when unscrewing the engine oil filter.p. 205
+Drain the engine oil only when the engine is warm.p. 205
Drain the engine oil only when the engine is warm.p. 205
+Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 205
Catch running out oil and dispose of environmentally together with the oil filter cartridge.p. 205
Fig. 12p. 205
+Unscrew the drain hosep. 205
+Unscrew the drain hosep. 205
(Fig. 12)p. 205
Reassemble the drain hose.p. 205
Fig. 13p. 205
+Unscrew the filter cartridge 1p. 205
+Unscrew the filter cartridge 1p. 205
(Fig. 13)p. 205
Wipe the sealing face clean.p. 205
Cover the rubber seal of the new engine oil filter slightly with clean oil.p. 205
Spin the new engine oil filter cartridge on and tighten it hand tight.p. 205
+Fill in new engine oil through the oil filler neck (2).p. 205
Fill in new engine oil through the oil filler neck (2).p. 205
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 205
+Tighten the oil filler cap properly.p. 205
Tighten the oil filler cap properly.p. 205
Fig. 14p. 205
+After a short test run check for leaks.p. 205
After a short test run check for leaks.p. 205
+Check the oil level on the dipstickp. 205
(Fig. 14)p. 205
+8.13 Replace the fuel filter cartridgep. 206
8.12 Fuel systemp. 206
+Regulatorp. 206
Regulatorp. 206
Fig. 15 Regulatorp. 206
The engine is equipped with a separate injection pump, combined with the small mechanical multi- function governor from Kubota. It also contains a torque limitation mechanism to control the maximum peak torque. This mechanism maintains the engine spe…p. 206
The governor is a mechanical governor which controls the fuel injection quantity over all speed ranges from idle speed to maximum speed by using spring force to simply compensate the centrifugal force of the governor weights.p. 206
Governor during startingp. 206
+If no centrifugal force acts on the governor weights (2)p. 206
(Fig. 16)p. 206
Fig. 16 Governor during startingp. 206
+1 Start springp. 206
1 Start springp. 206
2 Governor weightp. 206
Governor at idle speedp. 207
+The throttle lever (2)p. 207
(Fig. 17)p. 207
When the fork lever (1) is tensioned, both the spring bolt (3) and the for lever (5) will move in direction of arrow A to hold back the governor weights (6). The centrifugal force of the governor weights (6) is compensated in combination with the sta…p. 207
Fig. 17 Governor at idle speedp. 207
+1 Fork leverp. 207
1 Fork leverp. 207
2 Throttle leverp. 207
3 Spring boltp. 207
4 Start springp. 207
5 Fork leverp. 207
6 Governor weightp. 207
7 Governor springp. 207
Governor at nominal speedp. 207
+When the throttle control lever (2)p. 207
(Fig. 17)p. 207
(Fig. 17)p. 207
(Fig. 17)p. 207
(Fig. 18)p. 207
+When the engine is overloaded the engine speed will drop together with the centrifugal force of the governor weights (6)p. 207
(Fig. 17)p. 207
(Fig. 17)p. 207
Fig. 18 Governor at nominal speedp. 207
+1 Maximum speed without loadp. 207
1 Maximum speed without loadp. 207
2 Output power limitation screwp. 207
3 Torque limitation screwp. 207
Governor when shutting down the enginep. 208
+Interrupting the electric power to the shut-down solenoid (1) will release the centrifugal force of the solenoid, whereby the solenoid armature is ejected and moves the governor rack to position Bp. 208
(Fig. 19)p. 208
In order to shut down the engine manually, the shut- down lever must be shifted to the left.p. 208
Fig. 19 Governor when shutting down the enginep. 208
+1 Shut-down solenoidp. 208
1 Shut-down solenoidp. 208
2 Stop lever axlep. 208
2-stage nozzlep. 208
The nozzle holder, which is fitted with two springs, was designed for the reduction of nitrogen oxide and particle emissions.p. 208
The nozzle holder with two springs limits the valve stroke during initial opening of the valve in order to throttle the injection quantity. Main injection takes place when the line pressure has sufficiently increased and is able to open the needle va…p. 208
This results in the following characteristics.p. 209
+Improved engine stability at low and medium speeds.p. 209
Improved engine stability at low and medium speeds.p. 209
Reduced speed oscillations and speed jumps.p. 209
Reduced noise development at idle speed.p. 209
Reduced idle speed due to improved engine stability.p. 209
Stabilized fuel injection characteristics of injection pump and nozzle system and simplified adaptation of the governor characteristics to the engine requirements.p. 209
Initial opening pressurep. 209
The force generated by the high pressure of the fuel supplied by the injection pump presses the needle valve up. Once this force exceeds the rated force of the first spring the needle valve in the nozzle will move the first push rod up and open the v…p. 209
Second opening pressurep. 209
Once the first push rod has been lifted in the pre- stroke, it will touch the second push rod. Since the rated force of the second spring acts on the second push rod, the combined forces of the first and second springs will act on the needle valve, w…p. 209
+8.13 Replace the fuel filter cartridgep. 209
8.13 Replace the fuel filter cartridgep. 209
+Fire hazard!p. 209
+Fire hazard!p. 209
Fire hazard!p. 209
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 209
Catch running out fuel, do not let it seep into the ground.p. 209
Do not inhale any fuel fumes.p. 209
Fig. 21p. 209
+Loosen and unscrew fuel filter cartridge 1p. 209
+Loosen and unscrew fuel filter cartridge 1p. 209
(Fig. 21)p. 209
Clean the sealing face on the filter carrier from any dirt.p. 209
Slightly oil the rubber seal on the new filter cartridge.p. 209
+Turn the new filter cartridges on by hand, until the seal contacts.p. 209
Turn the new filter cartridges on by hand, until the seal contacts.p. 209
Tighten the filter cartridges for another half turn.p. 209
Check the filter cartridge for leaks after a short test run.p. 209
+8.14 Check, clean the water separatorp. 210
8.14 Check, clean the water separatorp. 210
+Danger of injury!p. 210
+Danger of injury!p. 210
Danger of injury!p. 210
Support the engine hood for all maintenance and repair work.p. 210
+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. 210
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. 210
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. 210
+Catch running out fuel and dispose of environmentally.p. 210
Catch running out fuel and dispose of environmentally.p. 210
+Open the access door on the right side of the vehicle.p. 210
Open the access door on the right side of the vehicle.p. 210
Fig. 22p. 210
+Slacken the drain plugp. 210
+Slacken the drain plugp. 210
(Fig. 22)p. 210
Tighten the drain plug again and check for leaks, if necessary replace the seal ring.p. 210
+8.15 Replace the fuel pre-filter, bleed the fuel systemp. 210
8.15 Replace the fuel pre-filter, bleed the fuel systemp. 210
+Fire hazard!p. 210
+Fire hazard!p. 210
Fire hazard!p. 210
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 210
+Health hazard!p. 210
Health hazard!p. 210
Do not inhale any fuel fumes.p. 210
+Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 210
Ensure strict cleanliness! Thoroughly clean the area around the fuel filters.p. 210
After work on the fuel system bleed the system, perform a test run and check for leaks.p. 210
Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory.p. 210
+Any fuel must be caught and disposed of in an environmentally friendly manner.p. 210
Any fuel must be caught and disposed of in an environmentally friendly manner.p. 210
+Change the fuel pre-filter cartridgep. 210
Change the fuel pre-filter cartridgep. 210
Fig. 23p. 210
+Tighten the cable on the water separatorp. 210
+Tighten the cable on the water separatorp. 210
(Fig. 23)p. 210
(1) Loosen the bleeding screw and drain off fuel from the bleeding screw.p. 210
(2) Loosen and unscrew the fuel pre-filter cartridge using an appropriate filter wrench.p. 210
(3) Unscrew the water separator from the filter cartridge.p. 210
(4) Apply a thin coat of oil to the rubber seal of the water separator.p. 210
(5) Turn the water separator on by hand, until the seal contacts, then tighten hand-tight.p. 211
(6) Apply a thin coat of oil to the rubber seal of the filter element (5).p. 211
(7) Turn the filter cartridge on by hand, until the seal contacts, then tighten hand-tight.p. 211
Plug the water sensor cable back on.p. 211
+Bleed the fuel systemp. 211
Bleed the fuel systemp. 211
+The fuel system is equipped with an electric fuel pump. Tom purge the system switch on the ignition and wait about 15 seconds before starting the engine.p. 211
The fuel system is equipped with an electric fuel pump. Tom purge the system switch on the ignition and wait about 15 seconds before starting the engine.p. 211
+8.16 Checking fuel lines and clampsp. 211
8.16 Checking fuel lines and clampsp. 211
+Danger of burning!p. 211
+Danger of burning!p. 211
Danger of burning!p. 211
Perform inspection work only after the engine has cooled down and with the engine stopped.p. 211
+If fuel lines or hose clamps are found to be damaged, the corresponding parts must be immediately repaired or replaced.p. 211
If fuel lines or hose clamps are found to be damaged, the corresponding parts must be immediately repaired or replaced.p. 211
After replacing lines or hose clamps the fuel system needs to be bled.p. 211
Disassembled or new fuel lines must be closed with clean cloths on both ends, to make sure that no dirt will enter into the fuel system. Dirt particles can destroy the injection pump.p. 211
Fig. 24p. 211
+Check the condition and tight fit of all hose clamps (1)p. 211
+Check the condition and tight fit of all hose clamps (1)p. 211
(Fig. 24)p. 211
+8.17 Checking the fuel injection nozzlesp. 212
8.17 Checking the fuel injection nozzlesp. 212
+This work must only be performed by authorized service personnel.p. 212
+This work must only be performed by authorized service personnel.p. 212
This work must only be performed by authorized service personnel.p. 212
+8.18 Check the fuel injection timingp. 212
8.18 Check the fuel injection timingp. 212
+This work must only be performed by authorized service personnel.p. 212
+This work must only be performed by authorized service personnel.p. 212
This work must only be performed by authorized service personnel.p. 212
+8.19 Check the fuel injection pumpp. 213
8.19 Check the fuel injection pumpp. 213
+This work must only be performed by authorized service personnel.p. 213
+This work must only be performed by authorized service personnel.p. 213
This work must only be performed by authorized service personnel.p. 213
+8.20 Checking the condition and tightness of the generator V- beltp. 213
8.20 Checking the condition and tightness of the generator V- beltp. 213
Fig. 25p. 213
+Check the entire circumference of the V-beltp. 213
+Check the entire circumference of the V-beltp. 213
(Fig. 25)p. 213
Check with thumb pressure (2) whether the V-belt can be depressed more than 10 to 12 mm between the V-belt pulleys, retighten if necessary.p. 213
To retighten loosen the fastening screws (1) and move the generator to adjust the V-belt tension.p. 213
Finally tighten the fastening screws again.p. 213
+8.21 Service the combustion air filterp. 214
8.21 Service the combustion air filterp. 214
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 214
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 214
Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 214
Fig. 26p. 214
+Maintenance of the dry air filter is due when control light ap. 214
(Fig. 26)p. 214
However, the filter cartridge must be replaced at the latest after two years.p. 214
After completion of the filter service reset the indicator piston back to "Zero" by pressing the button.p. 214
+Open the engine hood completely and secure it.p. 214
Open the engine hood completely and secure it.p. 214
+Removing the main filter elementp. 214
Removing the main filter elementp. 214
Fig. 27p. 214
+Loosen both locking hooksp. 214
+Loosen both locking hooksp. 214
(Fig. 27)p. 214
Fig. 28p. 214
+Pull the main filter elementp. 214
+Pull the main filter elementp. 214
(Fig. 28)p. 214
+Cleaning the main filter elementp. 214
Cleaning the main filter elementp. 214
+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. 214
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. 214
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. 214
Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new filter cartridge.p. 214
Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine.p. 214
Replace the safety cartridge if the main filter element is defective!p. 214
Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.p. 214
Fig. 29p. 214
+Blow the cartridgep. 214
+Blow the cartridgep. 214
(Fig. 29)p. 214
Fig. 30p. 215
+Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 215
+Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 215
(Fig. 30)p. 215
+Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 215
Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 215
+Installing the main filter elementp. 215
Installing the main filter elementp. 215
+Slide the main filter element carefully into the housing.p. 215
Slide the main filter element carefully into the housing.p. 215
When closing the housing cover the main filter element is automatically forced in the correct position.p. 215
+Changing the safety filter elementp. 215
Changing the safety filter elementp. 215
+The safety filter element must not be cleaned and should not be used again after it has been removed.p. 215
The safety filter element must not be cleaned and should not be used again after it has been removed.p. 215
Break the seal only to replace the safety filter element.p. 215
The safety filter element must be replaced:p. 215
If the main filter element is defective.p. 215
after five service intervals of the filter cartridge,p. 215
at the latest after 2 years,p. 215
if the warning light comes on again after servicing the main filter cartridge.p. 215
+Remove the housing cover and pull the main filter element off.p. 215
Remove the housing cover and pull the main filter element off.p. 215
Fig. 31p. 215
+Pull the safety elementp. 215
+Pull the safety elementp. 215
(Fig. 31)p. 215
Push in a new safety filter element.p. 215
Reassemble main filter element and cover.p. 215
+Make sure that the cover locks engage correctly.p. 215
Make sure that the cover locks engage correctly.p. 215
+8.22 Check the engine mountsp. 216
8.22 Check the engine mountsp. 216
Fig. 32p. 216
+Check the fastening of intake and exhaust tubesp. 216
+Check the fastening of intake and exhaust tubesp. 216
(Fig. 32)p. 216
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. 216
Check fastening screws on oil sump and engine mounts for tight fit.p. 216
+Check condition and tight fit of engine pillow blocks.p. 216
Check condition and tight fit of engine pillow blocks.p. 216
+8.23 Engine conservationp. 216
8.23 Engine conservationp. 216
+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. 216
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. 216
+8.24 Checking, adjusting the valve clearancep. 217
8.24 Checking, adjusting the valve clearancep. 217
+We recommend to have this work carried out by trained personnel or our after sales service.p. 217
+We recommend to have this work carried out by trained personnel or our after sales service.p. 217
We recommend to have this work carried out by trained personnel or our after sales service.p. 217
Check the valve clearance only when the engine is cold.p. 217
Fig. 33p. 217
+Loosen the plug connections (4)p. 217
+Loosen the plug connections (4)p. 217
(Fig. 33)p. 217
Unscrew and take off the injection lines (1).p. 217
Unscrew and take off the valve cover (2).p. 217
Adjustment value for intake and exhaust valves: 0.15/0.02 mmp. 217
+Adjustment schematicp. 217
Adjustment schematicp. 217
+Cylinderp. 217
Cylinderp. 217
+Intakep. 217
Intakep. 217
+Exhaustp. 217
Exhaustp. 217
+Cylinder 1 in TDCp. 217
Cylinder 1 in TDCp. 217
+1p. 217
1p. 217
+xp. 217
xp. 217
+xp. 217
xp. 217
+2p. 217
2p. 217
+xp. 217
xp. 217
+3p. 217
3p. 217
+xp. 217
xp. 217
+4p. 217
4p. 217
+Cylinder 1 overlappingp. 217
Cylinder 1 overlappingp. 217
+1p. 217
1p. 217
+2p. 217
2p. 217
+xp. 217
xp. 217
+3p. 217
3p. 217
+xp. 217
xp. 217
+4p. 217
4p. 217
+xp. 217
xp. 217
+xp. 217
xp. 217
Fig. 34p. 217
+Set cylinder 1 to TDCp. 217
+Set cylinder 1 to TDCp. 217
(Fig. 34)p. 217
Fig. 35p. 217
+A feeler gauge of appropriate thickness (A) must fit with little resistance between rocker armp. 217
+A feeler gauge of appropriate thickness (A) must fit with little resistance between rocker armp. 217
(Fig. 35)p. 217
If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.p. 217
Fig. 36p. 217
+Loosen the counter nut (4)p. 217
+Loosen the counter nut (4)p. 217
(Fig. 36)p. 217
Adjust the valve clearance by the adjustment screw (3) and tighten the counter nut.p. 217
+Set cylinder 1 to overlapping and check the valve clearance as per adjustment schematic, adjust if necessary.p. 217
Set cylinder 1 to overlapping and check the valve clearance as per adjustment schematic, adjust if necessary.p. 217
Fig. 37p. 218
+Check the valve cover gasket for damage, change if necessary.p. 218
Check the valve cover gasket for damage, change if necessary.p. 218
+Assemble the valve cover (2)p. 218
(Fig. 37)p. 218
Fig. 38p. 218
+Reinstall the injection lines (1)p. 218
+Reinstall the injection lines (1)p. 218
(Fig. 38)p. 218
Make sure that the clamps (5) are correctly positioned.p. 218
Screw in the preheating plugs, tightening torque: 8 Nm.p. 218
Plug in the plug connections.p. 218
8.25 Engine problemsp. 219
+Faultp. 219
Faultp. 219
+Possible causep. 219
Possible causep. 219
+Remedyp. 219
Remedyp. 219
+Engine does not startp. 219
Engine does not startp. 219
+Starter defective or pinion does not engagep. 219
Starter defective or pinion does not engagep. 219
+Have examined by a specialistp. 219
Have examined by a specialistp. 219
+Fuel tank emptyp. 219
Fuel tank emptyp. 219
+Fill tank and bleedp. 219
Fill tank and bleedp. 219
+Temperature below starting limitp. 219
Temperature below starting limitp. 219
+Choose winter fuel and engine oil according to ambient temperatures.p. 219
Choose winter fuel and engine oil according to ambient temperatures.p. 219
+Fuel filter clogged, in winter due to paraffin separationp. 219
Fuel filter clogged, in winter due to paraffin separationp. 219
+Change the filter, use winter fuelp. 219
Change the filter, use winter fuelp. 219
+Fuel lines leakingp. 219
Fuel lines leakingp. 219
+Check all line connections for leaks and tighten the fittingsp. 219
Check all line connections for leaks and tighten the fittingsp. 219
+Battery not charged or not connectedp. 219
Battery not charged or not connectedp. 219
+Tighten the terminal clamps on the battery, check all cable connectionsp. 219
Tighten the terminal clamps on the battery, check all cable connectionsp. 219
+Injection valves or injection pump defectivep. 219
Injection valves or injection pump defectivep. 219
+Have examined by a specialistp. 219
Have examined by a specialistp. 219
+Poor starting of engine or engine works irregularly with poor powerp. 219
Poor starting of engine or engine works irregularly with poor powerp. 219
+Battery power too low, terminal clamps loose or oxidized causing the starter to turn too slowly.p. 219
Battery power too low, terminal clamps loose or oxidized causing the starter to turn too slowly.p. 219
+Have the battery tested, clean the terminal clamps, tighten and cover them with acid-free greasep. 219
Have the battery tested, clean the terminal clamps, tighten and cover them with acid-free greasep. 219
+Especially during winter: use of too viscous engine oilp. 219
Especially during winter: use of too viscous engine oilp. 219
+Use an engine oil complying with the ambient temperaturesp. 219
Use an engine oil complying with the ambient temperaturesp. 219
+Fuel supply too low, fuel system clogged by paraffin separation during winterp. 219
Fuel supply too low, fuel system clogged by paraffin separation during winterp. 219
+Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel under cold conditionsp. 219
Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel under cold conditionsp. 219
+The specified valve clearance is not correctp. 219
The specified valve clearance is not correctp. 219
+Adjusting the valve clearancep. 219
Adjusting the valve clearancep. 219
+Injection valve defectivep. 219
Injection valve defectivep. 219
+Have examined by a specialistp. 219
Have examined by a specialistp. 219
+Injection lines leakingp. 219
Injection lines leakingp. 219
+Check lines for leaksp. 219
Check lines for leaksp. 219
+Dry air filter cartridge soiledp. 219
Dry air filter cartridge soiledp. 219
+clean, if necessary use a new onep. 219
clean, if necessary use a new onep. 219
+Excessive play in throttle cablep. 219
Excessive play in throttle cablep. 219
+Adjust the throttle cable, replace if necessaryp. 219
Adjust the throttle cable, replace if necessaryp. 219
+Excessive exhaust smokep. 219
Excessive exhaust smokep. 219
+Engine oil level too highp. 219
Engine oil level too highp. 219
+Drain the oil down to the top dipstick markp. 219
Drain the oil down to the top dipstick markp. 219
+Dry air filter soiledp. 219
Dry air filter soiledp. 219
+clean, if necessary use a new onep. 219
clean, if necessary use a new onep. 219
+Poor compression due to burned or broken compression rings or incorrect valve clearancep. 219
Poor compression due to burned or broken compression rings or incorrect valve clearancep. 219
+Have compression rings and pistons examined by a specialist, adjust the valve clearancep. 219
Have compression rings and pistons examined by a specialist, adjust the valve clearancep. 219
+The specified valve clearance is not correctp. 219
The specified valve clearance is not correctp. 219
+Adjusting the valve clearancep. 219
Adjusting the valve clearancep. 219
+Engine overheating, engine must be shut down immediately!p. 220
Engine overheating, engine must be shut down immediately!p. 220
+Cooling fins on radiator extremely dirty (the warning light "Engine oil temperature" lights)p. 220
Cooling fins on radiator extremely dirty (the warning light "Engine oil temperature" lights)p. 220
+Clean the cooling finsp. 220
Clean the cooling finsp. 220
+Injection valve defectivep. 220
Injection valve defectivep. 220
+Have examined by a specialistp. 220
Have examined by a specialistp. 220
+Engine oil level too lowp. 220
Engine oil level too lowp. 220
+Top up engine oil up to the top dipstick markp. 220
Top up engine oil up to the top dipstick markp. 220
+Injection pump displacement not correctly adjustedp. 220
Injection pump displacement not correctly adjustedp. 220
+Have corrected by a specialistp. 220
Have corrected by a specialistp. 220
+Insufficient cooling air supply to the cooling fanp. 220
Insufficient cooling air supply to the cooling fanp. 220
+Remove any clogging from the cooling air ductp. 220
Remove any clogging from the cooling air ductp. 220
+V-belt loose or brokenp. 220
V-belt loose or brokenp. 220
+Tension or replace the V-beltp. 220
Tension or replace the V-beltp. 220
+Insufficient engine powerp. 220
Insufficient engine powerp. 220
+Engine oil level too highp. 220
Engine oil level too highp. 220
+Drain the engine oil down to the top dipstick markp. 220
Drain the engine oil down to the top dipstick markp. 220
+Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittingsp. 220
Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittingsp. 220
+The charge control light lights during operation, the warning buzzer soundsp. 220
The charge control light lights during operation, the warning buzzer soundsp. 220
+Generator speed too lowp. 220
Generator speed too lowp. 220
+Check the V-belt tension, if necessary replace the V-beltp. 220
Check the V-belt tension, if necessary replace the V-beltp. 220
+The generator does not charge the battery, because of defect on generator or regularp. 220
The generator does not charge the battery, because of defect on generator or regularp. 220
+Have examined by a specialistp. 220
Have examined by a specialistp. 220
+9 Material hopper, descriptionp. 221
+9 Material hopper, descriptionp. 221
Material hopper and transportp. 222
+Material flow — overviewp. 222
Material flow — overviewp. 222
+The material is mainly conveyed by the following componentsp. 222
(Fig. 39)p. 222
+The material hopper (1)p. 222
The material hopper (1)p. 222
The scraper belts (2)p. 222
The augers (3)p. 222
Fig. 39 Material flow — overviewp. 222
+Material hopperp. 223
Material hopperp. 223
Fig. 40 Material hopperp. 223
+1 Material hopperp. 223
1 Material hopperp. 223
2 Locking systemp. 223
3 Hydraulic cylinderp. 223
+Description of functionp. 223
Description of functionp. 223
+The material hopper (1)p. 223
(Fig. 40)p. 223
3p. 223
The hydraulic cylinders (3) move the wings of the hopper (1) upwards, so that a sufficient amount of material is fed to the scraper belts at any time. Each wing can be moved independently from the other wing.p. 223
Each of the hydraulic cylinders (3) is equipped with locking systems (2) for transporting the finisher. With the cylinder (3) extended these are folded down and thus protect the piston rod during transport. Moreover, the locks (2) also make sure that…p. 223
+Scraper beltsp. 224
Scraper beltsp. 224
Fig. 41 Scraper beltsp. 224
+1 Chain tensioner for scraper belt drivep. 224
1 Chain tensioner for scraper belt drivep. 224
2 Hydraulic motorp. 224
3 Chainp. 224
4 Drive gear for scraper beltp. 224
5 Scraper belt rightp. 224
6 Scraper belt leftp. 224
7 Scraper belt tensionerp. 224
+Description of functionp. 224
Description of functionp. 224
+The scraper belts (5) & (6)p. 224
(Fig. 41)p. 224
The two scraper belts (5) & (6) made of high-tenacity steel work independently from one another an independently from the travel speed of the machine.p. 224
+Two sensors (mechanically (as so-called "Paddles") or ultrasonicp. 224
Optionp. 224
The tension of the scraper belts is adjusted with the tensioners (7) at the front of the frame.p. 224
Each scraper belt is driven by a hydraulic motor (2). The torque of the hydraulic motor is transferred with the help of a chaion, which is tensioned by a chain tensioner (1). The chain (3) runs over the drive gear (4), which drives the scraper belt.p. 224
+Augersp. 225
Augersp. 225
Fig. 42 Augersp. 225
+1 Hydraulic motorsp. 225
1 Hydraulic motorsp. 225
2 Hydraulic cylinderp. 225
3 Guide rodp. 225
4 Mounting rodp. 225
5 Augerp. 225
+Description of functionp. 225
Description of functionp. 225
+The augers (5)p. 225
(Fig. 42)p. 225
The augers (5) work independently from one another an independently from the travel speed of the machine. They are hydraulically operated via adjustable mechanical or ultrasonic sensors, by On/Off switches or proportional controls. Each auger (5) is …p. 225
The augers (5) can be adjusted in height with the hydraulic cylinders (2). The augers must be adjusted one step higher than the front edge of the screed plate (approx. 30-60 mm higher. This depends on the particle size of the material.)p. 225
The assembly flaps (4) prevent material being conveyed beyond the width of the screed.p. 225
+Care and maintenance workp. 225
+Care and maintenance workp. 225
+All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu- Trennkonzentrat, green")p. 225
before and afterp. 225
+10 Vibrating screed, descriptionp. 227
+10 Vibrating screed, descriptionp. 227
Screedp. 228
+Screed — overviewp. 228
Screed — overviewp. 228
+The screedp. 228
(Fig. 43)p. 228
+The drawing arms (1)p. 228
The drawing arms (1)p. 228
The screed (2)p. 228
Fig. 43 Screed — overviewp. 228
+Drawing armsp. 229
Drawing armsp. 229
Fig. 44 Drawing armsp. 229
+1 Scalep. 229
1 Scalep. 229
2 Drawing armp. 229
3 Hydraulic cylinder (lift-out cylinder)p. 229
4 Fastening points of the screedp. 229
5 Hydraulic cylinder (levelling cylinder)p. 229
6 Hook-in pointp. 229
+Description of functionp. 229
Description of functionp. 229
+The drawing arms (2)p. 229
(Fig. 44)p. 229
The hook-in point (6) of the drawing arm (2) can be hydraulically adjusted in height. This provides a possibility to influence the layer thickness (angle of attack). The scale (1) at the upper end of the hydraulic cylinder (5), which is responsible f…p. 229
The complete screed can be lifted with the help of the hydraulic cylinders (3).p. 229
Adjusting bolts can be found at the rear fastening point of the screed (4). These can be used to preset the angle of attack, if the angle to be adjusted can not be achieved via the hydraulic cylinders (5).p. 229
+Screedp. 230
Screedp. 230
Fig. 45 Screedp. 230
+1 Screedp. 230
1 Screedp. 230
2 Exit flapp. 230
+3 Heating rodp. 230
Optionp. 230
4 Outside control standp. 230
5 Control element for electric heatingp. 230
6 Vibrator unit central screedp. 230
7 Vibrator unit extendable screedp. 230
+8 Tamper unitp. 230
Optionp. 230
+9 Tamper unitp. 230
Optionp. 230
10 Base plate central screedp. 230
11 Base plate extendable screedp. 230
+Description of functionp. 230
Description of functionp. 230
+The screed (1)p. 230
(Fig. 45)p. 230
High initial compaction by the finisher has a favourable effect on the evenness of the layer and, at the same time, enables an early start of compaction, while the mix temperatures are still high. This favourably supports the compaction effect of the…p. 230
Once the augers have distributed material in front of the screed, the material is pre-compacted by tamper elements (8), (9). The exit flaps (2) make sure that the material will not flow too far towards the outside. The exit flaps (2) can be heated by…p. 231
The crown profile of the screed can also be adjusted, in addition to the angle of attack (see section "Drawing arms"). This is possible in positive, but also in negative direction. The adjustment is made manually on the screed itself, or hydraulicall…p. 231
The base plate (10), (11) skid along the material and compact it again. The base plates (10), (11) carry the vibrator units (6), (7). Their vibration causes further compaction of the material. The heating is also mounted on the base plates (10), (11)…p. 231
From the outside control stand (4) the screed personnel is able to control the auger sensor for mix quantity regulation via a potentiometer. Moreover, the optionally available ultrasonic sensors for the scraper belts, which are also used to regulate …p. 231
+Care and maintenance workp. 231
+Care and maintenance workp. 231
+All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu- Trennkonzentrat, geen")p. 231
before and afterp. 231
+11 Screed heating, repairp. 233
11 Screed heating, repairp. 233
+11.3 Replace heating elementsp. 234
11.1 Removing the screed heating generatorp. 234
+Danger of injury!p. 234
Danger of injury!p. 234
This work must not be carried out by the operator, but only by qualified personnel who has been specially instructed to do so.p. 234
Always use appropriate lifting gear to lift the generator, weight of generator: approx. 65 kg.p. 234
Preparationsp. 234
+Fig. 1p. 234
Fig. 1p. 234
+1. Open the hopper wings.p. 234
1. Open the hopper wings.p. 234
+2. Shut down the engine.p. 234
2. Shut down the engine.p. 234
+3. Switch the main battery switch to position "II" and pull it outp. 234
+3. Switch the main battery switch to position "II" and pull it outp. 234
(Fig. 1)p. 234
+Fig. 2p. 234
Fig. 2p. 234
+4. Unscrew the fastening screws from the engine compartment doorp. 234
+4. Unscrew the fastening screws from the engine compartment doorp. 234
(Fig. 2)p. 234
+5. Open the engine compartment door.p. 234
5. Open the engine compartment door.p. 234
Removing the screed heating generatorp. 235
+Fig. 3p. 235
Fig. 3p. 235
+1. Unscrew four screws from the cover of the electric junction box and take off the coverp. 235
+1. Unscrew four screws from the cover of the electric junction box and take off the coverp. 235
(Fig. 3)p. 235
+Fig. 4p. 235
Fig. 4p. 235
+2. Disconnect the electric supply, remove the cable and lay it to the sidep. 235
+2. Disconnect the electric supply, remove the cable and lay it to the sidep. 235
(Fig. 4)p. 235
+3. Unscrew the cable gland (arrow).p. 235
3. Unscrew the cable gland (arrow).p. 235
+Fig. 5p. 235
Fig. 5p. 235
+4. Looasen in four fastening screws (1) on both sides, but do not unscrew completelyp. 235
+4. Looasen in four fastening screws (1) on both sides, but do not unscrew completelyp. 235
(Fig. 5)p. 235
+5. Loosen the counter nuts (3).p. 235
5. Loosen the counter nuts (3).p. 235
+6. Loosen the V-belt with the screws (2), so that it can be removed.p. 235
6. Loosen the V-belt with the screws (2), so that it can be removed.p. 235
+7. Take off the V-belt and check for wear. If necessary replace the used V-belt with a new one.p. 235
7. Take off the V-belt and check for wear. If necessary replace the used V-belt with a new one.p. 235
+8. Unscrew both fastening screws (1).p. 235
8. Unscrew both fastening screws (1).p. 235
+Fig. 6p. 236
Fig. 6p. 236
+Danger of injury!p. 236
Danger of injury!p. 236
Always use appropriate lifting gear to lift the generator, weight of generator: approx. 65 kg.p. 236
+9. Pick up the generator with the workshop crane by attaching appropriate lifting tackle to the lifting eyes (1)p. 236
+9. Pick up the generator with the workshop crane by attaching appropriate lifting tackle to the lifting eyes (1)p. 236
(Fig. 6)p. 236
+10. Place suitable wooden blocks (2) under the generator.p. 236
10. Place suitable wooden blocks (2) under the generator.p. 236
+The wooden block should be so long, that the generator can be pushed out of the engine compartment along these blocks after it has been loosened.p. 236
The wooden block should be so long, that the generator can be pushed out of the engine compartment along these blocks after it has been loosened.p. 236
+11. Unscrew both upper fastening screws (1)p. 236
+11. Unscrew both upper fastening screws (1)p. 236
(Fig. 5)p. 236
+12. Pull the generator along the wooden blocks out of the engine compartment.p. 236
12. Pull the generator along the wooden blocks out of the engine compartment.p. 236
+13. Lift out the generator.p. 236
13. Lift out the generator.p. 236
+11.3 Replace heating elementsp. 237
11.2 Installation of screed heating generatorp. 237
+Danger of injury!p. 237
Danger of injury!p. 237
Always use appropriate lifting gear to lift the generator, weight of generator: approx. 65 kg.p. 237
Installation of screed heating generatorp. 237
+Fig. 1p. 237
Fig. 1p. 237
+1. Pick up the generator with the workshop crane by attaching appropriate lifting tackle to the lifting eyes (1)p. 237
+1. Pick up the generator with the workshop crane by attaching appropriate lifting tackle to the lifting eyes (1)p. 237
(Fig. 1)p. 237
+2. Place suitable wooden blocks (2) under the generator.p. 237
2. Place suitable wooden blocks (2) under the generator.p. 237
+3. Push the generator along the wooden blocks into the engine compartment.p. 237
3. Push the generator along the wooden blocks into the engine compartment.p. 237
+4. Screw in four fastening screws (1)p. 237
+4. Screw in four fastening screws (1)p. 237
(Fig. 2)p. 237
+5. Remove the wooden blocks, take off the chains.p. 237
5. Remove the wooden blocks, take off the chains.p. 237
+Fig. 2p. 237
Fig. 2p. 237
+6. Assemble the V-beltp. 237
+6. Assemble the V-beltp. 237
(Fig. 2)p. 237
+7. Tighten the V-belt evenly with the two screws (2) on the right and left hand side,p. 237
7. Tighten the V-belt evenly with the two screws (2) on the right and left hand side,p. 237
+8. Retighten the counter nuts (3) and the fastening screws (1).p. 237
8. Retighten the counter nuts (3) and the fastening screws (1).p. 237
+Fig. 3p. 237
Fig. 3p. 237
+Danger of injury!p. 237
Danger of injury!p. 237
This work must not be carried out by the operator, but only by qualified personnel who has been specially instructed to do so.p. 238
+9. Route the cable into the electric junction box and connect itp. 238
+9. Route the cable into the electric junction box and connect itp. 238
(Fig. 3)p. 238
+10. Screw on the cable gland (arrow) 12. .p. 238
10. Screw on the cable gland (arrow) 12. .p. 238
+Fig. 4p. 238
Fig. 4p. 238
+13. Attach and fasten the cover of the electric junction boxp. 238
+13. Attach and fasten the cover of the electric junction boxp. 238
(Fig. 4)p. 238
+Fig. 5p. 238
Fig. 5p. 238
+14. Close the engine compartment doorp. 238
+14. Close the engine compartment doorp. 238
(Fig. 5)p. 238
+15. Assemble the fastening screws.p. 238
15. Assemble the fastening screws.p. 238
+11.3 Replace heating elementsp. 239
11.3 Replace heating elementsp. 239
+Life hazard!p. 239
+Life hazard!p. 239
Life hazard!p. 239
High voltage 230/400 Voltp. 239
Work on the electric heating system must only be performed by electrically trained personnel.p. 239
Heating elements must only be changed with the engine shut down and the main battery switch pulled out.p. 239
+Danger of burning!p. 239
Danger of burning!p. 239
The heating elements become bvery hot during operation.p. 239
Always allow ample time for cooling down and wear heat insulated gloves to change heating elements.p. 239
+Shut down the engine.p. 239
Shut down the engine.p. 239
Fig. 6p. 239
+Switch the main battery switchp. 239
+Switch the main battery switchp. 239
(Fig. 6)p. 239
+Replacing the heating elements for the base platep. 239
Replacing the heating elements for the base platep. 239
Fig. 7p. 239
+Unscrew the fastening screwsp. 239
+Unscrew the fastening screwsp. 239
(Fig. 7)p. 239
Fig. 8p. 239
+Disconnect the connecting cable of the defective heating element at the plugp. 239
+Disconnect the connecting cable of the defective heating element at the plugp. 239
(Fig. 8)p. 239
Fig. 9p. 239
+Loosen the four clamping screwsp. 239
+Loosen the four clamping screwsp. 239
(Fig. 9)p. 239
Fig. 10p. 240
+Pull out the defective heating elementp. 240
+Pull out the defective heating elementp. 240
(Fig. 10)p. 240
+Install the new heating element and connect the plug.p. 240
Install the new heating element and connect the plug.p. 240
Tighten the clamping screws of the heating element and reassemble the protective covering.p. 240
+Replacing the heating element for the tamperp. 240
Replacing the heating element for the tamperp. 240
Fig. 11p. 240
+Unscrew the fastening screws from the coverp. 240
+Unscrew the fastening screws from the coverp. 240
(Fig. 11)p. 240
Fig. 12p. 240
+Loosen counter nuts 1p. 240
+Loosen counter nuts 1p. 240
(Fig. 12)p. 240
Unscrew setscrew (2).p. 240
Repeat this measure on the opposite side.p. 240
+Unhook and remove the coveringp. 240
(Fig. 11)p. 240
Fig. 13p. 240
+Loosen the fastening screwsp. 240
+Loosen the fastening screwsp. 240
(Fig. 13)p. 240
Fig. 14p. 241
+Disconnect the connecting cable of the defective heating element at the plugp. 241
+Disconnect the connecting cable of the defective heating element at the plugp. 241
(Fig. 14)p. 241
+Loosen the fastening screws of the holder and pull out the heating element.p. 241
Loosen the fastening screws of the holder and pull out the heating element.p. 241
Slide in, fasten and connect a new heating element.p. 241
+Re-engage the adjusting screwsp. 241
+Re-engage the adjusting screwsp. 241
(Fig. 12)p. 241
(Fig. 11)p. 241
Check and, if necessary, adjust the play between inner bar and taper bar (see corresponding chapter in this manual).p. 241
+12 Travel drive, descriptionp. 243
+12 Travel drive, descriptionp. 243
Travel systemp. 244
+Travel system — overviewp. 244
Travel system — overviewp. 244
+The travel systemp. 244
(Fig. 15)p. 244
+the rear wheel drivep. 244
the rear wheel drivep. 244
the front wheel drivep. 244
Fig. 15 Travel systemp. 244
Rear wheel drivep. 245
+The rear wheel drivep. 245
(Fig. 16)p. 245
+the travel motorp. 245
the travel motorp. 245
the travel gearp. 245
the brakesp. 245
the reduction gearsp. 245
the rear wheelsp. 245
Fig. 16 Rear wheel drivep. 245
+1 Travel motorp. 245
1 Travel motorp. 245
2 Travel gearp. 245
3 Brakesp. 245
4 Reduction gearp. 245
5 Wheelsp. 245
+This applies for all following points: Further information, see chapter "Technical data".p. 245
This applies for all following points: Further information, see chapter "Technical data".p. 245
Travel motorp. 245
The travel pump supplies the travel motor (1) with hydraulic oil and thereby drives the travel gear (2).p. 245
Travel gearp. 245
The travel gear (2) converts the torque of the travel motor (1) and passes it on to the reduction gear (4). The travel gear (2) is shiftable and thus enables two different travel speeds (“High” and “Low”).p. 245
Brakesp. 245
The brakes (3) are installed between travel gear (2) and reduction gear (4). The brakes are hydraulically released spring pressure applied multi-disc brakes. By operating the brake pedal the finisher can be additionally braked, if the braking distanc…p. 245
+Under “Normal conditions” it is quite sufficient ton return the travel lever to position “0”. The closed hydraulic circuit will in this case brake the machine automatically to standstill.p. 245
Under “Normal conditions” it is quite sufficient ton return the travel lever to position “0”. The closed hydraulic circuit will in this case brake the machine automatically to standstill.p. 245
Reduction gearp. 246
The reduction gear (4) converts the torque of the travel gear and passes it on to the rear wheels (5). The reduction gear increases the torque, making sure that the machine has sufficient power reserves.p. 246
Rear wheelsp. 246
The rear wheels (5) are air filled tires, which can additionally be filled with water in order to increase the weight and enhance the traction of the finisher.p. 246
Front wheel drivep. 247
+The front wheel drivep. 247
(Fig. 17)p. 247
+the steeringp. 247
the steeringp. 247
the pivotsp. 247
the wheelsp. 247
Fig. 17 Front axlep. 247
+1 Hydraulic cylinderp. 247
1 Hydraulic cylinderp. 247
2 Connecting rod, transversep. 247
3 Wheelp. 247
4 Connecting armp. 247
5 Pivotp. 247
6 Arm to take up the wheelp. 247
7 Fastening point on framep. 247
Steeringp. 247
The steering system works with a hydraulic cylinder (1). The force is introduced via connecting arms (4) and connecting rod (2) into the arms (6) which then swivel the wheels (3). The connecting rod (2) can be adjusted in length, so that the steering…p. 247
Pivotp. 247
The pivots (5) are the connection between wheels and frame. The pivots (5) are fastened to the frame via fixing points (7). The pivots (5) carry the arms (6) which in turn take up the wheels (3).p. 247
Wheelsp. 247
The wheels (3) are solid rubber wheels. Depending on the equipment, only the rear front wheels are driven (4×67) or all front wheels (6×6)p. 247
+Care and maintenance workp. 248
+All parts of the machine that have or had contact with material must be sprayed with a release agentp. 248
before and afterp. 248
+13 Travel drive, repairp. 249
13 Travel drive, repairp. 249
+13.1 Check the tire pressurep. 250
13.1 Check the tire pressurep. 250
+Because of the water filling in the tires, you should always check the tire pressure with the tire valve in top position!p. 250
+Because of the water filling in the tires, you should always check the tire pressure with the tire valve in top position!p. 250
Because of the water filling in the tires, you should always check the tire pressure with the tire valve in top position!p. 250
Always close the valves with their dust caps.p. 250
Fig. 18p. 250
+With the tire inflation valve in highest position check the air pressure on tire inflation valve 1p. 250
+With the tire inflation valve in highest position check the air pressure on tire inflation valve 1p. 250
(Fig. 18)p. 250
Nominal value, see "technical data".p. 250
+Ensure equal pressure in all rubber tires!p. 250
Ensure equal pressure in all rubber tires!p. 250
+Screw the valve caps back on again.p. 250
Screw the valve caps back on again.p. 250
+13.2 Check the oil level in the front wheel hubsp. 251
13.2 Check the oil level in the front wheel hubsp. 251
+For quality of oil refer to the "table of fuels and lubricants".p. 251
+For quality of oil refer to the "table of fuels and lubricants".p. 251
For quality of oil refer to the "table of fuels and lubricants".p. 251
Check the oil level in both wheel hubs.p. 251
Fig. 19p. 251
+Remove the coverp. 251
+Remove the coverp. 251
(Fig. 19)p. 251
Fig. 20p. 251
+Move the drive wheel so that the opening is in line with the lateral oil control plug (1)p. 251
+Move the drive wheel so that the opening is in line with the lateral oil control plug (1)p. 251
(Fig. 20)p. 251
Unscrew the level inspection plug .p. 251
The oil level must reach up to the lower edge of the bore, top up oil if necessary.p. 251
Screw the level control plug tightly back in and reassemble the cover.p. 251
+13.3 Oil level check in rear wheel drive differentialp. 252
13.3 Oil level check in rear wheel drive differentialp. 252
+Park the machine on level ground.p. 252
+Park the machine on level ground.p. 252
Park the machine on level ground.p. 252
Fig. 21p. 252
+Unscrew the level inspection plugp. 252
+Unscrew the level inspection plugp. 252
(Fig. 21)p. 252
The oil level must reach the bottom edge of the bore.p. 252
Fig. 22p. 252
+If necessary unscrew the oil filling plugp. 252
+If necessary unscrew the oil filling plugp. 252
(Fig. 22)p. 252
For quality of oil refer to the table of fuels and lubricants.p. 252
+Retighten level inspection and filler plugs.p. 252
Retighten level inspection and filler plugs.p. 252
The provision container takes up the cleaning agent. It has a capacity of 25 litres. For filling the cleaning container the driver's stand must be moved fully to the right, so that the filler neck can be accessed.p. 257
+Filterp. 257
Filterp. 257
The filter protects the spray gun against contamination. It is a wire mesh pre-filter.p. 257
+Pumpp. 257
Pumpp. 257
The pump delivers the cleaning agent from the provision container through the filter to the spray gun. The pump is an electrically driven two-piston pump, which is able to generate a maximum pressure of approx. 6.9 bar.p. 257
+Further information about the pump, see chapter "Technical data".p. 257
Further information about the pump, see chapter "Technical data".p. 257
+Hose reelp. 257
Hose reelp. 257
The hose reel holds the hose that leads to the spray gun. After cleaning the reel wind the hose up again. Just pull the hose to unwind.p. 257
+Spray gunp. 257
Spray gunp. 257
+The spray gun serves the purpose of cleaning the machine after finishing work, but also as an aid to apply cleaning/release agentp. 257
beforep. 257
+Control panelp. 257
Control panelp. 257
The cleaning system is switched on and off by the control panel. At the same time one can use the timer to pre- select a time for the active period of the cleaning system. Once this time has expired, the cleaning system will switch off. The max. adju…p. 257
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow. It has been designed for mobile applications, e.g. in construction equipment.p. 262
The 10VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits. The volumetric flow is proportional to the drive speed and the displacement.p. 262
Fig. 3 A10VGp. 262
+1p. 262
1p. 262
+Drive shaftp. 262
Drive shaftp. 262
+8p. 262
8p. 262
+Valve platep. 262
Valve platep. 262
+2p. 262
2p. 262
+Retracting platep. 262
Retracting platep. 262
+9p. 262
9p. 262
+Suction portp. 262
Suction portp. 262
+3p. 262
3p. 262
+Control pistonp. 262
Control pistonp. 262
+10p. 262
10p. 262
+High pressure sidep. 262
High pressure sidep. 262
+4p. 262
4p. 262
+Control unitp. 262
Control unitp. 262
+11p. 262
11p. 262
+Cylinderp. 262
Cylinderp. 262
+5p. 262
5p. 262
+Pressure override (optional)p. 262
Pressure override (optional)p. 262
+12p. 262
12p. 262
+Pistonp. 262
Pistonp. 262
+6p. 262
6p. 262
+Low pressure sidep. 262
Low pressure sidep. 262
+13p. 262
13p. 262
+Slipper padp. 262
Slipper padp. 262
+7p. 262
7p. 262
+Auxiliary pump (optional)p. 262
Auxiliary pump (optional)p. 262
+14p. 262
14p. 262
+Swashing cradlep. 262
Swashing cradlep. 262
+The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 262
The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 262
+Hydraulic diagramp. 263
Hydraulic diagramp. 263
Fig. 4 Hydraulic diagram, A10VG EPp. 263
+Ap. 263
Ap. 263
+Work connectionp. 263
Work connectionp. 263
+PSp. 263
+Pp. 263
Sp. 263
+Control pressure inletp. 263
Control pressure inletp. 263
+Bp. 263
Bp. 263
+Work connectionp. 263
Work connectionp. 263
+Rp. 263
Rp. 263
+Ventilationp. 263
Ventilationp. 263
+Gp. 263
Gp. 263
+Pressure port for charge circuitp. 263
Pressure port for charge circuitp. 263
+T1p. 263
+Tp. 263
1p. 263
+Leak oilp. 263
Leak oilp. 263
+MAp. 263
+Mp. 263
Ap. 263
+Pressure test port, pressure Ap. 263
Pressure test port, pressure Ap. 263
+T2p. 263
+Tp. 263
2p. 263
+Leak oilp. 263
Leak oilp. 263
+MBp. 263
+Mp. 263
Bp. 263
+Pressure test port, pressure Bp. 263
Pressure test port, pressure Bp. 263
+X1 X2p. 263
+Xp. 263
1p. 263
2p. 263
+Port for control pressures, pressure in front of nozzlep. 263
Port for control pressures, pressure in front of nozzlep. 263
+Connection overviewp. 264
Connection overviewp. 264
Fig. 5p. 264
+High pressure relief and charge pressure valvep. 264
High pressure relief and charge pressure valvep. 264
Fig. 6 Valve platep. 264
High pressure relief valves with integrated boost check valves and bypass (only travel pump / for towing)p. 264
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side. Th…p. 264
HP-valves are always adjusted 10% higher than the pressure override.p. 264
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and fl…p. 264
Bypass controlp. 265
+In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves integrated in the variable displacement pump have a so-called bypass function. This means that by turning the screw (1)p. 265
(Fig. 7)p. 265
Fig. 7 Bypass controlp. 265
+Shut down the engine.p. 265
Shut down the engine.p. 265
Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direction.p. 265
Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be noticed by the increasing resistance.p. 265
Turn the screw half a turn into the spring cup.p. 265
Towing finishedp. 265
After towing back the screw out again. This resets the high pressure valves to their original setting.p. 265
+Tightening torque for counter nut 22 Nm.p. 265
Tightening torque for counter nut 22 Nm.p. 265
Charge pressure relief valvep. 265
The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the pre-adjusted value.p. 265
Pressure override valvep. 265
The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation, which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent, that the adjusted pressure is j…p. 265
+EP – controlp. 266
EP – controlp. 266
Fig. 8 EP – controlp. 266
+1p. 266
1p. 266
+Setscrew for mechanical neutral positionp. 266
Setscrew for mechanical neutral positionp. 266
+5p. 266
5p. 266
+Proportional solenoid valvep. 266
Proportional solenoid valvep. 266
+2p. 266
2p. 266
+Neutral setting springp. 266
Neutral setting springp. 266
+6p. 266
6p. 266
+Valve spoolp. 266
Valve spoolp. 266
+3p. 266
3p. 266
+Control pistonp. 266
Control pistonp. 266
+7p. 266
7p. 266
+Feedback leverp. 266
Feedback leverp. 266
+4p. 266
4p. 266
+Control chamberp. 266
Control chamberp. 266
Fig. 9 EP controlp. 266
Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement of the pump can be infini…p. 266
+The spring reset in the control unit is no safety feature.p. 266
The spring reset in the control unit is no safety feature.p. 266
Internal contamination – like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system components – can cause blockage of the spool valve in the control unit. The flow volume from the variable displacement pump will in this case n…p. 266
+Axial piston pumps, A10VO/VSO 18 to 100 DFR1p. 267
Travel pump, A10VO28p. 267
+Axial piston pumps, A10VO/VSO 18 to 100 DFR1p. 267
Axial piston pumps, A10VO/VSO 18 to 100 DFR1p. 267
+This document is valid for pump typesp. 267
+This document is valid for pump typesp. 267
VOp. 267
VSOp. 267
The pump delivers oil only to one direction, i.e. the swash plate moves out of neutral position only to one direction. It is therefore particularly suitable for the use in open hydraulic circuits.p. 267
+The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 267
The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines.p. 267
Fig. 10p. 267
+DFR1, pressure-flow controllerp. 267
DFR1, pressure-flow controllerp. 267
Pressure regulatorp. 267
The pressure control valve keeps the pressure in an hydraulic system at a constant level within the control range of the pump. This way the pump will only deliver as much hydraulic fluid as can be absorbed by the hydraulic consumers. The pressure can…p. 267
DFR1 – pressure and flow controllerp. 267
In addition to the function of a pressure controller an orifice records the differential pressure before and after the orifice, which then controls the flow rate of the pump. The pump delivers the pressure fluid quantity actually required by the cons…p. 267
The pressure controller is superimposed.p. 267
Fig. 11 Sectional drawingp. 268
Fig. 12 Hydraulic diagramp. 268
+Bp. 268
Bp. 268
+Working linep. 268
Working linep. 268
+Sp. 268
Sp. 268
+Suctionp. 268
Suctionp. 268
+L / L1p. 268
L / L1p. 268
+Leak oilp. 268
Leak oilp. 268
+Xp. 268
Xp. 268
+Pilot pressurep. 268
Pilot pressurep. 268
+Working principlep. 269
Working principlep. 269
Fig. 13p. 269
+When thep. 269
+When thep. 269
+engine is not running (1)p. 269
(Fig. 13)p. 269
+Whenp. 269
starting the enginep. 269
Fig. 14p. 269
+If the system pressure increases because of active consumers (3) , the pressure depending on the so-called LS Load Sensing signal will displace the spool of the pressure controller. High pressure is thereby guided to the piston area of the control pi…p. 269
If the system pressure increases because of active consumers (3) , the pressure depending on the so-called LS Load Sensing signal will displace the spool of the pressure controller. High pressure is thereby guided to the piston area of the control pi…p. 269
If the system pressure increases beyond the value set on the flow controller (4), the spool in the flow controller is pushed against the spring and max. high pressure acts on the resetting piston and the swash plate is set to minimum displacement.p. 270
If the pressure drops below the set value of the flow controller, the swash plate will again return to maximum displacement.p. 270
+Swash plate principle, pumpp. 270
Swash plate principle, pumpp. 270
Fig. 15p. 270
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive shaft. The pistons are thereby supported by the swash plate.p. 270
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used in motor mode the hydrostat…p. 270
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor throughput, by simply changing the angle of the swash plate.p. 270
+Description of functionp. 271
Description of functionp. 271
Fig. 16p. 271
+1p. 271
1p. 271
+Drive shaftp. 271
Drive shaftp. 271
+8p. 271
8p. 271
+Through drivep. 271
Through drivep. 271
+2p. 271
2p. 271
+Pistonp. 271
Pistonp. 271
+9p. 271
9p. 271
+Valve platep. 271
Valve platep. 271
+3p. 271
3p. 271
+Piston areap. 271
Piston areap. 271
+10p. 271
10p. 271
+Top dead centre TDCp. 271
Top dead centre TDCp. 271
+4p. 271
4p. 271
+Piston strokep. 271
Piston strokep. 271
+11p. 271
11p. 271
+Bottom dead centre BTCp. 271
Bottom dead centre BTCp. 271
+5p. 271
5p. 271
+Slipping discp. 271
Slipping discp. 271
+12p. 271
12p. 271
+Control slots in suction side of swash plate (for sense of rotation shown)p. 271
Control slots in suction side of swash plate (for sense of rotation shown)p. 271
+6p. 271
6p. 271
+Adjusting anglep. 271
Adjusting anglep. 271
+13p. 271
13p. 271
+Control slot on pressure sidep. 271
Control slot on pressure sidep. 271
+7p. 271
7p. 271
+Cylinderp. 271
Cylinderp. 271
Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the swashing cradle an…p. 271
15.4 Troubleshooting axial piston pumpsp. 272
+The following table should be of help when performing troubleshooting This table is by no means complete.p. 272
The following table should be of help when performing troubleshooting This table is by no means complete.p. 272
In practice you may encounter problems that have not been listed here.p. 272
+Procedurep. 272
Procedurep. 272
+Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 272
Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.p. 272
Get an overview over the function of the product in connection with the overall system.p. 272
Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred.p. 272
Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver.p. 272
Try to detect changes to the overall system, the product is installed in:p. 272
+Have conditions or area of application of the product been changed?p. 272
Have conditions or area of application of the product been changed?p. 272
Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or to the product? If yes: What kind?p. 272
Has the product or the machine been operated as intended?p. 272
How does the fault occur?p. 272
+Faultp. 272
Faultp. 272
+Possible causep. 272
Possible causep. 272
+Remedyp. 272
Remedyp. 272
+Unusual noisesp. 272
Unusual noisesp. 272
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 272
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 272
+Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 272
Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid).p. 272
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 272
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 272
+Remove foreign bodies from inside the suction line.p. 272
Remove foreign bodies from inside the suction line.p. 272
+Inappropriate fastening of the axial piston unit.p. 272
Inappropriate fastening of the axial piston unit.p. 272
+Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 272
Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques.p. 272
+Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 272
Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines.p. 272
+Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 272
Fasten attachment parts as specified by the coupling or fittings manufacturer.p. 272
+Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 272
Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override).p. 272
+Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 272
Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department.p. 272
+Mechanical damage to the axial piston unit.p. 272
Mechanical damage to the axial piston unit.p. 272
+Replace the axial piston unit, consult the service department.p. 272
Replace the axial piston unit, consult the service department.p. 272
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 273
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 273
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 273
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 273
+Remove foreign bodies from inside the suction line.p. 273
Remove foreign bodies from inside the suction line.p. 273
+Pressure fluid not within the optimal viscosity range.p. 273
Pressure fluid not within the optimal viscosity range.p. 273
+Use appropriate pressure fluid.p. 273
Use appropriate pressure fluid.p. 273
+External control and setting facilities defective.p. 273
External control and setting facilities defective.p. 273
+Check the external control.p. 273
Check the external control.p. 273
+Pilot or control pressure too low.p. 273
Pilot or control pressure too low.p. 273
+Check pilot and control pressure, consult the service department.p. 273
Check pilot and control pressure, consult the service department.p. 273
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 273
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 273
+Consult the service department.p. 273
Consult the service department.p. 273
+Wear of the axial piston unit.p. 273
Wear of the axial piston unit.p. 273
+Replace the axial piston unit.p. 273
Replace the axial piston unit.p. 273
+Mechanical damage to the axial piston unit.p. 273
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 274
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 274
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 274
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 274
+Remove foreign bodies from inside the suction line.p. 274
Remove foreign bodies from inside the suction line.p. 274
+Pressure fluid not within the optimal viscosity range.p. 274
Pressure fluid not within the optimal viscosity range.p. 274
+Use appropriate pressure fluid.p. 274
Use appropriate pressure fluid.p. 274
+External control and setting facilities defective.p. 274
External control and setting facilities defective.p. 274
+Check the external control.p. 274
Check the external control.p. 274
+Pilot or control pressure too low.p. 274
Pilot or control pressure too low.p. 274
+Check pilot and control pressure.p. 274
Check pilot and control pressure.p. 274
+Functional disturbance in the control facility or the regulator on the axial piston unit.p. 274
Functional disturbance in the control facility or the regulator on the axial piston unit.p. 274
+Consult the service department.p. 274
Consult the service department.p. 274
+Wear of the axial piston unit.p. 274
Wear of the axial piston unit.p. 274
+Replace the axial piston unit.p. 274
Replace the axial piston unit.p. 274
+Mechanical damage to the axial piston unit.p. 274
Mechanical damage to the axial piston unit.p. 274
+Replace the axial piston unit.p. 274
Replace the axial piston unit.p. 274
+Drive unit defective (e.g. hydraulic motor or cylinder).p. 274
Drive unit defective (e.g. hydraulic motor or cylinder).p. 274
+Check the drive unit, replace if necessary.p. 274
Check the drive unit, replace if necessary.p. 274
+Fluctuations in pressure/volumetric flowp. 274
Fluctuations in pressure/volumetric flowp. 274
+Axial piston unit not or insufficiently purged.p. 274
Axial piston unit not or insufficiently purged.p. 274
+Completely purge the axial piston unit.p. 274
Completely purge the axial piston unit.p. 274
+Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 274
Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.p. 274
+Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 274
Completely purge the axial piston unit, fill the suction line with pressure fluid.p. 274
+Remove foreign bodies from inside the suction line.p. 274
Remove foreign bodies from inside the suction line.p. 274
+Pressure fluid too hot.p. 274
Pressure fluid too hot.p. 274
+Excessive input temperature on axial piston unit.p. 274
Excessive input temperature on axial piston unit.p. 274
+Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 274
Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low.p. 274
+Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 274
Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller).p. 274
+Consult the service department.p. 274
Consult the service department.p. 274
+Malfunction of the flushing valve (not for nominal size 18).p. 274
Malfunction of the flushing valve (not for nominal size 18).p. 274
+Consult the service department.p. 274
Consult the service department.p. 274
+Wear of the axial piston unit.p. 274
Wear of the axial piston unit.p. 274
+Replace the axial piston unit.p. 274
Replace the axial piston unit.p. 274
+Gear pump WP09p. 275
Vibration and tamper pump, HALDEX WP09 xxxp. 275
+Gear pump WP09p. 275
Gear pump WP09p. 275
+Descriptionp. 275
Descriptionp. 275
WP09 pumps are available as single or multiple configurations with up to four stages.p. 275
The basic pump has a three-part modular design.p. 275
Fig. 17 Gear pump – WP09p. 275
Mounting flange and end cover are made of grey cast iron, the pump housing is made of a high-strength aluminium alloy.p. 275
Gears and shafts are made of one piece. The tooth geometry with 13 teeth ensures a low noise level.p. 275
The bearing faces are Teflon coated. The bearing faces are permanently cooled and lubricated by the targeted feed of fresh oil.p. 275
+Connection overview (three-stage pump as an example)p. 276
Connection overview (three-stage pump as an example)p. 276
Fig. 18 Pressure connectionsp. 276
Fig. 19 Suction connectionsp. 276
+Vibration and tamper motor SNM2p. 277
Vibration and tamper motor, SAUER SNM2NNp. 277
+Vibration and tamper motor SNM2p. 277
Vibration and tamper motor SNM2p. 277
+The vibration and tamper motor is a reversible gear motor with a displacement range from 6 to 25 cmp. 277
3p. 277
Function and designp. 277
The motors SNM2NN are characterized by a pressure-compensated design, which ensures a high rate of efficiency. The robust design of the shaft seal has a integrated stiffening and a sealing lip. The housing, which is most suitable for high operating p…p. 277
Fig. 20 SNM2p. 277
+15.7 Component overview — hydraulicsp. 278
15.7 Component overview — hydraulicsp. 278
+Tractorp. 278
Tractorp. 278
Fig. 21p. 278
+Pos.p. 278
Pos.p. 278
+Descriptionp. 278
Descriptionp. 278
+1p. 278
1p. 278
+Brake valvep. 278
Brake valvep. 278
+2p. 278
2p. 278
+Brake releasing valvep. 278
Brake releasing valvep. 278
+3p. 278
3p. 278
+Valve – auger right forward/backwardp. 278
Valve – auger right forward/backwardp. 278
+4p. 278
4p. 278
+Valve – auger left forward/backwardp. 278
Valve – auger left forward/backwardp. 278
+5p. 278
5p. 278
+Valve – conveyor belt left forward/backwardp. 278
Valve – conveyor belt left forward/backwardp. 278
+6p. 278
6p. 278
+Valve – conveyor belt right forward/backwardp. 278
Valve – conveyor belt right forward/backwardp. 278
+Valve block – screed up, floating position, Load Control System (LCS)p. 278
Valve block – screed up, floating position, Load Control System (LCS)p. 278
+10p. 278
10p. 278
+Manifold linep. 278
Manifold linep. 278
+11p. 278
11p. 278
+Manifold line with spring loaded boost check valve (non-return valve)p. 278
Manifold line with spring loaded boost check valve (non-return valve)p. 278
+12p. 278
12p. 278
+Valve block – differential lock on/off, first gear, second gearp. 278
Valve block – differential lock on/off, first gear, second gearp. 278
+Arrangement of hydraulic pumpsp. 279
Screedp. 279
Fig. 22p. 279
+Pos.p. 279
Pos.p. 279
+Descriptionp. 279
Descriptionp. 279
+1p. 279
1p. 279
+Valve block for vibrationp. 279
Valve block for vibrationp. 279
+2p. 279
2p. 279
+Valve block for tampingp. 279
Valve block for tampingp. 279
+3p. 279
3p. 279
+Valve block to extend and retract the mobile sectionsp. 279
Valve block to extend and retract the mobile sectionsp. 279
+4p. 279
4p. 279
+Valve block for hydraulic crown adjustmentp. 279
Valve block for hydraulic crown adjustmentp. 279
+Arrangement of hydraulic pumpsp. 280
Arrangement of hydraulic pumpsp. 280
Fig. 23p. 280
+Pos.p. 280
Pos.p. 280
+Descriptionp. 280
Descriptionp. 280
+1p. 280
1p. 280
+Gear pump – screed rightp. 280
Gear pump – screed rightp. 280
+2p. 280
2p. 280
+Gear pump – tamping and vibrationp. 280
Gear pump – tamping and vibrationp. 280
+3p. 280
3p. 280
+Service pumpp. 280
Service pumpp. 280
+4p. 280
4p. 280
+Gear pump – screed leftp. 280
Gear pump – screed leftp. 280
+5p. 280
5p. 280
+Gear pump – scraper belt rightp. 280
Gear pump – scraper belt rightp. 280
+6p. 280
6p. 280
+Gear pump – scraper belt leftp. 280
Gear pump – scraper belt leftp. 280
+7p. 280
7p. 280
+Travel pump – rear wheel drivep. 280
Travel pump – rear wheel drivep. 280
+8p. 280
8p. 280
+Travel pump – front wheel drivep. 280
+Travel pump – front wheel drivep. 280
Optional equipmentp. 280
+15.13 Checking the hydraulic oil levelp. 281
Travel circuitp. 281
+Travel drive – rear wheel drivep. 281
Travel drive – rear wheel drivep. 281
The travel system consists of a closed hydraulic circuit. The most important components are the travel pump with integrated safety elements and control and the travel motor.p. 281
Fig. 24 Travel system — excerpt from hydraulic diagramp. 281
+1p. 281
1p. 281
+Travel motorp. 281
Travel motorp. 281
+2p. 281
2p. 281
+Travel pumpp. 281
Travel pumpp. 281
Travel pumpp. 282
The travel pump is flanged to the flywheel side of the diesel engine.p. 282
The duties of the travel pump are:p. 282
+the hydraulic oil supply for the travel circuitp. 282
the hydraulic oil supply for the travel circuitp. 282
the supply of the service brakep. 282
the supply of the differential lockp. 282
the supply of the hydraulically shiftable gear (1st gear, 2nd gear)p. 282
The oil is cleaned by a pressure filter, which is arranged directly in front of the travel pump.p. 282
A charge circuit supplies the closed circuits with cool and filtered hydraulic oil to compensate for leakage and flushing quantities. This hydraulic oil is additionally used to supply the travel system control, the hydraulically shiftable gears, the …p. 282
+Brake controlp. 282
Brake controlp. 282
Engine startp. 282
Once the engine is running, the multi-disc brake will be opened by charge pressure. The closed hydrostatic travel circuit will also take care of the braking function.p. 282
Driving – brakingp. 282
When shifting the travel lever forward or back, the machine will start to drive. When the operator shifts the travel lever towards "Neutral", the displacement of the travel pump is adjusted towards zero accordingly and the machine is hydraulically br…p. 282
Should this “hydraulic brake” be insufficient, the machine can be stopped by the operator kicking down the brake pedal. This proportionally reduces the pressure applied to the multi-disc brakes (depending on the brake pressure position). The mach…p. 282
Releasing the brake mechanically, towing the machinep. 282
Fig. 25 Brake releasing valvep. 282
+The pump lever extension is stored in the drivers stand, at the right in the frame.p. 282
The pump lever extension is stored in the drivers stand, at the right in the frame.p. 282
+Press the limp home buttonp. 282
+Press the limp home buttonp. 282
(Fig. 25)p. 282
+Release the brake by operating the hand pump.p. 282
Release the brake by operating the hand pump.p. 282
After towingp. 282
+Pull the emergency operation buttonp. 282
+Pull the emergency operation buttonp. 282
(Fig. 25)p. 282
+After starting the engine the emergency operation button is pushed out by hydraulic pressure.p. 282
After starting the engine the emergency operation button is pushed out by hydraulic pressure.p. 282
+Travel drive – front wheel drivep. 283
Optional equipmentp. 283
The travel system consists of a closed hydraulic circuit. The most important components are the travel pump with integrated safety elements and control and the travel motor.p. 283
Fig. 26 Front wheel drive — excerpt from hydraulic diagramp. 283
+1p. 283
1p. 283
+Travel motors axle 1 (only with equipment 6×6)p. 283
Travel motors axle 1 (only with equipment 6×6)p. 283
+2p. 283
2p. 283
+Travel motors axle 2 (with equipment 4×6 and 6×6)p. 283
Travel motors axle 2 (with equipment 4×6 and 6×6)p. 283
+3p. 283
3p. 283
+additional travel pump (for front wheel drive)p. 283
additional travel pump (for front wheel drive)p. 283
Travel pumpp. 284
The travel pump for front wheel drive is flanged to the travel pump for rear wheel drive.p. 284
+The duties of thisp. 284
additionalp. 284
+the hydraulic oil supply of the front wheel drive travel circuitp. 284
the hydraulic oil supply of the front wheel drive travel circuitp. 284
the supply of the traction controlp. 284
Filteringp. 284
The hydraulic oil is filtered by a pressure filter, which is arranged directly behind the travel pump.p. 284
Switching on the front wheel drivep. 284
When the operator switches on the front wheel drive, a solenoid valve directs charge pressure to the contgrol of the front travel motors. This charge pressure enables the motors to swash to maximum displacement (black/ white). The quantity of oil con…p. 284
Traction controlp. 284
Depending on the ground conditions and the load of the machine slippage of the front wheels may occur. As a measure to prevent this, the operator has the possibility to adjust the tractive force of the front wheels via a potentiometer on the control …p. 284
Rear axle travel motorsp. 285
The travel motors on the rear axle of the finisher are variable displacement swash plate motors.p. 285
+Product descriptionp. 285
Product descriptionp. 285
A plug-in fixed displacement motor converts the hydrostatic volumetric flow into mechanical rotary motion. It has mainly been designed for installation into mechanical gear drives.p. 285
+Functionp. 285
Functionp. 285
The hydraulic oil flows under high pressure through the corresponding port to the back of the working pistons. Since the working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform an axial stroke, thereby ca…p. 285
Once the respective piston has passed its dead centre (max. extended position), it will change to the low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is thereby displaced out of the cylinder chambe…p. 285
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block. The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the connection between output shaft and pist…p. 285
+Flushing valvep. 285
Flushing valvep. 285
In a closed circuit the same pressure fluid keeps permanently circulating between pump and motor. This can cause overheating of the pressure fluid.p. 285
The flushing valve has the function to support cooling of the oil circuit by flushing the motor and thus to prolong the service life of the motor. If the hydraulic motor is operated under load, the flushing valve opens during clockwise and anti-clock…p. 285
+Controlp. 285
Controlp. 285
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between cylinder block and output shaft.p. 285
With a large angle position the motor works with maximum displacement, slow speed and high torque.p. 285
When changing the swash plate position to minimal angle the motor works with minimum displacement, high speed and low torque.p. 285
+The displacement is changed by a control piston, which is tightly connected with the valve segment. The piston rod side (test port M4) is thereby permanently pressurized with the actual travel pressure. In 1st gear (solenoid de-energized) the piston …p. 285
minp. 285
Fig. 27p. 286
+1p. 286
1p. 286
+Control pistonp. 286
Control pistonp. 286
+7p. 286
7p. 286
+Taper roller bearingp. 286
Taper roller bearingp. 286
+2p. 286
2p. 286
+4-way valvep. 286
4-way valvep. 286
+8p. 286
8p. 286
+SAE-flangep. 286
SAE-flangep. 286
+3p. 286
3p. 286
+Proportional valvep. 286
Proportional valvep. 286
+9p. 286
9p. 286
+Synchronizing jointp. 286
Synchronizing jointp. 286
+4p. 286
4p. 286
+Minimum swashing angle settingp. 286
Minimum swashing angle settingp. 286
+10p. 286
10p. 286
+Speed sensorp. 286
Speed sensorp. 286
+5p. 286
5p. 286
+Valve segmentp. 286
Valve segmentp. 286
+11p. 286
11p. 286
+Pistonp. 286
Pistonp. 286
+6p. 286
6p. 286
+Bearing platep. 286
Bearing platep. 286
+12p. 286
12p. 286
+Flushing pressure relief valvep. 286
Flushing pressure relief valvep. 286
Travel and reduction gearsp. 287
The travel gear is a two-stage spurwheel gear with two power outputs.p. 287
The reduction gears are also two-stage spurwheel gears, but with only one power output. The power inputs are equipped with the multi-disc brakes, the power outputs carry the rear wheels of the machine.p. 287
Function and designp. 287
Fig. 28p. 287
+1p. 287
1p. 287
+Travel gearp. 287
Travel gearp. 287
+4p. 287
4p. 287
+Reduction gearp. 287
Reduction gearp. 287
+2p. 287
2p. 287
+Travel motorp. 287
Travel motorp. 287
+5p. 287
5p. 287
+Multi-disc brakesp. 287
Multi-disc brakesp. 287
+3p. 287
3p. 287
+Rear wheelp. 287
Rear wheelp. 287
The travel gear is driven by the travel motor. The travel gear transmits the torque generated by the travel motor to the reduction gears.p. 287
Hydraulically operated multi-disc brakes are installed between the travel gear and the reduction gear. Pressure is applied to the brake when the brake releasing valve is operated. This pressure works against the Belleville springs and opens the brake…p. 287
+15.13 Checking the hydraulic oil levelp. 288
+15.9 Vibration and tamper drivep. 288
The vibration and tamper drive has been designed as an open hydraulic circuit.p. 288
The most essential components are:p. 288
+the hydraulic pumpp. 288
the hydraulic pumpp. 288
the valve block for vibration drivep. 288
the valve block for tamper operationp. 288
the vibration motorsp. 288
the tamper motorsp. 288
Fig. 29 Vibration and tamper drive – excerpt from hydraulic diagramp. 288
+1p. 288
1p. 288
+Vibration motors (two for the main screed and one each for the mobile screeds)p. 288
Vibration motors (two for the main screed and one each for the mobile screeds)p. 288
+2p. 288
2p. 288
+Tamper motors (two for the main screed and one each for the mobile screeds)p. 288
Tamper motors (two for the main screed and one each for the mobile screeds)p. 288
+3p. 288
3p. 288
+Valve block for tamper operationp. 288
Valve block for tamper operationp. 288
+4p. 288
4p. 288
+Hydraulic pumpp. 288
Hydraulic pumpp. 288
+5p. 288
5p. 288
+Valve block for vibration drivep. 288
Valve block for vibration drivep. 288
Vibration and tamper pumpp. 289
Fig. 30 Vibration and tamper pumpp. 289
+The vibration and tamper pumpp. 289
(Fig. 30)p. 289
Valve blocksp. 289
+This hydraulic oil supply runs through separate valve blocks for vibration drive (5)p. 289
(Fig. 29)p. 289
(Fig. 29)p. 289
Vibration motorp. 289
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. 289
+Tamper motorp. 289
Optionp. 289
The tamper motors of screed and mobile screeds each drive a drive shaft which are connected with the corresponding tamper plate by eccentrically mounted connecting rods. This moves the conrods with the attached tamper plates up and down. This up and …p. 289
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. 289
+15.13 Checking the hydraulic oil levelp. 290
Scraper belt drivep. 290
+Scraper belt drivep. 290
Scraper belt drivep. 290
The scraper belt drive has been designed as an open hydraulic circuit.p. 290
The most essential components are:p. 290
+the scraper belt pumpsp. 290
the scraper belt pumpsp. 290
the scraper belt valve blocksp. 290
the scraper belt motorsp. 290
Fig. 31 Scraper belt drive – excerpt from hydraulic diagramp. 290
+1p. 290
1p. 290
+Scraper belt motor leftp. 290
Scraper belt motor leftp. 290
+4p. 290
4p. 290
+Valve block for right hand motorp. 290
Valve block for right hand motorp. 290
+2p. 290
2p. 290
+Scraper belt motor rightp. 290
Scraper belt motor rightp. 290
+5p. 290
5p. 290
+Gear pump for scraper belt motor leftp. 290
Gear pump for scraper belt motor leftp. 290
+3p. 290
3p. 290
+Valve block for left hand motorp. 290
Valve block for left hand motorp. 290
+6p. 290
6p. 290
+Gear pump for scraper belt motor rightp. 290
Gear pump for scraper belt motor rightp. 290
Scraper belt pump (gear pump)p. 291
Fig. 32 Gear pump for scraper belt drivep. 291
+The pump for the scraper belt drivep. 291
(Fig. 32)p. 291
Valve blocksp. 291
+The valve blocks for the scraper belt drive (3), (4)p. 291
(Fig. 31)p. 291
The solenoid valve attached to the valve block enables the user to run the scraper belts individually in forward or reverse mode, depending on the requirements when paving.p. 291
Scraper belt motorp. 291
The scraper belt motors both drive the scraper belts via a chain drive. Using an intermediate chain drive increases the torque.p. 291
Paddlep. 291
The end of the scraper belts is equipped with paddles. These touch the material and are thereby moved. If there is too much material on the scraper belt, the paddle sends a signal through an attached sensor, which forces the electronics to stop the c…p. 291
+Ultrasonic sensorp. 291
optionalp. 291
The material flow on the scraper belt is detected by an ultrasonic sensor. If there is too much material on the scraper belt, the ultrasonic sensor will generate a signal through an attached sensor, which forces the electronics to stop the correspond…p. 291
+15.13 Checking the hydraulic oil levelp. 292
Auger drivep. 292
+Auger drivep. 292
Auger drivep. 292
The auger drive has been designed as an open hydraulic circuit.p. 292
The most essential components are:p. 292
+the hydraulic pumpsp. 292
the hydraulic pumpsp. 292
the valve blocksp. 292
the auger motorsp. 292
Fig. 33 Auger drive – excerpt from hydraulic diagramp. 292
+1p. 292
1p. 292
+Auger motor leftp. 292
Auger motor leftp. 292
+4p. 292
4p. 292
+Valve block for right hand motorp. 292
Valve block for right hand motorp. 292
+2p. 292
2p. 292
+Auger motor rightp. 292
Auger motor rightp. 292
+5p. 292
5p. 292
+Gear pump for auger motor leftp. 292
Gear pump for auger motor leftp. 292
+3p. 292
3p. 292
+Valve block for left hand motorp. 292
Valve block for left hand motorp. 292
+6p. 292
6p. 292
+Gear pump for auger motor rightp. 292
Gear pump for auger motor rightp. 292
Pump for auger drive (gear pump)p. 293
Fig. 34 Gear pump for auger drivep. 293
+The auger drive pumpp. 293
(Fig. 34)p. 293
Valve blocksp. 293
+The valve blocks for the auger drive (3), (4)p. 293
(Fig. 33)p. 293
The solenoid valve attached to the valve block enables the user to run the augers individually in forward or reverse mode, depending on the requirements when paving.p. 293
Auger motorp. 293
The auger motors both drive the auger shafts via a chain drive. Using an intermediate chain drive increases the torque.p. 293
+15.13 Checking the hydraulic oil levelp. 294
Cylinder functionsp. 294
+Cylinder functionsp. 294
Cylinder functionsp. 294
The cylinder functions can be sub-divided into the following sections:p. 294
+Hopper functionsp. 294
+Hopper functionsp. 294
Hopperp. 294
+Screed functionsp. 294
Screedp. 294
+Auger functionsp. 294
Augerp. 294
+All cylinders are supplied by the working pumpp. 294
(Fig. 35)p. 294
Fig. 35 Work pump – excerpt from hydraulic diagramp. 294
Hopperp. 295
The hopper functions can be sub-divided into two sections:p. 295
+Lift/lower left hand hopper wingp. 295
Lift/lower left hand hopper wingp. 295
Lift/lower right hand hopper wingp. 295
Fig. 36 Hopper functions — excerpt from hydraulic diagramp. 295
+1p. 295
1p. 295
+Lift/lower left hand wingp. 295
Lift/lower left hand wingp. 295
+2p. 295
2p. 295
+Lift/lower right hand wingp. 295
Lift/lower right hand wingp. 295
+Opening / closing the hopper wingsp. 296
Opening / closing the hopper wingsp. 296
The hopper wings can be adjusted in height. This changes the volume of the material hopper. This adjustment is accomplished by hydraulic cylinders, which are fastened to the outside of the wings. When paving the hopper has to take up the material. Fo…p. 296
Screedp. 297
The screed functions can be sub-divided into the following sections:p. 297
+Lifting/lowering the left/right hook-in pointp. 297
Lifting/lowering the left/right hook-in pointp. 297
Lifting/lowering the complete screedp. 297
Extending/retracting the extendable screed left/rightp. 297
+Lifting/lowering the screed Load Control System (LCS)p. 298
Lifting/lowering the screed Load Control System (LCS)p. 298
+3p. 298
3p. 298
+Extending/retracting the extendable screedp. 298
Extending/retracting the extendable screedp. 298
+2p. 298
2p. 298
+Lifting / lowering the hook in pointsp. 298
Lifting / lowering the hook in pointsp. 298
+4p. 298
4p. 298
+Crown adjustmentp. 298
Crown adjustmentp. 298
+Lifting/lowering the left/right hook-in pointp. 299
Lifting/lowering the left/right hook-in pointp. 299
With their height the hook-in points directly influence the thickness of the material to be applied. For this reason they are adjustable in height. This is accomplished with hydraulic cylinders mounted at the front end of the drawing arms. These cyli…p. 299
+Lifting/lowering the complete screedp. 299
Lifting/lowering the complete screedp. 299
Lifting/lowering the screed is accomplished by two hydraulic cylinders at the rear ends of both side arms. These cylinders lift/lower or release the screed by means of the screed load control system (L.C.S.) intervening in the hydraulic circuit. This…p. 299
+Extending/retracting the extendable screed left/rightp. 299
Extending/retracting the extendable screed left/rightp. 299
Extending and retracting the extendable screed is accomplished by two hydraulic cylinders in the centre of the screed. The extendable screeds can thereby by infinitely extended or retracted independently from one another.p. 299
Augersp. 300
The auger functions can be sub-divided into two sections:p. 300
+Augers upp. 300
Augers upp. 300
Augers downp. 300
Fig. 38 Auger functionsp. 301
+1p. 301
1p. 301
+Lifting / lowering the augersp. 301
Lifting / lowering the augersp. 301
+Lifting / lowering the augersp. 302
Lifting / lowering the augersp. 302
The augers can be adjusted in height. This adjustment is accomplished by hydraulic cylinders, which are fastened to the auger unit. The auger can be adjusted in height to make sure that a sufficient amount of material is placed in front of the screed…p. 302
+15.13 Checking the hydraulic oil levelp. 303
15.13 Checking the hydraulic oil levelp. 303
+Risk of overfilling!p. 303
+Risk of overfilling!p. 303
Risk of overfilling!p. 303
+Fully open the hopper.p. 303
Fully open the hopper.p. 303
Completely retract the screed extension.p. 303
Raise the screed to half height.p. 303
Fig. 39p. 303
+Check the hydraulic oil level in the inspection glassp. 303
+Check the hydraulic oil level in the inspection glassp. 303
(Fig. 39)p. 303
Normal levelp. 303
approx. 3 cm below the top edge of the inspection glass.p. 303
Minimum levelp. 303
Middle of inspection glass.p. 303
+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. 303
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. 303
+If necessary fill in hydraulic oil through the filler neck.p. 303
If necessary fill in hydraulic oil through the filler neck.p. 303
For quality and quantity of oil refer to the table of fuels and lubricants.p. 303
+15.14 Changing hydraulic oil and hydraulic oil filterp. 303
15.14 Changing hydraulic oil and hydraulic oil filterp. 303
+See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 303
+See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 303
See also the notes on the hydraulic system in the chapter "General notes on maintenance".p. 303
+Danger of scalding!p. 303
Danger of scalding!p. 303
When draining off hot hydraulic oil!p. 303
+The hydraulic oil must also be changed after major repairs in the hydraulic system.p. 303
The hydraulic oil must also be changed after major repairs in the hydraulic system.p. 303
Perform the oil change when the hydraulic oil is warm.p. 303
Replace the hydraulic oil filter element with every hydraulic oil change.p. 303
Change the filter only after the hydraulic oil change and after the test run.p. 303
Clean the area round hydraulic oil tank, filler opening and breather filter.p. 303
Do not start the engine after draining the hydraulic oil.p. 303
Do not use any detergents to clean the system.p. 303
For quality and quantity of oil refer to the "table of fuels and lubricants".p. 303
+Catch running out oil and dispose of environmentally.p. 303
Catch running out oil and dispose of environmentally.p. 303
Fig. 40p. 303
+Unscrew the plugp. 303
+Unscrew the plugp. 303
(Fig. 40)p. 303
Turn the plug tightly back in.p. 303
+Remove the filler cap.p. 303
Remove the filler cap.p. 303
Fill in new hydraulic oil through the screen.p. 303
+We recommend to use our filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.p. 304
We recommend to use our filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.p. 304
Fig. 41p. 304
+Check the oil level in the inspection glassp. 304
+Check the oil level in the inspection glassp. 304
(Fig. 41)p. 304
Nominal value:p. 304
approx. 3 cm below the upper edge of the inspection glassp. 304
+The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap.p. 304
The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap.p. 304
+Close the tank with a new cover.p. 304
Close the tank with a new cover.p. 304
+Open the hopper wings and remove the cover to the engine compartment.p. 304
Open the hopper wings and remove the cover to the engine compartment.p. 304
Fig. 42p. 304
+Unscrew spigot nut 4p. 304
+Unscrew spigot nut 4p. 304
(Fig. 42)p. 304
Examine the surface of the filter element thoroughly for any visible dirt.p. 304
+Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to…p. 304
Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to…p. 304
Do not clean or reuse the filter element.p. 304
+Take the old filter element (3) out, clean the filter bowl and thread.p. 304
Take the old filter element (3) out, clean the filter bowl and thread.p. 304
Install the filter bowl with new filter element, check the condition of O-rings (1) and (2), if necessary use new ones.p. 304
After a short test run check the filter for leaks.p. 304
+16 Tests and adjustmentsp. 305
16 Tests and adjustmentsp. 305
+16.2 Checking and adjusting the vibrationp. 306
16.1 Special tools, tests and adjustmentsp. 306
+The following list informs about special tools for testing and adjustment work. You should choose the corresponding tool for the work to be carried out.p. 306
The following list informs about special tools for testing and adjustment work. You should choose the corresponding tool for the work to be carried out.p. 306
+Fig. 1p. 306
Fig. 1p. 306
+16. Vibration reed frequency meterp. 306
16. Vibration reed frequency meterp. 306
+1000 – 4.000 rpmp. 306
1000 – 4.000 rpmp. 306
+17 – 67 Hzp. 306
17 – 67 Hzp. 306
+BOMAG part-no.: 300 120 80p. 306
BOMAG part-no.: 300 120 80p. 306
+Fig. 2p. 306
Fig. 2p. 306
+17. Sirometer (frequency meter)p. 306
17. Sirometer (frequency meter)p. 306
+800 – 50.000 rpmp. 306
800 – 50.000 rpmp. 306
+14 – 750 Hzp. 306
14 – 750 Hzp. 306
+BOMAG part-no.: 059 710 02p. 306
BOMAG part-no.: 059 710 02p. 306
+Fig. 3p. 306
Fig. 3p. 306
+18. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Plastic, temperature range: down to -40 °Cp. 306
18. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Plastic, temperature range: down to -40 °Cp. 306
BOMAG part-no.: 050 100 75p. 306
+Fig. 4p. 307
Fig. 4p. 307
+19. Digital rpm-meter for petrol enginesp. 307
19. Digital rpm-meter for petrol enginesp. 307
BOMAG part-no.: 079 948 99p. 307
+Fig. 5p. 307
Fig. 5p. 307
+20. Digital rpm-meter for petrol enginesp. 307
20. Digital rpm-meter for petrol enginesp. 307
BOMAG part-no.: 059 711 12p. 307
+Fig. 6p. 307
Fig. 6p. 307
+21. Digital rpm-meter, optical/mechanical, universal usep. 307
21. Digital rpm-meter, optical/mechanical, universal usep. 307
BOMAG part-no.: 079 948 98p. 307
+Fig. 7p. 307
Fig. 7p. 307
+22. Infrared hand-held thermometer, -18 to 275°Cp. 307
22. Infrared hand-held thermometer, -18 to 275°Cp. 307
BOMAG part-no.: 057 668 06p. 307
+Fig. 8p. 308
Fig. 8p. 308
+23. Hydraulic test case, largep. 308
23. Hydraulic test case, largep. 308
BOMAG part-no.: 007 610 03p. 308
+4 X 600 bar pressure gaugesp. 308
4 X 600 bar pressure gaugesp. 308
4 X 60 bar pressure gaugesp. 308
8 pressure test hosesp. 308
+Fig. 9p. 308
Fig. 9p. 308
+24. Hydraulic test case, smallp. 308
24. Hydraulic test case, smallp. 308
BOMAG part-no.: 079 930 01p. 308
+2X 60 bar pressure gaugesp. 308
2X 60 bar pressure gaugesp. 308
2X 600 bar pressure gaugesp. 308
4 pressure test hosesp. 308
+Fig. 10p. 308
Fig. 10p. 308
+25. Pressure test hosesp. 308
25. Pressure test hosesp. 308
+1000 mm BOMAG part-no.: 079 930 02p. 308
1000 mm BOMAG part-no.: 079 930 02p. 308
+2500 mm BOMAG part-no.: 079 930 03p. 308
2500 mm BOMAG part-no.: 079 930 03p. 308
+Fig. 11p. 308
Fig. 11p. 308
+26. Pressure gaugep. 308
26. Pressure gaugep. 308
+60 bar BOMAG part-no.: 059 721 07p. 308
60 bar BOMAG part-no.: 059 721 07p. 308
+600 bar BOMAG part-no.: 059 721 04p. 308
600 bar BOMAG part-no.: 059 721 04p. 308
+Fig. 12p. 309
Fig. 12p. 309
+27. Adapter for pressure test hosep. 309
27. Adapter for pressure test hosep. 309
BOMAG part-no.: 055 439 02p. 309
+Fig. 13p. 309
Fig. 13p. 309
+28. Gear pump testing devicep. 309
28. Gear pump testing devicep. 309
BOMAG part-no.: 007 610 05p. 309
+Fig. 14p. 309
Fig. 14p. 309
+29. Vacuum pump for hydraulic oil tankp. 309
29. Vacuum pump for hydraulic oil tankp. 309
+BOMAG part-no.: 007 610 04 (12 Volt)p. 309
BOMAG part-no.: 007 610 04 (12 Volt)p. 309
+BOMAG part-no.: 007 610 24 (24 Volt)p. 309
BOMAG part-no.: 007 610 24 (24 Volt)p. 309
+16.2 Checking and adjusting the vibrationp. 310
16.2 Checking and adjusting the vibrationp. 310
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 310
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 310
+The following section describes the test for thep. 338
+The following section describes the test for thep. 338
leftp. 338
+Fig. 1p. 338
Fig. 1p. 338
+Danger of injury!p. 338
Danger of injury!p. 338
Before connecting the pressure gauge make sure that the engine has been shut down!p. 338
+1. Connect a high pressure gauge (600 bar) to pressure test port (1) on the pumpp. 338
+1. Connect a high pressure gauge (600 bar) to pressure test port (1) on the pumpp. 338
(Fig. 1)p. 338
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 338
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 338
+2. Block the auger with suitable means.p. 338
2. Block the auger with suitable means.p. 338
+Fig. 2p. 338
Fig. 2p. 338
+3. Start the engine and set the switch to position "MAX"p. 338
+3. Start the engine and set the switch to position "MAX"p. 338
(Fig. 2)p. 338
+Fig. 3p. 339
Fig. 3p. 339
+4. Activate the hydraulic systemp. 339
+4. Activate the hydraulic systemp. 339
(Fig. 3)p. 339
+Fig. 4p. 339
Fig. 4p. 339
+5. Activate the parking brakep. 339
+5. Activate the parking brakep. 339
(Fig. 4)p. 339
+Fig. 5p. 339
Fig. 5p. 339
+6. Select "Work"-modep. 339
+6. Select "Work"-modep. 339
(Fig. 5)p. 339
+Fig. 6p. 339
Fig. 6p. 339
+Run the following pressure test only for max. 5 seconds.p. 339
Run the following pressure test only for max. 5 seconds.p. 339
+7. Set the switch “b” (right auger : “c”) downwards.p. 339
+7. Set the switch “b” (right auger : “c”) downwards.p. 339
(Fig. 6)p. 339
+8. Read the hydraulic oil pressure in the pressure gauge.p. 339
8. Read the hydraulic oil pressure in the pressure gauge.p. 339
+9. Turn switch "b" ("c") to position "0".p. 339
9. Turn switch "b" ("c") to position "0".p. 339
+Fig. 7p. 340
Fig. 7p. 340
+Nominal valuep. 340
Nominal valuep. 340
See chapter "Technical Data".p. 340
+If the nominal pressure of the pressure relief valve is not reached:p. 340
If the nominal pressure of the pressure relief valve is not reached:p. 340
1. Adjust the pressure relief valve (PRV) on the "Auger drive" valve block (see next step).p. 340
2. Solenoid valve (Y210, Y211 (right auger: Y212, Y213)) – check electrical control and mechanical function.p. 340
3. Check the gear pump ("defect?").p. 340
4. Check the auger motor ("defect?").p. 340
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 340
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 340
+10. Remove the cap from the PRVp. 340
+10. Remove the cap from the PRVp. 340
(Fig. 7)p. 340
+11. Loosen the counter nut (1) and turn the setscrew (2) in or out, until the nominal value is reached.p. 340
11. Loosen the counter nut (1) and turn the setscrew (2) in or out, until the nominal value is reached.p. 340
+Turning clockwisep. 340
+Turning clockwisep. 340
increasesp. 340
reducesp. 340
+12. Check the pressure once again (see above).p. 340
12. Check the pressure once again (see above).p. 340
+13. Retighten the counter nut (1) and replace the cap.p. 340
13. Retighten the counter nut (1) and replace the cap.p. 340
+Fig. 8p. 340
Fig. 8p. 340
+14. Turn the switch to position "MIN" and shut down the enginep. 340
+14. Turn the switch to position "MIN" and shut down the enginep. 340
(Fig. 8)p. 340
+Danger of injury!p. 340
Danger of injury!p. 340
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 340
+15. Disconnect the pressure gauge.p. 340
15. Disconnect the pressure gauge.p. 340
+16. Remove the blockage from the auger.p. 340
16. Remove the blockage from the auger.p. 340
Rotary speed test augerp. 341
+The following section describes the test for one side. The other side must be checked accordingly.p. 341
The following section describes the test for one side. The other side must be checked accordingly.p. 341
+Fig. 9p. 341
Fig. 9p. 341
+1. Fasten a reflex mark (2) on the auger (1)p. 341
+1. Fasten a reflex mark (2) on the auger (1)p. 341
(Fig. 9)p. 341
+Fig. 10p. 341
Fig. 10p. 341
+2. Start the engine and set the switch to position "MAX"p. 341
+2. Start the engine and set the switch to position "MAX"p. 341
(Fig. 10)p. 341
+Fig. 11p. 341
Fig. 11p. 341
+3. Activate the hydraulic systemp. 341
+3. Activate the hydraulic systemp. 341
(Fig. 11)p. 341
+Fig. 12p. 342
Fig. 12p. 342
+4. Activate the parking brakep. 342
+4. Activate the parking brakep. 342
(Fig. 12)p. 342
+Fig. 13p. 342
Fig. 13p. 342
+5. Select "Work"-modep. 342
+5. Select "Work"-modep. 342
(Fig. 13)p. 342
+Fig. 14p. 342
Fig. 14p. 342
+6. Set the switch “b” (right auger : “c”) downwards.p. 342
+6. Set the switch “b” (right auger : “c”) downwards.p. 342
(Fig. 14)p. 342
+Fig. 15p. 342
Fig. 15p. 342
+7. Shift the travel lever to "forward" positionp. 342
+7. Shift the travel lever to "forward" positionp. 342
(Fig. 15)p. 342
+8. Read the shaft speed.p. 342
8. Read the shaft speed.p. 342
+Nominal valuep. 342
Nominal valuep. 342
See chapter "Technical Data".p. 342
+9. Shift the travel lever to "Neutral" position.p. 342
9. Shift the travel lever to "Neutral" position.p. 342
+10. Turn switch "b" ("c") to position "0".p. 342
10. Turn switch "b" ("c") to position "0".p. 342
+If the nominal pressure of the pressure relief valve is not reached:p. 342
If the nominal pressure of the pressure relief valve is not reached:p. 342
1. Check the PRV ("defect?").p. 342
2. Solenoid valve (Y210, Y211 (right auger: Y212, Y213)) – check electrical control and mechanical function.p. 343
3. Check the gear pump ("defect?").p. 343
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 343
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 343
+Fig. 16p. 343
Fig. 16p. 343
+11. Turn the switch to position "MIN" and shut down the enginep. 343
+11. Turn the switch to position "MIN" and shut down the enginep. 343
(Fig. 16)p. 343
+16.6 Checking/adjusting the main screedp. 344
16.6 Checking/adjusting the main screedp. 344
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 344
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 344
+Special toolsp. 344
Special toolsp. 344
+Hydraulic test casep. 344
[BOMAG Part-No.: 079 930 01]p. 344
Pressure limitation main screedsp. 344
+Fig. 1p. 344
Fig. 1p. 344
+Danger of injury!p. 344
Danger of injury!p. 344
Before connecting the pressure gauge make sure that the engine has been shut down!p. 344
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 344
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 344
(Fig. 1)p. 344
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 344
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 344
+Fig. 2p. 344
Fig. 2p. 344
+2. Start the engine and set the switch to position "MAX"p. 344
+2. Start the engine and set the switch to position "MAX"p. 344
(Fig. 2)p. 344
+Fig. 3p. 344
Fig. 3p. 344
+3. Activate the hydraulic systemp. 344
+3. Activate the hydraulic systemp. 344
(Fig. 3)p. 344
+Fig. 4p. 345
Fig. 4p. 345
+4. Select "Work"-modep. 345
+4. Select "Work"-modep. 345
(Fig. 4)p. 345
+Fig. 5p. 345
Fig. 5p. 345
+For the following pressure test drive the screed max. 5 seconds against block.p. 345
For the following pressure test drive the screed max. 5 seconds against block.p. 345
+5. Lift the screed completely and read the pressure gaugep. 345
+5. Lift the screed completely and read the pressure gaugep. 345
(Fig. 5)p. 345
+Nominal valuep. 345
Nominal valuep. 345
See chapter "Technical Data".p. 345
+Fig. 6p. 345
Fig. 6p. 345
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 345
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 345
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 345
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 345
(Fig. 6)p. 345
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 345
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 345
+Fig. 7p. 345
Fig. 7p. 345
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 345
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 345
(Fig. 7)p. 345
+Turning clockwisep. 345
+Turning clockwisep. 345
increasesp. 345
reducesp. 345
+7. Check the pressure once again (see above).p. 345
7. Check the pressure once again (see above).p. 345
+8. Retighten the counter nut (2).p. 345
8. Retighten the counter nut (2).p. 345
+Fig. 8p. 346
Fig. 8p. 346
+9. Deactivate the hydraulic systemp. 346
+9. Deactivate the hydraulic systemp. 346
(Fig. 8)p. 346
+Fig. 9p. 346
Fig. 9p. 346
+10. Turn the switch to position "MIN" and shut down the enginep. 346
+10. Turn the switch to position "MIN" and shut down the enginep. 346
(Fig. 9)p. 346
+Danger of injury!p. 346
Danger of injury!p. 346
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 346
+11. Disconnect the pressure gauge.p. 346
11. Disconnect the pressure gauge.p. 346
Time measurement for lifting and lowering the main screedp. 347
+Fig. 10p. 347
Fig. 10p. 347
+1. Start the engine and set the switch to position "MAX"p. 347
+1. Start the engine and set the switch to position "MAX"p. 347
(Fig. 10)p. 347
+Fig. 11p. 347
Fig. 11p. 347
+2. Activate the hydraulic systemp. 347
+2. Activate the hydraulic systemp. 347
(Fig. 11)p. 347
+Fig. 12p. 347
Fig. 12p. 347
+3. Select "Work"-modep. 347
+3. Select "Work"-modep. 347
(Fig. 12)p. 347
+Fig. 13p. 348
Fig. 13p. 348
+4. If necessary lower the screed (1) completelyp. 348
+4. If necessary lower the screed (1) completelyp. 348
(Fig. 13)p. 348
+5. Lift the screed completely and measure the required time.p. 348
+5. Lift the screed completely and measure the required time.p. 348
5. Liftp. 348
+Nominal valuep. 348
Nominal valuep. 348
+3-5 secondsp. 348
3-5 secondsp. 348
+6. Lower the screed completely and measure the required time.p. 348
+6. Lower the screed completely and measure the required time.p. 348
6. Lowerp. 348
+Nominal valuep. 348
Nominal valuep. 348
+3-5 secondsp. 348
3-5 secondsp. 348
+If the nominal value is not reached, this may have one of the following causes:p. 348
If the nominal value is not reached, this may have one of the following causes:p. 348
– Throttle (see hydraulic diagram) dirty –> cleanp. 348
– Valves Y226, Y237, Y228 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 348
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 348
– Flow volume from service pump too low –> check the pumpp. 348
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 348
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 348
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 348
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 348
+– Bigger throttle: The screed movesp. 348
fasterp. 348
+– Smaller throttle: The screed movesp. 348
slowerp. 348
+Fig. 14p. 348
Fig. 14p. 348
+7. Deactivate the hydraulic systemp. 348
+7. Deactivate the hydraulic systemp. 348
(Fig. 14)p. 348
+Fig. 15p. 349
Fig. 15p. 349
+8. Turn the switch to position "MIN" and shut down the enginep. 349
+8. Turn the switch to position "MIN" and shut down the enginep. 349
(Fig. 15)p. 349
+16.7 Checking/adjusting the screed levellingp. 350
16.7 Checking/adjusting the screed levellingp. 350
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 350
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 350
+Special toolsp. 350
Special toolsp. 350
+Hydraulic test casep. 350
[BOMAG Part-No.: 079 930 01]p. 350
Pressure test screed levellingp. 350
+Fig. 1p. 350
Fig. 1p. 350
+Danger of injury!p. 350
Danger of injury!p. 350
Before connecting the pressure gauge make sure that the engine has been shut down!p. 350
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 350
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 350
(Fig. 1)p. 350
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 350
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 350
+Fig. 2p. 350
Fig. 2p. 350
+2. Start the engine and set the switch to position "MAX"p. 350
+2. Start the engine and set the switch to position "MAX"p. 350
(Fig. 2)p. 350
+Fig. 3p. 350
Fig. 3p. 350
+3. Activate the hydraulic systemp. 350
+3. Activate the hydraulic systemp. 350
(Fig. 3)p. 350
+Fig. 4p. 351
Fig. 4p. 351
+4. Select "Work"-modep. 351
+4. Select "Work"-modep. 351
(Fig. 4)p. 351
+Fig. 5p. 351
Fig. 5p. 351
+For the following pressure test move the screed levelling max. 5 seconds against block.p. 351
For the following pressure test move the screed levelling max. 5 seconds against block.p. 351
+5. Lift the screed levelling completely and read the pressure gaugep. 351
+5. Lift the screed levelling completely and read the pressure gaugep. 351
(Fig. 5)p. 351
+Nominal valuep. 351
Nominal valuep. 351
See chapter "Technical Data".p. 351
+Fig. 6p. 351
Fig. 6p. 351
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 351
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 351
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 351
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 351
(Fig. 6)p. 351
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 351
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 351
+Fig. 7p. 351
Fig. 7p. 351
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 351
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 351
(Fig. 7)p. 351
+Turning clockwisep. 351
+Turning clockwisep. 351
increasesp. 351
reducesp. 351
+7. Check the pressure once again (see above).p. 351
7. Check the pressure once again (see above).p. 351
+8. Retighten the counter nut (2).p. 351
8. Retighten the counter nut (2).p. 351
+Fig. 8p. 352
Fig. 8p. 352
+9. Deactivate the hydraulic systemp. 352
+9. Deactivate the hydraulic systemp. 352
(Fig. 8)p. 352
+Fig. 9p. 352
Fig. 9p. 352
+10. Turn the switch to position "MIN" and shut down the enginep. 352
+10. Turn the switch to position "MIN" and shut down the enginep. 352
(Fig. 9)p. 352
+Danger of injury!p. 352
Danger of injury!p. 352
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 352
+11. Disconnect the pressure gauge.p. 352
11. Disconnect the pressure gauge.p. 352
Time measurement screed levellingp. 353
+Fig. 10p. 353
Fig. 10p. 353
+1. Start the engine and set the switch to position "MAX"p. 353
+1. Start the engine and set the switch to position "MAX"p. 353
(Fig. 10)p. 353
+Fig. 11p. 353
Fig. 11p. 353
+2. Activate the hydraulic systemp. 353
+2. Activate the hydraulic systemp. 353
(Fig. 11)p. 353
+Fig. 12p. 353
Fig. 12p. 353
+3. Select "Work"-modep. 353
+3. Select "Work"-modep. 353
(Fig. 12)p. 353
+Fig. 13p. 353
Fig. 13p. 353
+4. If necessary lower the drawing arms completelyp. 353
+4. If necessary lower the drawing arms completelyp. 353
(Fig. 13)p. 353
+5. Lift the drawing arms completely and measure the required time.p. 353
+5. Lift the drawing arms completely and measure the required time.p. 353
5. Liftp. 353
+Nominal valuep. 353
Nominal valuep. 353
+27-29 secondsp. 353
27-29 secondsp. 353
+6. Lower the drawing arms completely and measure the required time.p. 353
+6. Lower the drawing arms completely and measure the required time.p. 353
6. Lowerp. 353
+Nominal valuep. 353
Nominal valuep. 353
+23-25 secondsp. 353
23-25 secondsp. 353
+If the nominal value is not reached, this may have one of the following causes:p. 354
If the nominal value is not reached, this may have one of the following causes:p. 354
– Throttle (see hydraulic diagram) dirty –> cleanp. 354
– Valves Y220, Y221, Y222, Y223 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 354
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 354
– Flow volume from service pump too low –> check the pumpp. 354
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 354
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 354
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 354
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 354
+– Bigger throttle: The levelling cylinder movesp. 354
fasterp. 354
+– Smaller throttle: The levelling cylinder movesp. 354
slowerp. 354
+Fig. 14p. 354
Fig. 14p. 354
+7. Deactivate the hydraulic systemp. 354
+7. Deactivate the hydraulic systemp. 354
(Fig. 14)p. 354
+Fig. 15p. 355
Fig. 15p. 355
+8. Turn the switch to position "MIN" and shut down the enginep. 355
+8. Turn the switch to position "MIN" and shut down the enginep. 355
(Fig. 15)p. 355
+16.8 Checking/adjusting the hopper wingsp. 356
16.8 Checking/adjusting the hopper wingsp. 356
+Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 356
Perform measurements at operating temperature of the hydraulic oil (40 °C).p. 356
+Special toolsp. 356
Special toolsp. 356
+Hydraulic test casep. 356
[BOMAG Part-No.: 079 930 01]p. 356
Pressure test for hopper wingsp. 356
+Fig. 1p. 356
Fig. 1p. 356
+Danger of injury!p. 356
Danger of injury!p. 356
Before connecting the pressure gauge make sure that the engine has been shut down!p. 356
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 356
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 356
(Fig. 1)p. 356
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 356
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 356
+Fig. 2p. 356
Fig. 2p. 356
+2. Start the engine and set the switch to position "MAX"p. 356
+2. Start the engine and set the switch to position "MAX"p. 356
(Fig. 2)p. 356
+Fig. 3p. 356
Fig. 3p. 356
+3. Activate the hydraulic systemp. 356
+3. Activate the hydraulic systemp. 356
(Fig. 3)p. 356
+Fig. 4p. 357
Fig. 4p. 357
+4. Select "Work"-modep. 357
+4. Select "Work"-modep. 357
(Fig. 4)p. 357
+Fig. 5p. 357
Fig. 5p. 357
+For the following pressure test move the hopper wings max. 5 seconds against block.p. 357
For the following pressure test move the hopper wings max. 5 seconds against block.p. 357
+5. Close the hopper wings completely and read the pressure gaugep. 357
+5. Close the hopper wings completely and read the pressure gaugep. 357
(Fig. 5)p. 357
+Nominal valuep. 357
Nominal valuep. 357
See chapter "Technical Data".p. 357
+Fig. 6p. 357
Fig. 6p. 357
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 357
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 357
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 357
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 357
(Fig. 6)p. 357
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 357
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 357
+Fig. 7p. 357
Fig. 7p. 357
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 357
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 357
(Fig. 7)p. 357
+Turning clockwisep. 357
+Turning clockwisep. 357
increasesp. 357
reducesp. 357
+7. Check the pressure once again (see above).p. 357
7. Check the pressure once again (see above).p. 357
+8. Retighten the counter nut (2).p. 357
8. Retighten the counter nut (2).p. 357
+Fig. 8p. 358
Fig. 8p. 358
+9. Deactivate the hydraulic systemp. 358
+9. Deactivate the hydraulic systemp. 358
(Fig. 8)p. 358
+Fig. 9p. 358
Fig. 9p. 358
+10. Turn the switch to position "MIN" and shut down the enginep. 358
+10. Turn the switch to position "MIN" and shut down the enginep. 358
(Fig. 9)p. 358
+Danger of injury!p. 358
Danger of injury!p. 358
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 358
+11. Disconnect the pressure gauge.p. 358
11. Disconnect the pressure gauge.p. 358
Testing the hopper wing movement timep. 359
+Fig. 10p. 359
Fig. 10p. 359
+1. Start the engine and set the switch to position "MAX"p. 359
+1. Start the engine and set the switch to position "MAX"p. 359
(Fig. 10)p. 359
+Fig. 11p. 359
Fig. 11p. 359
+2. Activate the hydraulic systemp. 359
+2. Activate the hydraulic systemp. 359
(Fig. 11)p. 359
+Fig. 12p. 359
Fig. 12p. 359
+3. Select "Work"-modep. 359
+3. Select "Work"-modep. 359
(Fig. 12)p. 359
+Fig. 13p. 360
Fig. 13p. 360
+4. If necessary open the hopper wings completelyp. 360
+4. If necessary open the hopper wings completelyp. 360
(Fig. 13)p. 360
+5. Close the hopper wing completely and measure the required time.p. 360
+5. Close the hopper wing completely and measure the required time.p. 360
5. Closep. 360
+Nominal valuep. 360
Nominal valuep. 360
+4-5 secondsp. 360
4-5 secondsp. 360
+6. Open the hopper wing completely and measure the required time.p. 360
+6. Open the hopper wing completely and measure the required time.p. 360
6. Openp. 360
+Nominal valuep. 360
Nominal valuep. 360
+5-6 secondsp. 360
5-6 secondsp. 360
+If the nominal value is not reached, this may have one of the following causes:p. 360
If the nominal value is not reached, this may have one of the following causes:p. 360
– Throttles (see hydraulic diagram) dirty –> cleanp. 360
– Valves Y202, Y203, Y204, Y205 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 360
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 360
– Flow volume from service pump too low –> check the pumpp. 360
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 360
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 360
+If the nominal value is still not reached despite these measures you may change the size of the throttles:p. 360
If the nominal value is still not reached despite these measures you may change the size of the throttles:p. 360
+– Bigger throttle: The hopper wings movep. 360
fasterp. 360
+– Smaller throttle: The hopper wings movep. 360
slowerp. 360
+Fig. 14p. 360
Fig. 14p. 360
+7. Deactivate the hydraulic systemp. 360
+7. Deactivate the hydraulic systemp. 360
(Fig. 14)p. 360
+Fig. 15p. 361
Fig. 15p. 361
+8. Turn the switch to position "MIN" and shut down the enginep. 361
+8. Turn the switch to position "MIN" and shut down the enginep. 361
(Fig. 15)p. 361
+16.9 Checking/adjusting the mobile screedp. 362
16.9 Checking/adjusting the mobile screedp. 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
+Special toolsp. 362
Special toolsp. 362
+Hydraulic test casep. 362
[BOMAG Part-No.: 079 930 01]p. 362
Pressure limitation mobile screedsp. 362
+Fig. 1p. 362
Fig. 1p. 362
+Danger of injury!p. 362
Danger of injury!p. 362
Before connecting the pressure gauge make sure that the engine has been shut down!p. 362
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 362
+1. Connect a high pressure gauge (600 bar) to the pressure test port on the service pumpp. 362
(Fig. 1)p. 362
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 362
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 362
+Fig. 2p. 362
Fig. 2p. 362
+2. Start the engine and set the switch to position "MAX"p. 362
+2. Start the engine and set the switch to position "MAX"p. 362
(Fig. 2)p. 362
+Fig. 3p. 362
Fig. 3p. 362
+3. Activate the hydraulic systemp. 362
+3. Activate the hydraulic systemp. 362
(Fig. 3)p. 362
+Fig. 4p. 363
Fig. 4p. 363
+4. Select "Work"-modep. 363
+4. Select "Work"-modep. 363
(Fig. 4)p. 363
+Fig. 5p. 363
Fig. 5p. 363
+For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 363
For the following pressure test drive the mobile screeds max. 5 seconds against block.p. 363
+Perform the pressure test by RETRACTING the mobile screed. In this case the bending forces acting on the screed are lower!p. 363
Perform the pressure test by RETRACTING the mobile screed. In this case the bending forces acting on the screed are lower!p. 363
+5. Completelyp. 363
+5. Completelyp. 363
retractp. 363
(Fig. 5)p. 363
+Nominal valuep. 363
Nominal valuep. 363
See chapter "Technical Data".p. 363
+Fig. 6p. 363
Fig. 6p. 363
+If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 363
If the nominal value of the pressure limitation is not reached, this may have one of the following causes:p. 363
– Pressure relief setting on the service pump not correct –> Adjust the pressure relief valve (PRV) on the service pump.p. 363
+– Solenoid valve Y194 dirty or defective –> clean or replacep. 363
(Fig. 6)p. 363
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 363
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 363
+Fig. 7p. 364
Fig. 7p. 364
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 364
+6. Loosen the counter nut (2) and turn the setscrew (1) in or out, until the nominal value is reachedp. 364
(Fig. 7)p. 364
+Turning clockwisep. 364
+Turning clockwisep. 364
increasesp. 364
reducesp. 364
+7. Check the pressure once again (see above).p. 364
7. Check the pressure once again (see above).p. 364
+8. Retighten the counter nut (2).p. 364
8. Retighten the counter nut (2).p. 364
+Fig. 8p. 364
Fig. 8p. 364
+9. Deactivate the hydraulic systemp. 364
+9. Deactivate the hydraulic systemp. 364
(Fig. 8)p. 364
+Fig. 9p. 364
Fig. 9p. 364
+10. Turn the switch to position "MIN" and shut down the enginep. 364
+10. Turn the switch to position "MIN" and shut down the enginep. 364
(Fig. 9)p. 364
+Danger of injury!p. 364
Danger of injury!p. 364
Before disconnecting the pressure gauge make sure that the engine has been shut down!p. 364
+11. Disconnect the pressure gauge.p. 364
11. Disconnect the pressure gauge.p. 364
Time measurement for extension and retraction of mobile screedsp. 365
+Fig. 10p. 365
Fig. 10p. 365
+1. Start the engine and set the switch to position "MAX"p. 365
+1. Start the engine and set the switch to position "MAX"p. 365
(Fig. 10)p. 365
+Fig. 11p. 365
Fig. 11p. 365
+2. Activate the hydraulic systemp. 365
+2. Activate the hydraulic systemp. 365
(Fig. 11)p. 365
+Fig. 12p. 365
Fig. 12p. 365
+3. Select "Work"-modep. 365
+3. Select "Work"-modep. 365
(Fig. 12)p. 365
+Fig. 13p. 366
Fig. 13p. 366
+4. If necessary retract the mobile screed completelyp. 366
+4. If necessary retract the mobile screed completelyp. 366
(Fig. 13)p. 366
+5. Fullyp. 366
+5. Fullyp. 366
extendp. 366
+Nominal valuep. 366
Nominal valuep. 366
+15-17 secondsp. 366
15-17 secondsp. 366
+6. Fullyp. 366
+6. Fullyp. 366
retractp. 366
+Nominal valuep. 366
Nominal valuep. 366
+12-14 secondsp. 366
12-14 secondsp. 366
+If the nominal value is not reached, this may have one of the following causes:p. 366
If the nominal value is not reached, this may have one of the following causes:p. 366
– Throttle (see hydraulic diagram) dirty –> cleanp. 366
– Valves Y216, Y217, Y218, Y219 dirty or defective –> clean as necessary, check electric power supply. Replace if defective.p. 366
– Valve Y194 dirty or defective –> clean if necessary, check electric power supply. Replace if defective.p. 366
– Flow volume from service pump too low –> check the pumpp. 366
+The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 366
The arrangement of hydraulic components is shown in chapter "Hydraulics" under section "Hydraulics overview of components".p. 366
+If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 366
If the nominal value is still not reached despite these measures you may change the size of the throttle:p. 366
+– Bigger throttle: The mobile screed movesp. 366
fasterp. 366
+– Smaller throttle: The mobile screed movesp. 366
slowerp. 366
+Fig. 14p. 366
Fig. 14p. 366
+7. Deactivate the hydraulic systemp. 366
+7. Deactivate the hydraulic systemp. 366
(Fig. 14)p. 366
+Fig. 15p. 367
Fig. 15p. 367
+8. Turn the switch to position "MIN" and shut down the enginep. 367
+8. Turn the switch to position "MIN" and shut down the enginep. 367
(Fig. 15)p. 367
+17 Central lubrication systemp. 369
+17 Central lubrication systemp. 369
BF 300P lubrication planp. 370
+BF 300P lubrication points on screed without tamperp. 370
BF 300P lubrication points on screed without tamperp. 370
+BF 300P lubrication points on screed with tamperp. 371
BF 300P lubrication points on screed with tamperp. 371
+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. 372
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. 372
+(Fig. 3) Through grease nipple with hand-operated or pneumatic grease gunp. 373
(Fig. 3)p. 373
17.3 Electric pumpp. 374
+Electric pump EP-1p. 374
Electric pump EP-1p. 374
+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. 374
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. 374
Fig. 4 EP-1 with 4 kg container and integrated electronic controlp. 374
Technical dadap. 374
Motor:p. 374
+Operating voltagep. 374
Operating voltagep. 374
12/24 V DCp. 374
Rated speedp. 374
15 rpmp. 374
Power consumption at idle speedp. 374
0.4 Ap. 374
Power consumption at full load speedp. 374
1.1 Ap. 374
Fusep. 374
3 Ap. 374
Pump:p. 374
+Max. operating pressurep. 374
Max. operating pressurep. 374
280 barp. 374
Permissible operating temperaturep. 374
-35°C to +80°Cp. 374
Container capacityp. 374
1.9 kg, 2.5 kg, 4 kg or 8 kgp. 374
Rotation of agitatorp. 374
counter-clockwisep. 374
Installation positionp. 374
Container vertically uprightp. 374
Protection classp. 374
IP5K9K acc. to DIN 40050p. 374
Working principlep. 375
Fig. 5p. 375
+A DC-motor 10p. 375
(Fig. 5)p. 375
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. 375
The pressure relief valve (9) is factory set to 280 bar.p. 375
Fig. 6 Pump element drawing in greasep. 375
Fig. 7 Pump element pumpingp. 375
Pump element PE-120Vp. 376
+Max. flow capacityp. 376
Max. flow capacityp. 376
+Pump element factory set to full strokep. 376
Pump element factory set to full strokep. 376
max. flow capacity 0.12 cm with full strokep. 376
Reduction of 0.013 cm per detent = 1/2 revolutionp. 376
Flow capacity regulation:p. 376
+Unscrew the plug 2p. 376
+Unscrew the plug 2p. 376
(Fig. 8)p. 376
The setscrew (3) is then regulated with a screwdriverp. 376
Turning clockwise reduces the flow capacityp. 376
Turn anti-clockwise increases the flow capacityp. 376
Max. stroke of setscrew is 2.4 mm = 6 detents.p. 376
1 turn of the setscrew is 0.8 mm = 2 detentsp. 376
Tighten the plug (2) with the seal ring.p. 376
Technical data:p. 376
+Max. flow capacityp. 376
Max. flow capacityp. 376
+0.04 to 0.12 cmp. 376
3p. 376
Flow capacity regulationp. 376
6 detents per 1/2 turnp. 376
Reductionp. 376
+0.013 cmp. 376
3p. 376
Piston returnp. 376
forcedp. 376
Fig. 8p. 376
Fig. 9p. 376
Installation of pump elementp. 377
+Installation and removal only with the pump stopped.p. 377
Installation and removal only with the pump stopped.p. 377
+Assembly of the pump element with the piston (4) partly pulled out, insert upwards under a slanted angle into the housing borep. 377
(Fig. 10)p. 377
+Once the piston head touches the pressing ring – move the element to horizontal positionp. 377
(Fig. 11)p. 377
The piston head must run in the groove of the guide ring.p. 377
Tighten the pump element.p. 377
Disassemble in reverse order.p. 377
+When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 377
When disassembling the pump element make sure that the piston (4) does not remain in the pump housing.p. 377
Fig. 10p. 377
Fig. 11p. 377
17.4 Integrated electronic controlp. 378
+The control unit is equipped with a data memory which logs the following values:p. 378
The control unit is equipped with a data memory which logs the following values:p. 378
+Control typep. 378
Control typep. 378
Version of control serial numberp. 378
Manufacturing datep. 378
Type of operation (time or speed control)p. 378
Settings (setting ranges).p. 378
+Functional sequencep. 378
Functional sequencep. 378
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. 378
+Each initial connection of the control triggers a lubrication process, the green LED 2p. 378
(Fig. 12)p. 378
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. 378
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. 378
Fig. 12p. 378
+1 Push button to trigger intermediate lubricationp. 378
1 Push button to trigger intermediate lubricationp. 378
2 Green LED to indicate functionp. 378
3 Red LED to indicate faultsp. 378
Technical data:p. 378
+Supply voltagep. 378
Supply voltagep. 378
10 to 60 V DCp. 378
Current load max.p. 378
6.0 Ap. 378
Fuse (not contained in the unit)p. 378
6.3 Ap. 378
Output for signal lampp. 378
0.4 Ap. 378
Temperature rangep. 378
-35°C to +75°Cp. 378
Protection classp. 378
IP 65p. 378
+Summary of signal displaysp. 379
Modes of operationp. 379
+A) Timer controlp. 379
A) Timer controlp. 379
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. 379
Fig. 13p. 379
+B) RPM-controlp. 379
B) RPM-controlp. 379
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. 379
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. 379
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. 379
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. 379
+Summary of signal displaysp. 379
Setting parametersp. 379
The cycle or lubrication times can be set with the help of maintained-contact switches in the inspection window of the control.p. 379
Fig. 14p. 379
+For setting the time disassemble the red frame from the motor protection housing of the pump using a flat screwdriverp. 379
(Fig. 14)p. 379
The cycle or lubrication time can be set with a flat screwdriver.p. 379
+The cycle time must not be changed.p. 379
The cycle time must not be changed.p. 379
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. 379
Fig. 15p. 379
+1 Connection of system diagnosep. 379
1 Connection of system diagnosep. 379
2 Maintained-contact switch to set the lubrication timep. 379
3 Maintained-contact switch to set the cycle timep. 379
Lubrication times:p. 380
1 to 16 min. (16 contacts for 1 min. each)p. 380
2 to 32 min. (16 contacts for 2 min. each)p. 380
2 to 32 sec. (16 contacts for 2 sec. each)p. 380
Cycle times:p. 380
0.5 to 8 h (16 contacts for 0.5 h each)p. 380
2 to 32 min. (16 contacts for 2 min. each)p. 380
2 to 32 h (16 contacts for 2 h each)p. 380
Pump revolutions:p. 380
1 to 16 revolutions (16 contacts for 1 revolution each)p. 380
10 to 160 revolutions (16 contacts for 10 revolution each)p. 380
170 to 320 revolutions (16 contacts for 10 revolution each)p. 380
+Summary of signal displaysp. 380
Summary of signal displaysp. 380
+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. 380
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. 380
Fig. 1 Indication of functional readinessp. 380
+1 Red LED to indicate faultsp. 380
1 Red LED to indicate faultsp. 380
2 Green LED to indicate functionp. 380
+a) Functional readinessp. 380
a) Functional readinessp. 380
Fig. 2 Indication of functional readinessp. 380
+b) Lubrication activep. 380
b) Lubrication activep. 380
Fig. 3 Lubrication sequencep. 380
+c) Rotary speed faultp. 380
c) Rotary speed faultp. 380
Fig. 4 Rotary speed fault on pump motorp. 380
+d) Fault CPU/memoryp. 380
d) Fault CPU/memoryp. 380
Fig. 5 Fault CPU/memoryp. 380
+e) Test lubrication (permanent lubrication)p. 380
e) Test lubrication (permanent lubrication)p. 380
Fig. 6 Test lubricationp. 380
+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. 380
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. 380
+Terminal diagramp. 381
Terminal diagramp. 381
Fig. 7p. 381
+(No. …) = Cable no. for mono-colour cablep. 381
(No. …) = Cable no. for mono-colour cablep. 381
17.5 Progressive distributorp. 382
+The progressive distributor can be employed as main or a secondary distributor.p. 382
The progressive distributor can be employed as main or a secondary distributor.p. 382
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. 382
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. 382
The different displacements per piston stroke are achieved by different piston diameters.p. 382
For correct functioning a progressive distributor requires at least three pistons, i.e. at lest three pumping elements.p. 382
Technical data:p. 382
+Operating pressure at inletp. 382
Operating pressure at inletp. 382
max. 300 barp. 382
Temperature rangep. 382
-35°C to + 80°Cp. 382
Number of elementsp. 382
Min. 3 piston elements, Max. 12 piston elementsp. 382
Fig. 8 Example: 4 piston elements and 8 outletsp. 382
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. 382
+Element designationp. 382
Element designationp. 382
+Max. flow capacityp. 382
Max. flow capacityp. 382
+Pistonp. 382
Pistonp. 382
+Æp. 382
Æp. 382
+per outletp. 382
per outletp. 382
+per elementp. 382
per elementp. 382
+MX- F25p. 382
MX- F25p. 382
+25 mm3p. 382
+25 mmp. 382
3p. 382
+50 mm3p. 382
+50 mmp. 382
3p. 382
+3 mmp. 382
3 mmp. 382
+MX- F45p. 382
MX- F45p. 382
+45 mm3p. 382
+45 mmp. 382
3p. 382
+90 mm3p. 382
+90 mmp. 382
3p. 382
+4 mmp. 382
4 mmp. 382
+MX- F75p. 382
MX- F75p. 382
+75 mm3p. 382
+75 mmp. 382
3p. 382
+150 mm3p. 382
+150 mmp. 382
3p. 382
+5 mmp. 382
5 mmp. 382
+MX- F105p. 382
MX- F105p. 382
+105 mm3p. 382
+105 mmp. 382
3p. 382
+210 mm3p. 382
+210 mmp. 382
3p. 382
+6 mmp. 382
6 mmp. 382
Description of functionp. 383
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 383
+Lubricant flows into the distributor inlet port through all distributor discs to piston Ip. 383
(Fig. 1)p. 383
(Fig. 2)p. 383
+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. 383
(Fig. 3)p. 383
Then the metering pistons (II) and (III) are displaced in succession and lubricant is pressed to outlets 5 and 6.p. 383
+After the displacement of pumping piston (III) the lubricant is once again guided to the right side of the pumping pistonp. 383
(Fig. 1)p. 383
Fig. 1p. 383
Fig. 2p. 383
Fig. 3p. 383
Connection of 2 outletsp. 384
For large lubrication points it may be necessary to join two or more outlets on the progressive distributor together.p. 384
The individual discs of the progressive distributor have two outlets.p. 384
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. 384
+2 outlets per distributor elementp. 384
+2 outlets per distributor elementp. 384
(Fig. 4)p. 384
Fig. 4 2 outletsp. 384
+1 Sealing screwp. 384
1 Sealing screwp. 384
+1 outlet per distributor elementp. 384
+1 outlet per distributor elementp. 384
(Fig. 5)p. 384
Fig. 5 1 outletp. 384
+1 Plugp. 384
1 Plugp. 384
For connecting outlets, plugs are required.p. 384
Connection of several outletsp. 384
+Connection of outlets with bridging pipes without outletp. 384
Connection of outlets with bridging pipes without outletp. 384
+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. 384
(Fig. 6)p. 384
Fig. 6 Bridging pipep. 384
+3 outlets joined togetherp. 384
(Fig. 7)p. 384
+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. 384
(Fig. 7)p. 384
The metered quantity is calculated on the basis of the metering parameters for all joined piston sides.p. 384
Fig. 7 3 outletsp. 384
+1 Sealing screwp. 384
1 Sealing screwp. 384
+4 outlets joined togetherp. 384
(Fig. 8)p. 384
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. 384
Fig. 8 4 outletsp. 385
Distributor bridge without outletp. 385
+Distributor bridge without check valvep. 385
+Distributor bridge without check valvep. 385
(Fig. 9)p. 385
Fig. 9 without check valvep. 385
+Distributor bridge with integrated check valvep. 385
Distributor bridge with integrated check valvep. 385
+In order to ensure proper functioning of a progressive distributor with three delivering elements but only two outletsp. 385
(Fig. 10)p. 385
(Fig. 11)p. 385
Fig. 10p. 385
Fig. 11 with check valvep. 385
Connection of outlets with distributor bridges with outletp. 386
Fig. 12 Distributor bridge with outletp. 386
+2 outlets joined togetherp. 386
+2 outlets joined togetherp. 386
(Fig. 13)p. 386
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. 386
Fig. 13 2 outletsp. 386
+3 outlets joined togetherp. 386
+3 outlets joined togetherp. 386
(Fig. 14)p. 386
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. 386
Fig. 14 3 outletsp. 386
+4 outlets joined togetherp. 386
+4 outlets joined togetherp. 386
(Fig. 15)p. 386
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. 386
Fig. 15 4 outletsp. 386
Check valvesp. 387
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. 387
There are two versions of check valves available, on which the pipe socket is screwed in.p. 387
+Check valve for main distributorp. 387
+Check valve for main distributorp. 387
(Fig. 16)p. 387
Fig. 16p. 387
+1 Cap screwp. 387
1 Cap screwp. 387
2 Duplex ringp. 387
+Check valve for secondary distributorp. 387
+Check valve for secondary distributorp. 387
(Fig. 17)p. 387
Fig. 17p. 387
+1 Cap nut and cutting ringp. 387
1 Cap nut and cutting ringp. 387
17.6 Fault – Cause – Remedyp. 388
+Faultp. 388
Faultp. 388
+Causep. 388
Causep. 388
+Remedyp. 388
Remedyp. 388
+Pump does not workp. 388
Pump does not workp. 388
+Integrated electronic control defectivep. 388
Integrated electronic control defectivep. 388
+Replace the lower part of the motor protection housingp. 388
Replace the lower part of the motor protection housingp. 388
+Electric line interruptedp. 388
Electric line interruptedp. 388
+Replace the electric linep. 388
Replace the electric linep. 388
+Pump defectivep. 388
Pump defectivep. 388
+Replace the pumpp. 388
Replace the pumpp. 388
+Pump works, but does not deliverp. 388
Pump works, but does not deliverp. 388
+Air cushion in pumping pistonp. 388
Air cushion in pumping pistonp. 388
+Vent the pumpp. 388
Vent the pumpp. 388
+Min. filling level fallen short ofp. 388
Min. filling level fallen short ofp. 388
+Fill up the provision containerp. 388
Fill up the provision containerp. 388
+Pump element defectivep. 388
Pump element defectivep. 388
+Replace the pump elementp. 388
Replace the pump elementp. 388
+No grease collar at the lubrication pointsp. 388
No grease collar at the lubrication pointsp. 388
+Pump does not workp. 388
Pump does not workp. 388
+See "Pump does not work"p. 388
See "Pump does not work"p. 388
+Pause time too long or lubrication period too shortp. 388
Pause time too long or lubrication period too shortp. 388
+Reduce pause time or extend lubrication timep. 388
Reduce pause time or extend lubrication timep. 388
+System blockedp. 388
System blockedp. 388
+See "Grease emerging from pressure relief valve"p. 388
See "Grease emerging from pressure relief valve"p. 388
+No grease collars at various lubrication pointsp. 388
No grease collars at various lubrication pointsp. 388
+Supply line to secondary distributor burst or leakingp. 388
Supply line to secondary distributor burst or leakingp. 388
+Replace the linep. 388
Replace the linep. 388
+Screw fittings leakingp. 388
Screw fittings leakingp. 388
+Retighten or replace screw fittingp. 388
Retighten or replace screw fittingp. 388
+No grease collar on one lubrication pointp. 388
No grease collar on one lubrication pointp. 388
+Corresponding grease line burst or leakingp. 388
Corresponding grease line burst or leakingp. 388
+Replace the linep. 388
Replace the linep. 388
+Screw fitting leakingp. 388
Screw fitting leakingp. 388
+Retighten or replace screw fittingp. 388
Retighten or replace screw fittingp. 388
+Pump speed too lowp. 388
Pump speed too lowp. 388
+High system pressure or low ambient temperaturep. 388
High system pressure or low ambient temperaturep. 388
+Check system / bearing pointp. 388
Check system / bearing pointp. 388
No damage (perform 1 or 2 intermediate lubrication cycles)p. 388
+Grease emerging from pressure relief valvep. 388
Grease emerging from pressure relief valvep. 388
+System pressure too highp. 388
System pressure too highp. 388
+Check systemp. 388
Check systemp. 388
+Progressive distributor blockedp. 388
Progressive distributor blockedp. 388
+Replace the distributorp. 388
Replace the distributorp. 388
+System blockedp. 388
System blockedp. 388
+Repair blocked / seized bearing pointsp. 388
Repair blocked / seized bearing pointsp. 388
+Valve spring defectivep. 388
Valve spring defectivep. 388
+Replace the pressure relief valvep. 388
Replace the pressure relief valvep. 388
+LED-displayp. 388
LED-displayp. 388
+The LED of the control flashes or is permanently onp. 388
The LED of the control flashes or is permanently onp. 388
+See "Summary of signal displays"p. 388
See "Summary of signal displays"p. 388
+Cause for a blockage in the systemp. 388
Cause for a blockage in the systemp. 388
+A crushed or blocked lubricant linep. 388
A crushed or blocked lubricant linep. 388
A bearing overfilled with lubricant or blockedp. 388
An unsuitable lubricant for central lubrication systemsp. 388
A blocked distributor outletp. 388
A blocked distributorp. 388
Indication of a blockagep. 388
+Grease emerging from pressure relief valvep. 388
Grease emerging from pressure relief valvep. 388
Identify the location of the blockagep. 389
+All repair work must be carried out with utmost cleanliness.p. 389
All repair work must be carried out with utmost cleanliness.p. 389
Fig. 18p. 389
+1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 389
1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered properly.p. 389
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. 389
3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication point.p. 389
Fig. 19 KIT to check central lubrication systemsp. 389
Repair of a blocked distributorp. 390
+Repair of a blocked distributorp. 390
Repair of a blocked distributorp. 390
+All repair work must be carried out with utmost cleanliness.p. 390
All repair work must be carried out with utmost cleanliness.p. 390
Fig. 20 Examplep. 390
Remove the distributor from the system. .p. 390
+Note the sequence of distributor discs.p. 390
Note the sequence of distributor discs.p. 390
+Remove the draw bars 1p. 390
(Fig. 20)p. 390
Take off the distributor disc(s).p. 390
+Pistons are not exchangeable among each other .p. 390
Pistons are not exchangeable among each other .p. 390
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. 390
+Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 390
Grease getting hard indicates that the grease is not suitable for central lubrication systems.p. 390
+Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 390
Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).p. 390
Screw the plugs back in.p. 390
Check the next distributor disc, until the blocked piston is found.p. 390
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. 390
+In case of severe damage replace the distributor disc.p. 390
In case of severe damage replace the distributor disc.p. 390
+Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 390
Once all distributor discs have been checked reassemble the distributor in the recorded sequence.p. 390
To prevent jamming of the pistons tighten the draw bars with 12 Nm.p. 390
Check function of the distributor.p. 390
+18 Suppliers documentationp. 391
18 Suppliers documentationp. 391
18.1 Travel pumpp. 393
18.2 Travel pumpp. 423
18.3 Steering and working pumpp. 481
18.4 Travel motorp. 511
18.5 Scraper belt / screw motorp. 605
18.6 Scraper belt / screw motorp. 619
18.7 Steering valvep. 637
+19 Circuit diagramsp. 653
19 Circuit diagramsp. 653
2p. 654
+2p. 655
2p. 655
19.1 Hydraulic diagramp. 655
+2p. 669
2p. 669
19.2 Electric circuit diagramsp. 669
Kubota V 3307 T Diesel Engine Servicing & Governor Systems
The powertrain section provides deep diagnostic and repair coverage for the Kubota V 3307 T water-cooled, 4-cylinder turbocharged diesel engine rated at 55.4 kW (75 HP) at 2200 rpm. The text outlines the architectural characteristics of the dual crankcase design, linerless cylinder construction, semi-floating valve cover with vibration dampening seals, and the Center Direct Injection System (E-CDIS) featuring four valves per cylinder and vertically centered two-stage injection nozzles. Technicians are provided with complete maintenance procedures, including valve lash adjustment (intake and exhaust clearances specified at 0.15 ± 0.02 mm cold), injection nozzle pressure testing (Phase 1 opening at 186 bar, Phase 2 opening at 225 bar, and seat leak tightness testing at 166 bar), along with timing verification and injection pump service.
Special focus is placed on the cooling circuit’s flow-control thermostat engineered with an integrated bypass recess to eliminate temperature overshooting and water temperature hunting during variable paving loads. The manual details bench-testing the thermostat in an agitated water bath (stroke initiation at 74.5°C to 78.5°C, reaching full stroke of ~8 mm at 90°C), radiator fin cleaning, and anti-freeze formulation (50% ethylene glycol). In the fuel delivery system, the mechanical multi-function governor is broken down across all operational phases: cold starting spring enrichment, idle stabilization (900 ± 100 rpm), high idle regulation (2300 ± 50 rpm), peak torque control, and engine shut-down solenoid (Y58) dual-coil testing (pick-up winding at ~0.38 Ω and holding winding at ~16 Ω). A comprehensive engine troubleshooting table details causes and corrective actions for hard starting, irregular running, excessive exhaust smoke, low oil pressure, and overheating.
ESX Electronic Control Unit, CAN-Bus Architecture & Metrology
Modern road finishers rely heavily on digital network integration. This Bomag BF 300 P service manual details the electronic control architecture centered around the 68-pole ESX micro-controller module (MC). Technicians learn the exact separation between chassis battery ground (terminal 31) and sensitive analog sensor ground (AGND), Pulse Width Modulation (PWM) duty cycles for proportional solenoid valves, and the implementation of dither frequencies to prevent valve spool stick-slip friction. Clear wiring loom overviews detail engine harnesses, preheating circuits, hydraulic valve manifolds, operator station looms, and screed control consoles.
Crucial diagnostic methodology is outlined for the 68-pole ESX controller, including precise test protocols using dummy load lamps (12V/21W) and high-impedance multimeters to verify voltage drop limits (maximum allowable drop ≤ 0.5V) across power supply pins (Pin 28 ignition feed, Pin 54 emergency stop enable, Pin 55 ground, and output bank Pins 56 through 60). Component servicing sections guide mechanics through the repair and testing of the three-phase charging generator, electronic voltage regulator, planetary reduction starter motor (pinion wear limits, commutator minimum diameter of 31.4 mm, and brush minimum length of 11.0 mm), Telemecanique switch blocks, inductive proximity switches, and water-tight Deutsch DT/DTM plug pinning and terminal extraction.
Dashboard Input Codes, System Teaching & Calibration Routines
A standout technical feature of this Bomag 008 917 45 service manual is the complete documentation of instrument cluster input codes. Rather than requiring proprietary external dealer scan tools, the paver allows technicians to configure parameters, calibrate actuators, and interrogate faults directly via the operator display buttons:
Service Mode Activation: Accessing service parameters with code 0001 under engaged parking brake conditions.
E-Throttle Calibration: Teaching the rotary servo actuator (M39) mechanical stops and electronic stroke positions using codes 5038, 5039 (idle position verification < 500), 5040 (maximum full throttle position), and 5041 (routine termination).
Load Control System (LCS) Teaching: Calibrating maximum paving work pressure and stop pressure potentiometers using codes 3006, 3007, and 3008 in conjunction with hydraulic gauge verification.
Fault Log Management: Accessing logged fault codes (code 0700), viewing error occurrences paired with recorded operating hours (code 0705), and clearing the ESX memory log (code 0710).
System Configuration & Overrides: Enabling limp-home travel via screed relief push buttons (codes 1100 and 1121), resetting electronic control units to factory baselines (code 7010 with machine-specific profiles 7860/7861), activating/deactivating front-wheel drive assistance (codes 1101/1102), and bypassing a defective brake pedal switch (code 1104).
Engine Speed Adaptation: Harmonizing software version v0.27 with generator V-belt pulley ratios on early serial machines using code 5046.
Closed-Loop Hydrostatic Drive & Material Feed Hydraulics
The manual provides rigorous schematics and step-by-step servicing instructions for the machine’s extensive hydraulic systems. The travel circuit is powered by an axial-piston variable displacement Bosch-Rexroth A10VG45 pump (45 cm³/re, delivering up to 152 l/min at 370–390 bar operating pressure with 24–26 bar charge pressure), feeding dual Sauer Danfoss 51D variable-displacement bent-axis motors on the rear axle and SAI BD1 radial piston motors on the front wheels. Technicians are provided with complete instructions for troubleshooting axial piston swashplate mechanisms, checking charge pressure filters, testing the shiftable two-speed Officine Meccaniche spur gear transmission (3.103:1 high / 8.052:1 low), and inspecting Bondioli & Pavesi planetary wheel reduction hubs (11.908:1 ratio).
IMAGES PREVIEW
The working hydraulics are supplied by an open-loop Bosch-Rexroth A10VO28 pump (84 l/min, 145–155 bar) alongside multi-stage Haldex WP09 gear pumps. Detailed sub-sections cover the independent dual-motor scraper belt conveyors (Sauer Danfoss OMS 160 orbital motors running at 60–64 rpm), reversible material distribution augers (OMS 160 motors at 80–84 rpm), and hydraulic cylinders controlling hopper folding wings, auger height elevation, screed lift, and crown profile curving (-3% to +4.5%). Testing protocols provide specific setup procedures for checking scraper belt tension, conveyor chain slack, auger clearances, and hydraulic relief valve pressure thresholds.
S340 Screed Mechanics, Electric Heating & Automated Lubrication
Asphalt mat quality depends entirely on the condition and setup of the screed. This manual details the BOMAG S340 vibrating screed assembly (paving widths from 1.70 m to 3.40 m, expandable to 4.00 m with extensions or down to 0.75 m using reduction shoes). The guide explains drawing arm leveling cylinder geometry, mechanical angle-of-attack preset bolts, eccentric shaft vibrator drives (20–50 Hz driven by Sauer Danfoss SNM2 motors at 2650–2850 rpm), and tamper compaction bars (0–30 Hz driven by SNM2 motors at 1800–2000 rpm).
Complete repair procedures are documented for the 230V/400V three-phase screed electric heating system. Service personnel are guided through removing and installing the heavy 65 kg auxiliary heating generator, setting generator V-belt tension via dual adjusting bolts, troubleshooting the external temperature control console, and replacing high-voltage heating rods inside the main screed base plates, extendable mobile sections, tamper bars, and lateral exit flaps. In addition, Section 17 covers the automated Lincoln central lubrication system, detailing grease reservoir refilling (NLGI class 3 lithium EP grease), electronic cycle timer setup, progressive metering valve block operation, and hydraulic blockage clearance techniques.
Professional Workshop Capability & Instant PDF Delivery
Owning the Bomag BF300 P Road Finisher Service Manual 00891745 empowers fleet managers, road construction contractors, and heavy plant workshops to conduct extensive maintenance, component rebuilds, and electrical diagnostics entirely in-house. Relying on guesswork when adjusting hydraulic charge pressures, setting fuel injection timing, or rewiring complex CAN-bus nodes risks catastrophic component failure, uneven asphalt compaction, and expensive machine downtime during active paving contracts. Following BOMAG’s verified procedures, torque sequences, and diagnostic fault trees ensures your machinery operates safely, efficiently, and to exact factory specifications.
This manual is supplied as an instant, downloadable PDF document. There are no shipping wait times, customs delays, or fragile paper pages to get ruined by grease and hydraulic oil on the jobsite. Compatible with all modern operating systems— including Windows, macOS, Android, iOS, and Linux—the file can be stored on your workshop computer, loaded onto a ruggedized field tablet for on-site troubleshooting, or printed out in crisp, high-resolution pages whenever physical technical documentation is needed in the repair bay.
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