BOMAG BW 226 DH-4 BVC Single Drum Roller Service Manual
This is the full service manual for the BOMAG BW 226 DH-4 BVC single drum roller, issued under document number 008 914 20 with a December 2010 print date. It covers serial numbers 101 582 86 1001 > 101 582 86 1108. The BOMAG BW 226 DH-4 BVC Single Drum Roller Service Manual is written for the qualified technician or BOMAG after-sales personnel and describes disassembly, dismantling, assembly, installation and repair of components and assemblies, together with the test and adjustment routines that keep the machine’s hydrostatic systems and Deutz engine within specification.
File Details
Manual type: Service / repair manual
Brand: BOMAG
Model: BW 226 DH-4 BVC single drum roller
Serial number range: 101 582 86 1001 > 101 582 86 1108
Document number: 008 914 20
Edition / date: December 2010
Language: English
File format: PDF
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BW 226 DH-4 BVC Single Drum Roller Service Manual – PDF Download” are as follows:
+BW 226 DH-4p. 1
+BW 226 DH-4p. 1
BW 226 DH-4p. 1
BVCp. 1
+S/N 101 582 86 1001 > 101 582 86 1108p. 1
S/N 101 582 86 1001 > 101 582 86 1108p. 1
Single drum rollerp. 1
+1 Generalp. 9
1 Generalp. 9
+1.1 Introductionp. 10
1.1 Introductionp. 10
+This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 10
This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work.p. 10
This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts…p. 10
+Documentationp. 10
Documentationp. 10
For the BOMAG machines described in this manual the following documentation is additionally available:p. 10
+1 Operating and maintenance instructionsp. 10
1 Operating and maintenance instructionsp. 10
2 Spare parts cataloguep. 10
3 Wiring diagram*p. 10
4 Hydraulic diagram*p. 10
5 Service Informationp. 10
Use only genuine BOMAG spare parts.p. 10
Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.p. 10
These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins".p. 10
In case of a new release all necessary changes will be included.p. 10
In the course of technical development we reserve the right for technical modifications without prior notification.p. 10
Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.p. 10
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 10
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 10
BOMAG GmbHp. 10
Printed in Germanyp. 10
Copyright by BOMAGp. 10
* The applicable documents valid at the date of printing are part of this manual.p. 10
+Generalp. 11
Safety regulationsp. 11
+Important notesp. 11
Important notesp. 11
+These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 11
These safety regulations must be read and applied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be ad…p. 11
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 11
Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obv…p. 11
This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment.p. 11
+Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 11
Paragraphs marked like this contain technical information for the optimal economical use of the machine.p. 11
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 11
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 11
+Paragraphs marked like this highlight possible dangers for persons.p. 11
Paragraphs marked like this highlight possible dangers for persons.p. 11
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 11
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 11
Observe the regulations for the protection of the environment.p. 11
+Generalp. 11
Generalp. 11
+l For repair and maintenance work move the machine on a firm base and shut it down.p. 11
l For repair and maintenance work move the machine on a firm base and shut it down.p. 11
l Always secure the machine against unintended rolling.p. 11
l Secure the engine reliably against unintentional starting.p. 11
l Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard.p. 11
l Block the articulated joint with the articulation lock.p. 11
l Use protective clothes like hard hat, safety boots and gloves.p. 11
l Keep unauthorized persons away from the machine during repair work.p. 11
l Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.p. 11
l Use only safe and approved lifting gear of sufficient load bearing capacity to remove and install parts or components from and to the machine.p. 11
l Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.p. 11
l Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank.p. 11
l When performing welding work strictly comply with the respective welding instructions.p. 11
+Transport work with cranes and lifting tacklep. 11
Transport work with cranes and lifting tacklep. 11
+Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 11
Cranes must only be operated by instructed persons who had been trained in handling cranes.p. 11
+l Follow the operating instructions of the manufacturer when working with cranes.p. 11
l Follow the operating instructions of the manufacturer when working with cranes.p. 11
+l Follow the operating instructions of the operator when working with cranes.p. 11
l Follow the operating instructions of the operator when working with cranes.p. 11
l Always comply with the applicable accident prevention instructions when working with cranes and lifting tackle.p. 11
+Precautions and codes of conduct for welding workp. 11
Precautions and codes of conduct for welding workp. 11
Welding work must only be carried out by properly trained personnel.p. 11
+Electric shock!p. 11
Electric shock!p. 11
Sparks, fire hazard, burning of skin!p. 11
Infrared or ultraviolet radiation (arc), flashing of eyes!p. 11
Health hazard caused by welding work on highly alloyed work pieces, metal coatings, paint coatings, plastic coatings, oil containing dirt deposits, grease or solvent residues, etc.!p. 11
+l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 11
l Check welding equipment and cables for damage before use (also the validity of inspection stickers).p. 11
l Ensure good conductivity between ground cable and workpiece, avoid joints and bearings.p. 11
l Start the extraction fan before starting work and guide with the progressing work as required.p. 12
l Always isolate the burner when laying it down (remove possible electrode residues).p. 12
l Protect cables from being damaged, use cables with insulated couplings.p. 12
l Ensure sufficient fire protection, keep a fire extinguisher at hand.p. 12
l Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission.p. 12
l Remove any combustible materials from the welding area or cover such items appropriately.p. 12
l Name a fire watch during and after welding work.p. 12
l Place welding rod holders and inert gas welding guns only on properly insulated bases.p. 12
l Place the inert gas bottles in a safe place and secure them against falling over.p. 12
l Use a protective screen or hand shield with welding filter, wear welding gloves and clothes.p. 12
l Switch the welding unit off before connecting welding cables.p. 12
l Check electrode holders and electric cables at regular intervals.p. 12
Behaviour in case of faultsp. 12
+l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 12
l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel.p. 12
l In case of failure of the extraction system switch the system off and have it repaired by expert personnel.p. 12
Maintenance; waste disposalp. 12
+l Replace damaged insulating jaws and welding rod holders immediately.p. 12
l Replace damaged insulating jaws and welding rod holders immediately.p. 12
l Replace the welding wire reels only in de-energized state.p. 12
What to do in case of accidents; First Aidp. 12
+l Keep calm.p. 12
l Keep calm.p. 12
l Call first air helpers.p. 12
l Report the accident.p. 12
l In case of an electric accident: Interrupt the power supply and remove the injured person from the electric circuit. If breathing and heart have stopped apply reactivation measures and call for an emergency doctor.p. 12
+Old oilsp. 12
Old oilsp. 12
Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appr…p. 12
+l Wear protective clothes and safety gloves, if possible.p. 12
l Wear protective clothes and safety gloves, if possible.p. 12
l If there is a risk of eye contact you should protect your eyes appropriately, e.g. chemistry goggles or full face visor; a facility suitable for rinsing the eyes should also be available.p. 12
l Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately.p. 12
l Apply protective cream before starting work, so that oil can be easier removed from the skin.p. 12
l Wash affected skin areas with water and soap (skin cleansers and nail brushes will help). Lanolin containing agents will replace natural skin oils that were lost.p. 12
l Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin.p. 12
l Do not put oil soaked cloths into your pockets.p. 12
l Avoid clothes getting soiled by oil.p. 12
l Overalls must be washed at regular intervals. Dispose of non-washable clothes environmentally.p. 12
l If possible degrease components before handling.p. 12
+It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 12
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 12
+Hydraulicsp. 12
Hydraulicsp. 12
+l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 12
l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.p. 12
l Always make sure that all screw fittings have been tightened properly and that hoses and pipes are in mint condition before pressurizing the system again.p. 12
l Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When injured by hydraulic oil escaping under pressure consult a physician immediately, as otherwise this …p. 12
l Do not step in front of or behind the drums, wheels or crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums, wheels or crawler tracks with wedges.p. 12
Reattach all guards and safety installations after all work has been completed.p. 13
+It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 13
It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities.p. 13
+Fuelsp. 13
Fuelsp. 13
+Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 13
Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 13
Follow the valid accident prevention instructions when handling fuels.p. 13
The following notes refer to general safety precautions for danger free handling of fuel.p. 13
Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilution with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop …p. 13
+l Fire extinguishers charged with FOAM, COp. 13
+l Fire extinguishers charged with FOAM, COp. 13
2p. 13
l The vehicle battery must always be disconnected, BEFORE work in the fuel system is started. Do not disconnect the battery while working on the fuel system. Sparks could cause explosion of the fuel fumes.p. 13
l Wherever fuel is stored, filled, drained off or where work on fuel systems is carried out, all potential ignition sources must be extinguished or removed. Search lights must be fire proof and well protected against possible contact with running out…p. 13
+Hot fuelsp. 13
Hot fuelsp. 13
Please apply the following measures before draining of fuel to prepare for repair work:p. 13
+l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 13
l Allow the fuel to cool down, to prevent any contact with a hot fluid.p. 13
l Vent the system, by removing the filler cap in a well ventilated area. Screw the filler cap back on, until the tank is finally emptied.p. 13
+Synthetic rubberp. 13
Synthetic rubberp. 13
Many O-rings, hoses, etc. are made of synthetic material, a so-called fluorocarbon elastomer. Under normal operating conditions this material is safe and does not impose any danger to health.p. 13
However, if this material becomes damaged by fire or extreme heat, it may decompose and form highly caustic hydrofluoric acid, which can cause severe burns in contact with skin.p. 13
+l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use.p. 13
l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use.p. 13
l If the material has contacted the skin despite these measures, take off the soiled clothes and seek medical advice immediately. In the meantime cool and wash the affected area of skin over a sufficient time with cold water or lime water.p. 13
+Poisonous substancesp. 13
Poisonous substancesp. 13
Some of the fluids and substances used are toxic and must under no circumstances be consumed.p. 13
Skin contact, especially with open wounds, must be avoided.p. 13
These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, fuels, washing additives, refrigerants, lubricants and various bonding agents.p. 13
+Enginep. 13
Enginep. 13
+Do not work on the fuel system while the engine is running. (Danger to life!)p. 13
Do not work on the fuel system while the engine is running. (Danger to life!)p. 13
Once the engine has stopped wait approx. 5 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!)p. 13
Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!)p. 13
When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!)p. 13
+l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att…p. 13
l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att…p. 13
l Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/- 0105 Electric precautions against dangerous contact voltages).p. 13
l Cover all electric components properly before wet cleaning.p. 14
+Air conditioning systemp. 14
Air conditioning systemp. 14
+Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment.p. 14
Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment.p. 14
+l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi…p. 14
l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi…p. 14
l Perform maintenance and repair work on air conditioning systems only in well ventilated rooms! Escaping refrigerant vapours will mix with the ambient air and displace the oxygen required for breathing (danger of suffocating).p. 14
l Smoking is prohibited when performing maintenance and repair work on air conditioning systems! Toxic breakdown products may be generated if refrigerant comes into contact with heat.p. 14
l Refrigerant should always be extracted and removed by flushing with nitrogen before starting welding or soldering work near components of the air conditioning system. The development of heat may cause the refrigerant to develop toxic and highly cor…p. 14
l Pungent smell! The toxic substances, which are responsible for the pungent smell, must not be inhaled, since this may cause damage to the respiratory system, the lung and other organs. Extract toxic breakdown products with a suitable extraction sys…p. 14
l When blowing out components with compressed air and when flushing with nitrogen the gas mixture escaping from the components must be extracted via suitable extraction facilities (workshop extraction systems).p. 14
+Handling pressure vesselsp. 14
Handling pressure vesselsp. 14
+l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert…p. 14
l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert…p. 14
l Secure pressure vessels against tipping over or rolling away.p. 14
l Do not throw pressure vessels! Pressure vessels may thereby be deformed to such an extent, that they will crack. The sudden evaporation and escape of refrigerant releases excessive forces. This applies also when snapping off valves on bottles. Bott…p. 14
l Refrigerant bottles must never be placed near heating radiators. Higher temperatures will cause higher pressures, whereby the permissible pressure of the vessel may be exceeded.p. 14
l Do not heat up refrigerant bottles with an open flame. Excessive temperatures can damage the material and cause the decomposition of refrigerant.p. 14
l Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures.p. 14
+It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service.p. 14
It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service.p. 14
+Batteryp. 14
Batteryp. 14
+l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin.p. 14
l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin.p. 14
l Work only well ventilated rooms (formation of oxyhydrogen gas).p. 14
l Do not lean over the battery while it is under load, being charged or tested (danger of explosion).p. 14
l Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the batteryp. 14
l Use battery chargers etc. only in strict compliance with the operating instructions.p. 14
l After an accident with acid flush the skin with a sufficient amount of water and seek medical advice.p. 14
l Do not allow children access to batteries.p. 14
l When mixing battery fluid always pour acid into water, never vice-versa.p. 14
+Special safety regulationsp. 15
Special safety regulationsp. 15
+l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine.p. 15
l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine.p. 15
l The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explici…p. 15
l Unauthorized changes to the machine are prohibited for safety reasons.p. 15
l Do not perform any cleaning work while the engine is running.p. 15
l If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine (danger of crushing!).p. 15
l If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!).p. 15
l Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous!p. 15
l Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.p. 15
l Always ensure an adequate supply of fresh air when refuelling in closed rooms.p. 15
l Dispose of used filters in accordance with applicable environmental regulations.p. 15
l When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations.p. 15
l Do not heat up oils higher than 160 °C because they may ignite.p. 15
l Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations.p. 15
l Dispose of old batteries according to applicable environmental regulations.p. 15
l There is a danger of scalding when draining off engine or hydraulic oil at operating temperature! Allow engine and hydraulic system to cool down to a sufficient level.p. 15
l Do not exceed the max. permissible tire pressure.p. 15
+The values specified in the table apply for screws:p. 16
General repair instructionsp. 16
+Generalp. 16
Generalp. 16
+l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 16
l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly.p. 16
l Before assembling and installing parts, assemblies or components oil or grease all movable parts or surfaces as required and in compliance with the compatibility of materials.p. 16
+The values specified in the table apply for screws:p. 16
Electricsp. 16
+Generalp. 16
Generalp. 16
Due to the fast technical development electric and electronic vehicle systems become more intelligent and more comprehensive day by day, and can hardly be dispensed with in hydraulic and mechanical vehicle systems.p. 16
Diagnostics according to planp. 16
Well structured trouble shooting procedures can save time and money.p. 16
Random tests have revealed that purely electronic components or control units only very rarely are the actual cause of failures:p. 16
+l In approx. 10 % of the examined cases the problems were caused by control units.p. 16
l In approx. 10 % of the examined cases the problems were caused by control units.p. 16
l In approx. 15 % sensors and actuators were the cause of the problems.p. 16
By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.).p. 16
General:p. 16
+l Before changing any expensive components, such as control units, you should run a systematic trouble shooting session to eliminate any other possible fault sources. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed…p. 16
l Before changing any expensive components, such as control units, you should run a systematic trouble shooting session to eliminate any other possible fault sources. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed…p. 16
l Check for good cable and ground contacts, therefore keep all mechanical transition points between electric conductors (terminals, plugs) free of oxide and dirt, as far as this is possible.p. 16
l Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately.p. 16
l Do not disconnect or connect battery or generator while the engine is running.p. 16
l Do not operate the main battery switch under load.p. 16
l Do not use jump leads after the battery has been removed.p. 16
l Sensors and electric actuators on control units must never be connected individually or between external power sources for the purpose of testing, but only in connection with the control unit in question.p. 16
l It is not permitted to pull plugs off while the voltage supply is switched on (terminal 15 "ON")! Switch the voltage supply "OFF" first and pull out the plug.p. 16
l Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!p. 16
l Plug-in connectors on control units are only dust and water tight if the mating connector is plugged on! Control units must be protected against spray water, until the mating connector is finally plugged on!p. 17
l Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions.p. 17
l Do not use any radio equipment or mobile phones in the vehicle cab without a proper aerial or in the vicinity of the control electronics!p. 17
+Electrics and weldingp. 17
Electrics and weldingp. 17
+Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o…p. 17
Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o…p. 17
+l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 17
l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch.p. 17
l Isolate the generator and all control units from the electric circuit.p. 17
l Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.p. 17
l When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings.p. 17
+The values specified in the table apply for screws:p. 17
Batteryp. 17
Rules for the handling of batteriesp. 17
When removing a battery always disconnect the minus pole before the plus pole. When installing the battery connect the minus pole after the plus pole to avoid short circuits.p. 17
Fasten the terminal clamps with a little force as possible.p. 17
Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related development of heat.p. 17
Make sure the battery is properly fastened in the vehicle.p. 17
+The values specified in the table apply for screws:p. 18
Generatorp. 18
Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off. Do not disconnect the generator while the engine is running, because this may cause extremely high voltage peaks…p. 18
When disassembling the battery cable, the B+-nut underneath on the generator side may also be loosened. This nut must in this case be retightened.p. 18
When connecting e.g. the battery cable to the terminal of the generator you must make sure that the polarity is correct (generator B+ to the + pole of the battery). Mixing up the polarities by mistake causes short circuit and damage to the rectifier …p. 18
The generator can only be operated with the battery connected. Under special conditions emergency operation without battery is permitted, the lifetime of the generator is in such cases especially limited.p. 18
Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle.p. 18
When cleaning the generator with a steam or water jet make sure not to direct the steam or water jet directly on or into the generator openings or ball bearings. After cleaning the generator should be operated for about 1 – 2 minutes to remove any de…p. 18
+The values specified in the table apply for screws:p. 18
Starter motorp. 18
So-called jump starting (using an additional external battery) without the battery connected is dangerous. When disconnecting the cables from the poles high inductivities (arcs, voltage peaks) may occur and destroy the electrical installation.p. 18
For purposes like e.g. purging the fuel systems, starters may be operated for maximum 1 minute without interruption. Then you should wait for at least 30 minutes (cooling down) until trying again. During the 1 minute starting period this process shou…p. 18
Starter motors must not be cleaned with high pressure steam cleaning equipment.p. 18
The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection).p. 18
When replacing the starter the ring gear on the engine flywheel must be checked for damage and its number of teeth – if necessary replace the ring gear.p. 18
Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.p. 18
+The values specified in the table apply for screws:p. 19
Hydraulic systemp. 19
+Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 19
Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG.p. 19
+Please notep. 19
Please notep. 19
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 19
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 19
+l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 19
l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal.p. 19
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 19
l During repair work keep all openings closed with clean plastic plugs and caps.p. 19
l Never run pumps, motors and engines without oil or hydraulic oil.p. 19
l When cleaning hydraulic components take care not to damage any fine machine surfaces.p. 19
l Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not let such substances come in contact with rubber parts.p. 19
l Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.p. 19
l Avoid the formation of rust on fine machined caused by hand sweat.p. 19
l Use new O-rings or seal rings for reassembly.p. 19
l Use only hydraulic oil as sliding agent when reassembling. Do not use any grease!p. 19
l Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.p. 19
l Check the hydraulic oil level before and after the work.p. 19
l Fill in only clean oil as specified in the maintenance instructions.p. 19
l Check the hydraulic system for leaks, if necessary find and rectify the cause.p. 19
l Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions.p. 19
l After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system.p. 19
l Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).p. 19
l After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.p. 19
l The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. On hard ground place the drums on a suitable base and check the drum pressure. Do not activate the vibration on a hard, concreted base, dang…p. 19
l After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized.p. 19
+Before commissioningp. 19
Before commissioningp. 19
+l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions.p. 19
l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions.p. 19
l After changing a component flush the hydraulic system as described in the flushing instructions.p. 19
+Taking into operationp. 19
Taking into operationp. 19
+l Bleed the hydraulic circuits.p. 19
l Bleed the hydraulic circuits.p. 19
l Start up the hydraulic system without load.p. 19
l Check the hydraulic oil level in the tank, if necessary top up with hydraulic oil as specified in the operating and maintenance instructions or drain oil off into a suitable container.p. 19
+After taking into operationp. 19
After taking into operationp. 19
+l Check fittings and flanges for leaks.p. 19
l Check fittings and flanges for leaks.p. 19
l After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary.p. 19
l Do not adjust pressure relief valves and control valves to values above their specified values.p. 19
+The values specified in the table apply for screws:p. 20
Air conditioning systemp. 20
+Chemicals/ozone layer regulationp. 20
Chemicals/ozone layer regulationp. 20
The chemicals/ozone layer regulation, which became effective on 01.12.2006, supplements the still directly applicable regulation (EG) no. 2037/2000 from 29.06.2000 concerning substances, which cause decomposition of the ozone layer and at the same ti…p. 20
Work on air conditioning systems must only be carried out by persons who:p. 20
+l have proven to have sufficient expert knowledge,p. 20
l have proven to have sufficient expert knowledge,p. 20
l have the necessary equipment to undertake such tasks,p. 20
l are reliable andp. 20
l are not any directives regarding their activities when carrying out inspection and maintenance work acc. to § 4 section 2 of the chemical/ozone layer regulation.p. 20
The inspection and maintenance tasks, including leak tests and possible repair activities, must be recorded in the operating instructions together with information about the refrigerant quantities used and regained, whereby the operator is obliged to…p. 20
+Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 20
Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system.p. 20
+l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 20
l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections.p. 20
l During repairs on refrigerant lines and components, these must be kept closed, as far as this is possible, to prevent the system from being contaminated by air, moisture and dirt. The operational safety of the system can only be assured as long as …p. 20
l Connections, screw fittings and their immediate surrounding areas must be cleaned before removal.p. 20
l Before loosening hoses, pipe lines etc. relieve all pressure from the system.p. 20
l During repair work keep all openings closed with clean plastic plugs and caps.p. 20
l All parts to be reused should be cleaned with a gasoline free solvent and blow-dried with clean compressed air or dried with a lint-free cloth.p. 20
l Before opening all components should have warmed up to ambient temperature, to avoid that damp air is drawn into the component by the difference in temperatures.p. 20
l Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but must generally be replaced.p. 20
l Do not fill up refrigerant, but extract existing refrigerant and refill the system.p. 20
l Different types of refrigerant must not be mixed. Only the refrigerant specified for the corresponding air conditioning system must be used.p. 20
l Refrigerant circuits with refrigerant type R134a must only be operated with the compressor oil / refrigeration oil approved for the compressor.p. 20
l Used compressor oil/refrigeration oil must be disposed of in strict compliance with applicable environmental regulations.p. 20
l Due to its chemical properties compressor oil / refrigeration oil must never be disposed of together with engine or transmission oil.p. 20
l Compressor oil / refrigeration oil is highly hydroscopic. Oil cans must strictly be kept closed until use. Oil rests should not be used, if the can had been opened over a longer period of time.p. 20
l All O-rings/seal rings as well as pipe/ hose fittings must be oiled with compressor/refrigeration oil bfore assembly.p. 20
l When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil/refrigeration oil lost by exchanging the components, must be replaced with fresh oil.p. 20
l A too high compressor oil / refrigeration oil level adversely affects the cooling performance and a too low oil level has a negative effect on the lifetime of the compressor.p. 20
l Use new O-rings or seal rings for reassembly.p. 20
l Always used 2 spanners to work on pipes/hoses to avoid damages .p. 20
l Tighten screw fittings with the specified torque.p. 20
l Check all pipes/hoses, screw fittings or components for damage, replace if necessary.p. 20
l Do not leave the refrigerant circuit unnecessarily open to the atmosphere.p. 20
l In case of a repair on the refrigeration system you should first evacuate the air conditioning system for at least 45 minutes to remove any moisture from the system, before you start to refill. Moisture bonded in the compressor oil / refrigeration …p. 20
l Compressor valves must only be opened after the system has been properly sealed.p. 20
l The use of leak detection spray is not permitted. If such substances are used the WARRANTY will become null and void.p. 20
l If the air conditioning system had been opened for repair work, a new drier should be installed in the refrigerant circuit.p. 21
l After completion of repair work screw locking caps (with seals) on all valve connections service connections.p. 21
l Before start up of the air conditioning system after a new filling: – Turn the compressor approx. 10 revolutions by hand using the clutch or V-belt pulley of the magnetic clutch. – Start the engine with the compressor/control valve switched off. – …p. 21
l Never run the compressor with an insufficient amount of refrigerant.p. 21
+The values specified in the table apply for screws:p. 21
Notes on cleanliness for Common Rail enginesp. 21
Special requirements with respect to cleanliness in the fuel system do apply for commissioning, maintenance and repair work, particularly for TEIRIII engines with the DEUTZ Common Rail System. Contamination like dirt, welding residues or similar can …p. 21
Fig. 1p. 21
+l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 21
l Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.p. 21
+l When parts are unpacked any connections must be closed with suitable plugs or caps, in order to preventp. 21
(Fig. 1)p. 21
+Notes and measures to be applied before starting work in the fuel systemp. 21
Notes and measures to be applied before starting work in the fuel systemp. 21
+l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 21
l The fuel system must be closed. Visual examination for leaks / damage in the fuel system.p. 21
l Before starting work in the fuel system clean the complete engine and the engine compartment with the system still closed.p. 21
l The engine should be dry before work is started in the fuel system.p. 21
l Blow drying with compressed air is only permitted while the fuel system is still closed.p. 22
l When using steam cleaning equipment cover control unit, cable plugs, all other electrical connections and the generator beforehand and do not expose these items to the direct steam jet.p. 22
l Electrical plug connections must be plugged in during jet cleaning.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 22
l Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 22
l Perform work on the fuel system only in a clean environment (no dust, no grinding or welding work). Avoid draughts (dust). The workshop floor must be cleaned at regular intervals. No brake or power test stand should be present or operated in the sa…p. 22
l Air movements, which could swirl up dust, such as brake repairs or starting of engines, must be strictly avoided.p. 22
l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l No general machine tools should be operated in this room.p. 22
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 22
l Engine compartment area where dirt particles could come loose, should be covered with new, clean foil.p. 22
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 22
+Notes and measures to be applied during work in the fuel systemp. 22
Notes and measures to be applied during work in the fuel systemp. 22
+l Wear clean working clothes.p. 22
l Wear clean working clothes.p. 22
l Use only lint-free cleaning cloths for work in the fuel system.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction. Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.p. 22
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 22
l Do not use any previously used cleaning or testing fluids for cleaning.p. 22
l Compressed air should never be used for cleaning when the fuel system is open.p. 22
l Work on disassembled components must only be carried out at a specially furnished work place.p. 22
l When disassembling or assembling components you should not use any materials from which particles or fibres could flake off (cardboard, wood, towels).p. 22
l Dismantled parts must only be wiped off with clean, lint-free cloths if required. No dirt particles must be wiped into the components.p. 22
l Close openings on components and engine immediately with suitable plugs/caps.p. 22
l Plugs/caps must only be removed just before the installation.p. 22
l Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use.p. 22
l Take new parts out of their original packaging just before installation.p. 22
l Disassembled components must be stored in new, sealable bags or – if available – in the packaging material of the new components.p. 22
l Always use the original packaging material of the new part to return the disassembled old component.p. 22
+Notes and measures concerning the workshop areap. 22
Notes and measures concerning the workshop areap. 22
+l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle r…p. 22
l The workshop floor must be sealed or tiled.p. 22
l No welding equipment, grinding machines, general machine tools, brake or power test benches must be operated in this room.p. 22
l Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.p. 22
+Notes and measures for work place and tools in the workshopp. 22
Notes and measures for work place and tools in the workshopp. 22
+l A special work place must be set up for work on disassembled components.p. 22
l A special work place must be set up for work on disassembled components.p. 22
l Clean disassembly and assembly tools at regular intervals and keep these in a closed tool cabinet.p. 22
l Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.p. 23
l Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.p. 23
+The values specified in the table apply for screws:p. 23
Fuel hosesp. 23
Fig. 2p. 23
+All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 23
All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay…p. 23
+The values specified in the table apply for screws:p. 24
Gaskets and mating surfacesp. 24
Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets.p. 24
+l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 24
l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage.p. 24
l Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.p. 24
l Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions.p. 24
l If necessary remove any old sealing compound before assembling. For this purpose do not use any tools that could damage the sealing surfaces.p. 24
l Sealing compound must be applied thin and evenly on the corresponding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores.p. 24
l Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone; take care that no grinding dust and dirt enters into tapped bores or enclosed components.p. 24
l Blow out lines, ducts and gaps with compressed air, replace any O-rings and seals that have been dislodged by the compressed air.p. 24
Assembly of radial sealsp. 24
Fig. 3p. 24
+l Lubricate the sealing lips (2)p. 24
+l Lubricate the sealing lips (2)p. 24
(Fig. 3)p. 24
l Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.p. 24
+If possible, use an assembly sleeve (1p. 24
+If possible, use an assembly sleeve (1p. 24
(Fig. 3)p. 24
to protect the lip from being damaged by sharp edges, threads or splines.p. 24
+l Lubricate the outer rim (arrow 3p. 24
+l Lubricate the outer rim (arrow 3p. 24
(Fig. 3)p. 24
Fig. 4p. 24
+l Press or knock the seal into the housing, until it is flush with the housing surface.p. 24
l Press or knock the seal into the housing, until it is flush with the housing surface.p. 24
+If possible, use a "bell" (1p. 24
+If possible, use a "bell" (1p. 24
(Fig. 4)p. 24
that the seal will not skew.p. 24
If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0,4 mm smaller than the outer diameter of the seal. Use VERY LIGHT blows with the hammer if no press is available.p. 24
+The values specified in the table apply for screws:p. 25
Feather keys and keywaysp. 25
+Feather keys may only be reused if they are free of damage.p. 25
Feather keys may only be reused if they are free of damage.p. 25
Fig. 5p. 25
+l Clean and thoroughly examine the feather key.p. 25
l Clean and thoroughly examine the feather key.p. 25
l Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling.p. 25
+The values specified in the table apply for screws:p. 25
Ball and roller bearingsp. 25
+Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 25
Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear.p. 25
Fig. 6p. 25
+l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 25
l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced.p. 25
l Remove any lubricant residues from the ball or roller bearing to be examined by washing it with gasoline or any other appropriate degreasing agent. Ensure strict cleanliness.p. 25
l Check balls or rollers, running surfaces, outer faces of outer races and inner faces of inner races for visible damage. Replace the ball or roller bearing if necessary.p. 25
l Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary.p. 25
l Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly.p. 25
l On greased bearings (e.g. wheel bearings) fill the space between ball or roller bearing and outer seal with the recommended type of grease before assembling the seal.p. 25
l Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats.p. 26
l Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing.p. 26
l Always mark the individual parts of separable ball or roller bearings (e.g. taper roller bearings) to enable correct reassembling. Never assemble the rollers to an outer race that has already been used, replace the complete ball or roller bearing i…p. 26
Fig. 7p. 26
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 26
+When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1p. 26
(Fig. 7)p. 26
When fitting the bearing into the housing load must only be applied to the outer race (2).p. 26
+The values specified in the table apply for screws:p. 26
Screws and nutsp. 26
Tightening torquep. 26
+Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 26
Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.p. 26
Damaged screws must under no circumstances be used any longer. Recutting threads with thread cutters or taps adversely affects the strength and leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque value rea…p. 26
Self-locking nuts must generally be replaced after disassembly.p. 26
The use of screws with too high strength can cause damage!p. 26
+l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 26
l Nut of a higher strength can generally be used instead of nuts of a lower strength classification.p. 26
l When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque.p. 26
+l Before tightening you should lightly oil the thread, in order to ensure low friction movement.p. 26
The same applies for self-locking nuts.p. 26
l Make sure that no oil or grease will enter into blind tapped bores. The hydraulic power generated when turning in the screw could cause breakage of the effected part.p. 26
Strength classes, metric screwsp. 27
The strength classes (from 3.6 to 12.9) are specified for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw.p. 27
Fig. 8 Identification of screwsp. 27
Example: A screw is identified with 12.9.p. 27
+The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mmp. 27
2p. 27
+l The nominal tensile strength is 12 X 100 N/mmp. 27
+l The nominal tensile strength is 12 X 100 N/mmp. 27
2p. 27
2p. 27
The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio).p. 27
+When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 27
When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation).p. 27
When exceeding the upper yield point the material will not restore its original shape after being relieved.p. 27
+l The lower tensile strength is 9/10 X 1200 N/mmp. 27
+l The lower tensile strength is 9/10 X 1200 N/mmp. 27
2p. 27
2p. 27
+However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together.p. 27
However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together.p. 27
Strength classes of metric nutsp. 27
Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified.p. 27
Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12)p. 27
Fig. 9 Identification of nutsp. 27
+In a connection with a screw, these nuts 1p. 27
(Fig. 9)p. 27
Nut height above 0.8 d (d = nominal dimension).p. 27
+Strength class of nutp. 27
Strength class of nutp. 27
+Strength class of associated screwp. 27
Strength class of associated screwp. 27
+4p. 27
4p. 27
+3.6, 4.6, 4.8p. 27
3.6, 4.6, 4.8p. 27
+5p. 27
5p. 27
+3.6, 4.6, 4.8p. 27
3.6, 4.6, 4.8p. 27
5.6, 5.8p. 27
+6p. 27
6p. 27
+6.8p. 27
6.8p. 27
+8p. 27
8p. 27
+8.8p. 27
8.8p. 27
+9p. 27
9p. 27
+9.8p. 27
9.8p. 27
+10p. 27
10p. 27
+10.8p. 27
10.8p. 27
+12p. 27
12p. 27
+12.8p. 27
12.8p. 27
Nuts for screw joints with limited load factor (04, 05)p. 27
+The preceding "0" indicates that, due to their low height, nuts 2p. 27
(Fig. 9)p. 27
Nut height below 0,8 d (d = nominal dimension).p. 27
Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H)p. 27
+This standard contains strength classes (hardness classes) for nuts 3p. 27
(Fig. 9)p. 27
Nut height below 0,5 d (d = nominal dimension).p. 27
Identification in clock systemp. 28
Fig. 10 Identification of nuts in clock systemp. 28
+For small nutsp. 28
(Fig. 10)p. 28
+l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 28
l The 12 o'clock position is identified by a dot or the manufacturer's symbol.p. 28
l The strength class is identified by a dash (b).p. 28
Identification of UNF-threadsp. 28
Fig. 11p. 28
Screwsp. 28
+The screw head is marked with a stamped in, round cavity 3p. 28
(Fig. 11)p. 28
Nutsp. 28
An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2).p. 28
Studs and brake rodsp. 28
At the outmost end a short end of the component is reduced to its core diameter (1).p. 28
Cotter pinsp. 29
Fig. 12p. 29
In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly.p. 29
Cotter pins must be assembled as shown in the illustration, unless specified differently.p. 29
+The values specified in the table apply for screws:p. 30
Tightening torquesp. 30
+The values specified in the table apply for screws:p. 30
The values specified in the table apply for screws:p. 30
+l black oiledp. 30
l black oiledp. 30
l with surface protection A4Cp. 30
l with surface protection DACROMETp. 30
+DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 30
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 30
+Tightening torques for screws with metric unified threadp. 30
+Tightening torques for screws with metric unified threadp. 30
+Tightening torques for screws with metric unified threadp. 30
+Coefficient of friction m tot. = 0,14p. 30
mp. 30
+Screw dimensionp. 30
Screw dimensionp. 30
+Tightening torques Nmp. 30
Tightening torques Nmp. 30
+8.8p. 30
8.8p. 30
+10.9p. 30
10.9p. 30
+12.9p. 30
12.9p. 30
+M4p. 30
M4p. 30
+3p. 30
3p. 30
+5p. 30
5p. 30
+5p. 30
5p. 30
+M5p. 30
M5p. 30
+6p. 30
6p. 30
+9p. 30
9p. 30
+10p. 30
10p. 30
+M6p. 30
M6p. 30
+10p. 30
10p. 30
+15p. 30
15p. 30
+18p. 30
18p. 30
+M8p. 30
M8p. 30
+25p. 30
25p. 30
+35p. 30
35p. 30
+45p. 30
45p. 30
+M10p. 30
M10p. 30
+50p. 30
50p. 30
+75p. 30
75p. 30
+83p. 30
83p. 30
+M12p. 30
M12p. 30
+88p. 30
88p. 30
+123p. 30
123p. 30
+147p. 30
147p. 30
+M14p. 30
M14p. 30
+137p. 30
137p. 30
+196p. 30
196p. 30
+235p. 30
235p. 30
+M16p. 30
M16p. 30
+211p. 30
211p. 30
+300p. 30
300p. 30
+358p. 30
358p. 30
+M18p. 30
M18p. 30
+290p. 30
290p. 30
+412p. 30
412p. 30
+490p. 30
490p. 30
+M20p. 30
M20p. 30
+412p. 30
412p. 30
+578p. 30
578p. 30
+696p. 30
696p. 30
+M22p. 30
M22p. 30
+560p. 30
560p. 30
+785p. 30
785p. 30
+942p. 30
942p. 30
+M24p. 30
M24p. 30
+711p. 30
711p. 30
+1000p. 30
1000p. 30
+1200p. 30
1200p. 30
+M27p. 30
M27p. 30
+1050p. 30
1050p. 30
+1480p. 30
1480p. 30
+1774p. 30
1774p. 30
+M30p. 30
M30p. 30
+1420p. 30
1420p. 30
+2010p. 30
2010p. 30
+2400p. 30
2400p. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Tightening torques for screws with metric unified fine threadp. 30
+Coefficient of friction m tot. = 0,14p. 30
mp. 30
+Screw dimensionp. 30
Screw dimensionp. 30
+Tightening torques Nmp. 30
Tightening torques Nmp. 30
+8.8p. 30
8.8p. 30
+10.9p. 30
10.9p. 30
+12.9p. 30
12.9p. 30
+M8 x 1p. 30
M8 x 1p. 30
+26p. 30
26p. 30
+37p. 30
37p. 30
+48p. 30
48p. 30
+M10 x 1.25p. 30
M10 x 1.25p. 30
+52p. 30
52p. 30
+76p. 30
76p. 30
+88p. 30
88p. 30
+M12 x 1,25p. 30
M12 x 1,25p. 30
+98p. 30
98p. 30
+137p. 30
137p. 30
+126p. 30
126p. 30
+M12 x 1.5p. 30
M12 x 1.5p. 30
+93p. 30
93p. 30
+127p. 30
127p. 30
+152p. 30
152p. 30
+M14 x 1.5p. 30
M14 x 1.5p. 30
+152p. 30
152p. 30
+216p. 30
216p. 30
+255p. 30
255p. 30
+M16 x 1.5p. 30
M16 x 1.5p. 30
+225p. 30
225p. 30
+318p. 30
318p. 30
+383p. 30
383p. 30
+M18 x 1.5p. 30
M18 x 1.5p. 30
+324p. 30
324p. 30
+466p. 30
466p. 30
+554p. 30
554p. 30
+M20 x 1.5p. 30
M20 x 1.5p. 30
+461p. 30
461p. 30
+628p. 30
628p. 30
+775p. 30
775p. 30
+M22 x 1.5p. 30
M22 x 1.5p. 30
+618p. 30
618p. 30
+863p. 30
863p. 30
+1058p. 30
1058p. 30
+M24 x 2p. 30
M24 x 2p. 30
+780p. 30
780p. 30
+1098p. 30
1098p. 30
+1294p. 30
1294p. 30
+M27 x2p. 30
M27 x2p. 30
+1147p. 30
1147p. 30
+1578p. 30
1578p. 30
+1920p. 30
1920p. 30
+M30 x 2p. 30
M30 x 2p. 30
+1568p. 30
1568p. 30
+2254p. 30
2254p. 30
+2695p. 30
2695p. 30
+Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)p. 31
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 31
+Tightening torques for screws treated with anti-seizure paste OKS 240p. 31
Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive effects. Prevents seizure and corrosion.p. 31
+Screw dimensionp. 31
Screw dimensionp. 31
+Tightening torques Nmp. 31
Tightening torques Nmp. 31
+8.8p. 31
8.8p. 31
+10.9p. 31
10.9p. 31
+12.9p. 31
12.9p. 31
+M16p. 31
M16p. 31
+169p. 31
169p. 31
+240p. 31
240p. 31
+287p. 31
287p. 31
+M16 x 1.5p. 31
M16 x 1.5p. 31
+180p. 31
180p. 31
+255p. 31
255p. 31
+307p. 31
307p. 31
+M18p. 31
M18p. 31
+232p. 31
232p. 31
+330p. 31
330p. 31
+392p. 31
392p. 31
+M18 x 1.5p. 31
M18 x 1.5p. 31
+260p. 31
260p. 31
+373p. 31
373p. 31
+444p. 31
444p. 31
+M20p. 31
M20p. 31
+330p. 31
330p. 31
+463p. 31
463p. 31
+557p. 31
557p. 31
+M20 x 1.5p. 31
M20 x 1.5p. 31
+369p. 31
369p. 31
+502p. 31
502p. 31
+620p. 31
620p. 31
+M22p. 31
M22p. 31
+448p. 31
448p. 31
+628p. 31
628p. 31
+754p. 31
754p. 31
+M22 x 1.5p. 31
M22 x 1.5p. 31
+495p. 31
495p. 31
+691p. 31
691p. 31
+847p. 31
847p. 31
+M24p. 31
M24p. 31
+569p. 31
569p. 31
+800p. 31
800p. 31
+960p. 31
960p. 31
+M24 x 2p. 31
M24 x 2p. 31
+624p. 31
624p. 31
+879p. 31
879p. 31
+1036p. 31
1036p. 31
+M27p. 31
M27p. 31
+840p. 31
840p. 31
+1184p. 31
1184p. 31
+1520p. 31
1520p. 31
+M27 X 2p. 31
M27 X 2p. 31
+918p. 31
918p. 31
+1263p. 31
1263p. 31
+1536p. 31
1536p. 31
+M30p. 31
M30p. 31
+1136p. 31
1136p. 31
+1608p. 31
1608p. 31
+1920p. 31
1920p. 31
+M30 x 2p. 31
M30 x 2p. 31
+1255p. 31
1255p. 31
+1804p. 31
1804p. 31
+2156p. 31
2156p. 31
+3/4“ – 10 UNCp. 31
3/4“ – 10 UNCp. 31
+276p. 31
276p. 31
+388p. 31
388p. 31
+464p. 31
464p. 31
+3/4“ – 16 UNCp. 31
3/4“ – 16 UNCp. 31
+308p. 31
308p. 31
+432p. 31
432p. 31
+520p. 31
520p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Tightening torques for wheel nuts (fine thread)p. 31
+Coefficient of friction m tot. = 0,14p. 31
mp. 31
These values result in a 90% utilization of the yield pointp. 31
+Thread diameterp. 31
Thread diameterp. 31
+Tightening torques Nmp. 31
Tightening torques Nmp. 31
+10.9p. 31
10.9p. 31
+M12x1.5p. 31
M12x1.5p. 31
+100p. 31
100p. 31
+M14x1.5p. 31
M14x1.5p. 31
+150p. 31
150p. 31
+M18x1.5p. 31
M18x1.5p. 31
+300 – 350p. 31
300 – 350p. 31
+M20x1.5p. 31
M20x1.5p. 31
+400 – 500p. 31
400 – 500p. 31
+M22x1.5p. 31
M22x1.5p. 31
+500 – 600p. 31
500 – 600p. 31
The values specified in the table apply for screws:p. 32
+l black oiledp. 32
l black oiledp. 32
l with surface protection A4Cp. 32
l with surface protection DACROMETp. 32
+The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.p. 32
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.p. 32
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.p. 32
+Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 32
+Tightening torques for screws with UNC thread,p. 32
+Tightening torques for screws with UNC thread,p. 32
+Coefficient of friction m tot. = 0,14p. 32
mp. 32
UNC Unified Coarse Thread Series, American Unified Coarse Threadp. 32
+Screw dimensionp. 32
Screw dimensionp. 32
+Tightening torques Nmp. 32
Tightening torques Nmp. 32
+8.8p. 32
8.8p. 32
+10.9p. 32
10.9p. 32
+12.9p. 32
12.9p. 32
+1/4“ – 20p. 32
1/4“ – 20p. 32
+11p. 32
11p. 32
+15p. 32
15p. 32
+19p. 32
19p. 32
+5/16“ – 18p. 32
5/16“ – 18p. 32
+23p. 32
23p. 32
+32p. 32
32p. 32
+39p. 32
39p. 32
+3/8“ – 16p. 32
3/8“ – 16p. 32
+39p. 32
39p. 32
+55p. 32
55p. 32
+66p. 32
66p. 32
+7/16“ – 14p. 32
7/16“ – 14p. 32
+62p. 32
62p. 32
+87p. 32
87p. 32
+105p. 32
105p. 32
+1/2“ – 13p. 32
1/2“ – 13p. 32
+96p. 32
96p. 32
+135p. 32
135p. 32
+160p. 32
160p. 32
+9/16“ – 12p. 32
9/16“ – 12p. 32
+140p. 32
140p. 32
+200p. 32
200p. 32
+235p. 32
235p. 32
+5/8“ – 11p. 32
5/8“ – 11p. 32
+195p. 32
195p. 32
+275p. 32
275p. 32
+330p. 32
330p. 32
+3/4“ – 10p. 32
3/4“ – 10p. 32
+345p. 32
345p. 32
+485p. 32
485p. 32
+580p. 32
580p. 32
+7/8“ – 9p. 32
7/8“ – 9p. 32
+560p. 32
560p. 32
+770p. 32
770p. 32
+940p. 32
940p. 32
+1“ – 8p. 32
1“ – 8p. 32
+850p. 32
850p. 32
+1200p. 32
1200p. 32
+1450p. 32
1450p. 32
+1 1/8“ – 7p. 32
1 1/8“ – 7p. 32
+1200p. 32
1200p. 32
+1700p. 32
1700p. 32
+2000p. 32
2000p. 32
+1 1/4“ – 7p. 32
1 1/4“ – 7p. 32
+1700p. 32
1700p. 32
+2400p. 32
2400p. 32
+2900p. 32
2900p. 32
+1 3/8“ – 6p. 32
1 3/8“ – 6p. 32
+2200p. 32
2200p. 32
+3100p. 32
3100p. 32
+3700p. 32
3700p. 32
+1 1/2“ – 6p. 32
1 1/2“ – 6p. 32
+3000p. 32
3000p. 32
+4200p. 32
4200p. 32
+5100p. 32
5100p. 32
+Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Threadp. 32
+Tightening torques for screws with UNF thread,p. 32
+Tightening torques for screws with UNF thread,p. 32
+Coefficient of friction m tot. = 0,14p. 33
mp. 33
UNF Unified National Fine Thread Series, American Unified Fine Threadp. 32
+Screw dimensionp. 32
Screw dimensionp. 32
+Tightening torques Nmp. 32
Tightening torques Nmp. 32
+8.8p. 32
8.8p. 32
+10.9p. 32
10.9p. 32
+12.9p. 32
12.9p. 32
+1/4“ – 28p. 32
1/4“ – 28p. 32
+13p. 32
13p. 32
+18p. 32
18p. 32
+22p. 32
22p. 32
+5/16“ – 24p. 32
5/16“ – 24p. 32
+25p. 32
25p. 32
+35p. 32
35p. 32
+42p. 32
42p. 32
+3/8“ – 24p. 32
3/8“ – 24p. 32
+45p. 32
45p. 32
+63p. 32
63p. 32
+76p. 32
76p. 32
+7/16“ – 20p. 32
7/16“ – 20p. 32
+70p. 32
70p. 32
+100p. 32
100p. 32
+120p. 32
120p. 32
+1/2“ – 20p. 32
1/2“ – 20p. 32
+110p. 32
110p. 32
+155p. 32
155p. 32
+185p. 32
185p. 32
+9/16“ – 18p. 32
9/16“ – 18p. 32
+155p. 32
155p. 32
+220p. 32
220p. 32
+260p. 32
260p. 32
+5/8“ – 18p. 32
5/8“ – 18p. 32
+220p. 32
220p. 32
+310p. 32
310p. 32
+370p. 32
370p. 32
+3/4“ – 16p. 32
3/4“ – 16p. 32
+385p. 32
385p. 32
+540p. 32
540p. 32
+650p. 32
650p. 32
+7/8“ -14p. 32
7/8“ -14p. 32
+620p. 32
620p. 32
+870p. 32
870p. 32
+1050p. 32
1050p. 32
+1“ – 12p. 33
1“ – 12p. 33
+930p. 33
930p. 33
+1300p. 33
1300p. 33
+1600p. 33
1600p. 33
+1 1/8“ – 12p. 33
1 1/8“ – 12p. 33
+1350p. 33
1350p. 33
+1900p. 33
1900p. 33
+2300p. 33
2300p. 33
+1 1/4“ – 12p. 33
1 1/4“ – 12p. 33
+1900p. 33
1900p. 33
+2700p. 33
2700p. 33
+3200p. 33
3200p. 33
+1 3/8“ – 12p. 33
1 3/8“ – 12p. 33
+2600p. 33
2600p. 33
+3700p. 33
3700p. 33
+4400p. 33
4400p. 33
+1 1/2“ – 12p. 33
1 1/2“ – 12p. 33
+3300p. 33
3300p. 33
+4600p. 33
4600p. 33
+5600p. 33
5600p. 33
+2 Technical datap. 35
2 Technical datap. 35
Technical datap. 36
Fig. 13p. 36
+Dimensions in mmp. 36
Dimensions in mmp. 36
+Ap. 36
Ap. 36
+Bp. 36
Bp. 36
+Dp. 36
Dp. 36
+Hp. 36
Hp. 36
+H2p. 36
H2p. 36
+Kp. 36
Kp. 36
+Lp. 36
Lp. 36
+O1p. 36
O1p. 36
+O2p. 36
O2p. 36
+Sp. 36
Sp. 36
+Wp. 36
Wp. 36
+BW 226 DH-4 BVCp. 36
BW 226 DH-4 BVCp. 36
+3355p. 36
3355p. 36
+2440p. 36
2440p. 36
+1700p. 36
1700p. 36
+2300p. 36
2300p. 36
+3072p. 36
+3072p. 36
Depending on tire pressurep. 36
+430p. 36
430p. 36
+6582p. 36
6582p. 36
+155p. 36
155p. 36
+155p. 36
155p. 36
+40p. 36
40p. 36
+2130p. 36
2130p. 36
+The right for technical modifications remains reservedp. 36
The right for technical modifications remains reservedp. 37
+BW 226 DH-4 BVCp. 36
BW 226 DH-4 BVCp. 36
+Weightsp. 36
Weightsp. 36
+Operating weight (CECE) with ROPS and cabinp. 36
Operating weight (CECE) with ROPS and cabinp. 36
+kgp. 36
kgp. 36
+25760p. 36
25760p. 36
+Axle load, drum (CECE)p. 36
Axle load, drum (CECE)p. 36
+kgp. 36
kgp. 36
+17590p. 36
17590p. 36
+Axle load, wheels (CECE)p. 36
Axle load, wheels (CECE)p. 36
+kgp. 36
kgp. 36
+8170p. 36
8170p. 36
+Static linear loadp. 36
Static linear loadp. 36
+kg/cmp. 36
kg/cmp. 36
+82.6p. 36
82.6p. 36
+Travel characteristicsp. 36
Travel characteristicsp. 36
+Travel speedp. 36
Travel speedp. 36
+km/hp. 36
km/hp. 36
+0 … 11p. 36
0 … 11p. 36
+Max. gradability (depending on soil)p. 36
Max. gradability (depending on soil)p. 36
+%p. 36
%p. 36
+45p. 36
45p. 36
+Enginep. 36
Enginep. 36
+Engine manufacturerp. 36
Engine manufacturerp. 36
+Deutzp. 36
Deutzp. 36
+Typep. 36
Typep. 36
+TCD 2012 L06 2Vp. 36
TCD 2012 L06 2Vp. 36
+Coolingp. 36
Coolingp. 36
+Waterp. 36
Waterp. 36
+Number of cylindersp. 36
Number of cylindersp. 36
+6p. 36
6p. 36
+Rated power ISO 3046p. 36
Rated power ISO 3046p. 36
+kWp. 36
kWp. 36
+150p. 36
150p. 36
+Rated speedp. 36
Rated speedp. 36
+rpmp. 36
rpmp. 36
+2200p. 36
2200p. 36
+Electrical equipmentp. 36
Electrical equipmentp. 36
+Vp. 36
Vp. 36
+12p. 36
12p. 36
+Drive systemp. 36
Drive systemp. 36
+hydrostaticp. 36
hydrostaticp. 36
+Driven axlesp. 36
Driven axlesp. 36
+2p. 36
2p. 36
+Permissible ambient temperaturesp. 36
Permissible ambient temperaturesp. 36
+°Cp. 36
°Cp. 36
+-20 … +50p. 36
-20 … +50p. 36
+Brakep. 36
Brakep. 36
+Service brakep. 36
Service brakep. 36
+hydrostaticp. 36
hydrostaticp. 36
+Parking brakep. 36
Parking brakep. 36
+hydr.-mech.p. 36
hydr.-mech.p. 36
+Steeringp. 37
Steeringp. 37
+Type of steeringp. 37
Type of steeringp. 37
+articulatedp. 37
articulatedp. 37
+Steering operationp. 37
Steering operationp. 37
+hydrostaticp. 37
hydrostaticp. 37
+Vibrationp. 37
Vibrationp. 37
+Vibrating drump. 37
Vibrating drump. 37
+Drive systemp. 37
Drive systemp. 37
+hydrostaticp. 37
hydrostaticp. 37
+Frequencyp. 37
Frequencyp. 37
+Hzp. 37
Hzp. 37
+26p. 37
26p. 37
+Amplitudep. 37
Amplitudep. 37
+mp. 37
mp. 37
+0 … 2.3p. 37
0 … 2.3p. 37
+Tiresp. 37
Tiresp. 37
+Tire sizep. 37
Tire sizep. 37
+23.5-25 16PR L-3p. 37
23.5-25 16PR L-3p. 37
+Air pressure, nominal valuep. 37
Air pressure, nominal valuep. 37
+barp. 37
barp. 37
+2p. 37
2p. 37
+Air pressure, spanp. 37
Air pressure, spanp. 37
+barp. 37
barp. 37
+1 – 2p. 37
1 – 2p. 37
+Filling capacitiesp. 37
Filling capacitiesp. 37
+Enginep. 37
Enginep. 37
+Litresp. 37
Litresp. 37
+23,5,5p. 37
23,5,5p. 37
+Coolantp. 37
Coolantp. 37
+Litresp. 37
Litresp. 37
+16p. 37
16p. 37
+Fuelp. 37
Fuelp. 37
+Litresp. 37
Litresp. 37
+340p. 37
340p. 37
+Hydraulic oilp. 37
Hydraulic oilp. 37
+Litresp. 37
Litresp. 37
+60p. 37
60p. 37
+Additional engine datap. 37
Additional engine datap. 37
+Combustion principlep. 37
Combustion principlep. 37
+4-stroke dieselp. 37
4-stroke dieselp. 37
+Low idle speedp. 37
Low idle speedp. 37
+rpmp. 37
rpmp. 37
+800 – 900p. 37
800 – 900p. 37
+High idle speedp. 37
High idle speedp. 37
+rpmp. 37
rpmp. 37
+2150 – 2250p. 37
2150 – 2250p. 37
+Specific fuel consumptionp. 37
Specific fuel consumptionp. 37
+g/kWhp. 37
g/kWhp. 37
+235p. 37
235p. 37
+Valve clearance intakep. 37
Valve clearance intakep. 37
+mmp. 37
mmp. 37
+0,3p. 37
0,3p. 37
+Valve clearance exhaustp. 37
Valve clearance exhaustp. 37
+mmp. 37
mmp. 37
+0,5p. 37
0,5p. 37
+Injection valves opening pressurep. 37
Injection valves opening pressurep. 37
+barp. 37
barp. 37
+250p. 37
250p. 37
+Starter powerp. 37
Starter powerp. 37
+kWp. 37
kWp. 37
+3,1p. 37
3,1p. 37
+Travel pumpp. 37
Travel pumpp. 37
+Manufacturerp. 37
Manufacturerp. 37
+Sauerp. 37
Sauerp. 37
+Typep. 37
Typep. 37
+90R100 (EP)p. 37
90R100 (EP)p. 37
+Systemp. 37
Systemp. 37
+Axial piston/swash platep. 37
Axial piston/swash platep. 37
+Max. displacementp. 37
Max. displacementp. 37
+cm3/rev.p. 37
+cmp. 37
3p. 37
+100p. 37
100p. 37
+Max. flow capacityp. 37
Max. flow capacityp. 37
+ccm x n l/minp. 37
ccm x n l/minp. 37
+100p. 37
100p. 37
+High pressure limitationp. 37
High pressure limitationp. 37
+barp. 37
barp. 37
+435 ± 15p. 37
435 ± 15p. 37
+Charge pressure, high idlep. 37
Charge pressure, high idlep. 37
+barp. 37
barp. 37
+26 ± 1p. 37
26 ± 1p. 37
+Drum reduction gearp. 37
Drum reduction gearp. 37
+Typep. 37
Typep. 37
+715 C 3Bp. 37
715 C 3Bp. 37
+Transmission ratiop. 37
Transmission ratiop. 37
+129,2p. 37
129,2p. 37
+Drum drive motorp. 37
Drum drive motorp. 37
+Manufacturerp. 37
Manufacturerp. 37
+Sauerp. 37
Sauerp. 37
+Typep. 37
Typep. 37
+51C 110 (EP)p. 37
51C 110 (EP)p. 37
+Systemp. 37
Systemp. 37
+Axial piston – bent axlep. 37
Axial piston – bent axlep. 37
+Displacement (stage 1)p. 37
Displacement (stage 1)p. 37
+cm3/rev.p. 37
+cmp. 37
3p. 37
+110p. 37
110p. 37
+Displacement (stage 2)p. 37
Displacement (stage 2)p. 37
+cm3/rev.p. 37
+cmp. 37
3p. 37
+31,4p. 37
31,4p. 37
+Perm. leak oil ratep. 37
Perm. leak oil ratep. 37
+l/minp. 37
lp. 37
+2 ± 10p. 37
2 ± 10p. 37
+Flushing ratep. 37
Flushing ratep. 37
+l/minp. 37
lp. 37
+10p. 37
10p. 37
+Flushing limitationp. 38
Flushing limitationp. 38
+barp. 38
barp. 38
+16p. 38
16p. 38
+Axle drive motorp. 38
Axle drive motorp. 38
+Manufacturerp. 38
Manufacturerp. 38
+Sauerp. 38
Sauerp. 38
+Typep. 38
Typep. 38
+51D 110 (EP)p. 38
51D 110 (EP)p. 38
+Systemp. 38
Systemp. 38
+Axial piston – bent axlep. 38
Axial piston – bent axlep. 38
+Max. displacement (stage 1)p. 38
Max. displacement (stage 1)p. 38
+cm3/rev.p. 38
+cmp. 38
3p. 38
+110p. 38
110p. 38
+Min. displacement (stage 2)p. 38
Min. displacement (stage 2)p. 38
+cm3/rev.p. 38
+cmp. 38
3p. 38
+55,3p. 38
55,3p. 38
+Perm. leak oil ratep. 38
Perm. leak oil ratep. 38
+l/minp. 38
lp. 38
+2 ± 10p. 38
2 ± 10p. 38
+Flushing ratep. 38
Flushing ratep. 38
+l/minp. 38
lp. 38
+10p. 38
10p. 38
+Flushing limitationp. 38
Flushing limitationp. 38
+barp. 38
barp. 38
+16p. 38
16p. 38
+Vibration pumpp. 38
Vibration pumpp. 38
+Manufacturerp. 38
Manufacturerp. 38
+Sauerp. 38
Sauerp. 38
+Typep. 38
Typep. 38
+90R 075 (EP)p. 38
90R 075 (EP)p. 38
+Systemp. 38
Systemp. 38
+Axial piston/swash platep. 38
Axial piston/swash platep. 38
+Max. displacementp. 38
Max. displacementp. 38
+cm3/rev.p. 38
+cmp. 38
3p. 38
+75p. 38
75p. 38
+Start up pressurep. 38
Start up pressurep. 38
+barp. 38
barp. 38
+365 ± 65p. 38
365 ± 65p. 38
+Operating pressure (soil dependent)p. 38
Operating pressure (soil dependent)p. 38
+barp. 38
barp. 38
+approx. 100p. 38
approx. 100p. 38
+Vibration motorp. 38
Vibration motorp. 38
+Manufacturerp. 38
Manufacturerp. 38
+Bosch-Rexrothp. 38
Bosch-Rexrothp. 38
+Typep. 38
Typep. 38
+A2FM 80 HDDp. 38
A2FM 80 HDDp. 38
+Systemp. 38
Systemp. 38
+Axial piston/swash platep. 38
Axial piston/swash platep. 38
+Displacementp. 38
Displacementp. 38
+cm3/rev.p. 38
+cmp. 38
3p. 38
+80p. 38
80p. 38
+Flushing ratep. 38
Flushing ratep. 38
+l/minp. 38
l/minp. 38
+6p. 38
6p. 38
+Flushing pressure limitationp. 38
Flushing pressure limitationp. 38
+barp. 38
barp. 38
+13p. 38
13p. 38
+Check steering/p. 38
Check steering/p. 38
+Typep. 38
Typep. 38
+HY/ZFFS11/16+8p. 38
HY/ZFFS11/16+8p. 38
+Systemp. 38
Systemp. 38
+Tandem gear pumpp. 38
Tandem gear pumpp. 38
+Displacementp. 38
Displacementp. 38
+cm3/rev.p. 38
+cmp. 38
3p. 38
+16 / 8p. 38
16 / 8p. 38
+Max. steering pressurep. 38
Max. steering pressurep. 38
+barp. 38
barp. 38
+205 ± 15p. 38
205 ± 15p. 38
+Steering valvep. 38
Steering valvep. 38
+Manufacturerp. 38
Manufacturerp. 38
+Danfossp. 38
Danfossp. 38
+Typep. 38
Typep. 38
+OSPC 500 ONp. 38
OSPC 500 ONp. 38
+Systemp. 38
Systemp. 38
+Rotary spoolp. 38
Rotary spoolp. 38
+Swivel motorp. 38
Swivel motorp. 38
+Typep. 38
Typep. 38
+STF 1-000-21p. 38
STF 1-000-21p. 38
+Systemp. 38
Systemp. 38
+Piston rackp. 38
Piston rackp. 38
+Rear axlep. 38
Rear axlep. 38
+Manufacturerp. 38
Manufacturerp. 38
+Danap. 38
Danap. 38
+Typep. 38
Typep. 38
+CHC 193/55p. 38
CHC 193/55p. 38
+Differentialp. 38
Differentialp. 38
+No-Spinp. 38
No-Spinp. 38
+Degree of lockingp. 38
Degree of lockingp. 38
+%p. 38
%p. 38
+100p. 38
100p. 38
+Reduction ratiop. 38
Reduction ratiop. 38
+93,74p. 38
93,74p. 38
The following noise and vibration data acc. top. 39
were determined at nominal speed of the drive engine and with vibration running. The machine was standing on an elastic base.p. 39
During operation these values may vary because of the existing operating conditions.p. 39
+Noise valuep. 39
Noise valuep. 39
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation isp. 39
sound pressure level at the work place of the operator (with cabin):p. 39
+Lp. 39
+Lp. 39
pAp. 39
75 dB(A)p. 39
The nose emission value for the machine according to the noise emission regulation 2000/14/EG isp. 39
guaranteed sound capacity level of the machine:p. 39
+Lp. 39
+Lp. 39
WAp. 39
110 dB(A)p. 39
+These sound values were determined according to ISO 3744 for the sound capacity level (Lp. 39
wAp. 39
pAp. 39
+Vibration valuep. 39
Vibration valuep. 39
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:p. 39
Vibration of the entire body (driver’s seat)p. 39
+The weighted effective acceleration value determined in accordance with ISO 7096 isp. 39
gp. 39
£p. 39
2p. 39
Hand-arm vibration valuesp. 39
+The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , isp. 39
gp. 39
£p. 39
2p. 39
+3 Maintenancep. 41
3 Maintenancep. 41
+3.1 General notes on maintenancep. 42
3.1 General notes on maintenancep. 42
+When performing maintenance work always comply with the appropriate safety regulations.p. 42
When performing maintenance work always comply with the appropriate safety regulations.p. 42
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. 42
The terms right/left correspond with travel direction forward.p. 42
+l Support the engine hood for all maintenance and repair work.p. 42
l Support the engine hood for all maintenance and repair work.p. 42
l Always clean machine and engine thoroughly before starting maintenance work.p. 42
l For maintenance work stand the machine on level ground.p. 42
l Perform maintenance work only with the motor switched off.p. 42
l Relieve hydraulic pressures before working on hydraulic lines.p. 42
l Before working on electric parts of the machine disconnect the battery and cover it with insulation material.p. 42
l When working in the area of the articulated joint attach the articulation lock (transport lock).p. 42
+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. 42
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. 42
Keep used filters in a separate waste container and dispose of environmentally.p. 42
Catch biodegradable oils separately.p. 42
+Notes on the fuel systemp. 42
Notes on the fuel systemp. 42
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.p. 42
+l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 42
l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.p. 42
l Drums with inside zinc lining are not suitable to store fuel.p. 42
l When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.p. 42
l Do not let the hose stir up the slurry at the bottom of the drum.p. 42
l The fuel drum must rest for a longer period of time before drawing off fuel.p. 42
l The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.p. 42
+Notes on the performance of the enginep. 42
Notes on the performance of the enginep. 42
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. 42
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. 42
+Notes on the cooling systemp. 42
Notes on the cooling systemp. 42
Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.p. 42
Coolant is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water.p. 42
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. 42
+Notes on the hydraulic systemp. 42
Notes on the hydraulic systemp. 42
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. 42
+l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 42
l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.p. 42
l Seal external leaks immediately. If necessary inform the responsible customer service.p. 42
l Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes.p. 42
l We recommend to use the BOMAG 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. 42
l Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.p. 42
l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.p. 42
+3.2 Fuels and lubricantsp. 43
3.2 Fuels and lubricantsp. 43
+Engine oilp. 43
Engine oilp. 43
Qualityp. 43
For use in DEUTZ engines the lubrication oils are classified in DEUTZ Lubrication Oil Quality Classes (DQC).p. 43
+Approved engine oilsp. 43
Approved engine oilsp. 43
+Deutzp. 43
Deutzp. 43
+ACEAp. 43
+ACEAp. 43
Association des Constructeurs European d’Automobilesp. 43
+APIp. 43
+APIp. 43
American Petroleum Institutep. 43
+DHDp. 43
DHDp. 43
+DQC II-05p. 43
DQC II-05p. 43
+E3-96, E5-02, E7-04, E4-07, E6-04p. 43
E3-96, E5-02, E7-04, E4-07, E6-04p. 43
+CG-4, CH-4, CI-4, CI-4 Plus, CJ-4p. 43
CG-4, CH-4, CI-4, CI-4 Plus, CJ-4p. 43
+DHD-1p. 43
DHD-1p. 43
+DQC II-05p. 43
DQC II-05p. 43
+–p. 43
–p. 43
+–p. 43
–p. 43
+–p. 43
–p. 43
+DQC IV-05p. 43
DQC IV-05p. 43
+–p. 43
–p. 43
+–p. 43
–p. 43
+–p. 43
–p. 43
The list of approved lubrication oils is also available in the Internet under the following address:p. 43
+www.deutz.comp. 43
www.deutz.comp. 43
+dep. 43
dep. 43
+>>SERVICE >> Betriebsstoffe und Diagnose >> DeutzQualityClass >> DQC-Freigabelistep. 43
>>SERVICE >> Betriebsstoffe und Diagnose >> DeutzQualityClass >> DQC-Freigabelistep. 43
+enp. 43
enp. 43
+>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >>DQC- release listp. 43
>>SERVICE >> Fuels and lubricants and diagnostics >> DeutzQualityClass >>DQC- release listp. 43
Consult your local service station if in doubt.p. 43
+l Use winter grade engine oil for winter operation!p. 43
l Use winter grade engine oil for winter operation!p. 43
Oil viscosityp. 43
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. 43
Too high viscosity can cause starting difficulties, too low ´viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption.p. 43
Fig. 14p. 43
+Optimal operating conditions can be achieved by using the oil viscosity chartp. 43
(Fig. 14)p. 43
At ambient temperatures below -40 °C the lubrication oil must be pre-heated (e.g. by parking the machine indoors).p. 43
The viscosity is classified acc. to SAE. Multi-purpose oils should generally be used.p. 43
Oil change intervalsp. 43
The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operati…p. 43
+DQC II, DQC III, DQC IVp. 43
DQC II, DQC III, DQC IVp. 43
500 operating hoursp. 43
+When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10°C and when using biodegradable diesel fuel the oil change intervals must be halved.p. 43
When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10°C and when using biodegradable diesel fuel the oil change intervals must be halved.p. 43
+Fuelsp. 43
Fuelsp. 43
You should only use commercially available brand diesel fuel with a sulphur content of less than 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals.p. 43
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. 44
Qualityp. 44
The following fuel specifications are permitted:p. 44
+l EN 590p. 44
l EN 590p. 44
l DIN 51628p. 44
l ASTM D975 Grade-No. 1-D and 2-D.p. 44
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication properties acc. to EN 590p. 44
Winter fuelp. 44
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. Diesel fuels suitable for temperatures down to -44 °C are available for arctic climates. At very low temperatures disturbing paraffin separation can …p. 44
The admixture of petroleum and the addition of "flow enhancing additives" (fuel additives) is not permitted.p. 44
+Coolantp. 44
Coolantp. 44
For fluid cooled engines the cooling fluid must be prepared by admixing a cooling system protection agent to the fresh water and should be checked within the specified maintenance intervals.p. 44
This prevents damage caused by corrosion, cavitation, freezing and overheating.p. 44
Fresh water qualityp. 44
The correct quality of water is highly important when preparing coolant. Clear and clean water within the boundaries of the following analysis values should generally be used.p. 44
+Fresh water analysis valuesp. 44
Fresh water analysis valuesp. 44
+pH-value at 20 °Cp. 44
pH-value at 20 °Cp. 44
+6.5 – 8.5p. 44
6.5 – 8.5p. 44
+Chloride ion content (mg/l) (ppm)p. 44
Chloride ion content (mg/l) (ppm)p. 44
+max. 100p. 44
max. 100p. 44
+Sulphate ion content (mg/l) (ppm)p. 44
Sulphate ion content (mg/l) (ppm)p. 44
+max. 100p. 44
max. 100p. 44
+Total hardness [°dGH]p. 44
Total hardness [°dGH]p. 44
+3 – 12p. 44
3 – 12p. 44
+corresponds with a potash ion content (mmol/l) ofp. 44
corresponds with a potash ion content (mmol/l) ofp. 44
+0.54 – 3.56p. 44
0.54 – 3.56p. 44
+Carbon hardness proportion of the total hardness (°d)p. 44
Carbon hardness proportion of the total hardness (°d)p. 44
+min. 3p. 44
min. 3p. 44
+corresponds with a content of CaCO3 (mg/l) (ppm)p. 44
+corresponds with a content of CaCOp. 44
3p. 44
+min. 53.4p. 44
min. 53.4p. 44
Information concerning the water quality can be obtained from the waterworks.p. 44
If the fresh water analysis values are unknown, these must be determined with the help of a water analysis.p. 44
If the values of the analysis deviate, the water must be treated accordingly.p. 44
+l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 44
l pH-value too low Adding of caustic lye of soda or caustic potash solution.p. 44
l Total hardness or chlorides and/or sulphates too high: Mixing with dehardened water (e.g. distilled water).p. 44
l Total hardness or carbonate hardness too low: Mixing with hardened water (harder water is in most cases available in the form of drinking water).p. 44
+Another analysis must be made after the fresh water has been prepared.p. 44
Another analysis must be made after the fresh water has been prepared.p. 44
Cooling system protection agentp. 44
As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.p. 44
Coolant for fluid cooled engines is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water.p. 44
We therefore highly recommend our BOMAG cooling system protection agent (BOMAG part-no. 009 940 08)..p. 44
If our cooling system protection agent is not available for any important reasons, you may, in exceptional cases, use products that have been approved by the engine manufacturer.p. 44
The list of approved cooling system protection agents can be found in the internet under www.deutz.com >>SERVICE >> Fuels and lubricants and diagnostics >> Collig system protection >>Technical circular Cooling System Protection Agents.p. 44
Products of the same product group (see Deutz Technical Circular Cooling System Protection Agents) can be mixed with each other.p. 44
The BOMAG cooling system protection agent corresponds with product group A.p. 44
+Do not mix different coolants and additives of any other kind.p. 44
Do not mix different coolants and additives of any other kind.p. 44
Before changing the product you must clean the entire cooling system.p. 44
Consult your local service station if in doubt.p. 44
To ensure proper corrosion protection you must use the cooling system protection agent all year around, whereby the following concentration must not be fallen short of or exceeded.p. 44
+Mixing ratiop. 45
Mixing ratiop. 45
+Cooling system protection agentp. 45
Cooling system protection agentp. 45
+Fresh waterp. 45
Fresh waterp. 45
+Cold protection down top. 45
Cold protection down top. 45
+min. 35%p. 45
min. 35%p. 45
+65%p. 45
65%p. 45
+-22 °Cp. 45
-22 °Cp. 45
+40%p. 45
40%p. 45
+60%p. 45
60%p. 45
+-28 °Cp. 45
-28 °Cp. 45
+max. 45%p. 45
max. 45%p. 45
+55%p. 45
55%p. 45
+-35 °Cp. 45
-35 °Cp. 45
+A proportion of more than 45% of cooling system protection agent causes a drop in cooling power.p. 45
A proportion of more than 45% of cooling system protection agent causes a drop in cooling power.p. 45
The use of corrosion protection oils as cooling system protection agents is not permitted.p. 45
+When working at temperature below -35 °C you should consult our local service representative.p. 45
When working at temperature below -35 °C you should consult our local service representative.p. 45
+Coolant must be disposed of environmentally.p. 45
Coolant must be disposed of environmentally.p. 45
+Mineral oil based hydraulic oilp. 45
Mineral oil based hydraulic oilp. 45
+The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mmp. 45
2p. 45
+Bio-degradable hydraulic oilp. 45
Bio-degradable hydraulic oilp. 45
The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.p. 45
The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524.p. 45
In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up.p. 45
When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.p. 45
+Check the filter more frequently after this change.p. 45
Check the filter more frequently after this change.p. 45
Perform regular oil analyses for content of water and mineral oil.p. 45
Replace the hydraulic oil filter element every 500 operating hours.p. 45
+Oil for drive axlep. 45
Oil for drive axlep. 45
Qualityp. 45
Forthe drive axle use only multi-purpose gear oils of API-GL5-class, SAE 90.p. 45
This is a hypoid lubricant of highest quality class for extremely loaded transmissions.p. 45
The additives in this oil ensure low wear lubrication under all operating conditions.p. 45
+Oil for Vario vibration unitp. 45
Oil for Vario vibration unitp. 45
For the Vario vibration unit in the drum you should use special BOMAG oil (BOMAG part-no. 009 925 05 in 20 litre drums) or a gear oil SAE 70W-90, API GL5.p. 45
+Lubrication greasep. 45
Lubrication greasep. 45
For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G.p. 45
3.3 Table of fuels and lubricantsp. 46
+Assemblyp. 46
Assemblyp. 46
+Fuel or lubricantp. 46
Fuel or lubricantp. 46
+Quantityp. 46
Quantityp. 46
+Summerp. 46
Summerp. 46
+Winterp. 46
Winterp. 46
+Attentionp. 46
+Attentionp. 46
Attentionp. 46
Observe the level marksp. 46
+Enginep. 46
Enginep. 46
+– Engine oilp. 46
– Engine oilp. 46
+ACEA: E3-96, E5-02, E7-04, E4-07, E6-04p. 46
ACEA: E3-96, E5-02, E7-04, E4-07, E6-04p. 46
API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4p. 46
+approx. 24 litres incl. oil filterp. 46
approx. 24 litres incl. oil filterp. 46
+SAE 10W-40 (-15 °C to +40 °C)p. 46
SAE 10W-40 (-15 °C to +40 °C)p. 46
+SAE 15W-40 (-5 °C to +40 °C)p. 46
SAE 15W-40 (-5 °C to +40 °C)p. 46
+SAE 5W-40 (-30 °C to +40 °C)p. 46
SAE 5W-40 (-30 °C to +40 °C)p. 46
+– Fuelp. 46
– Fuelp. 46
+Dieselp. 46
Dieselp. 46
+Winter diesel fuelp. 46
Winter diesel fuelp. 46
+approx. 340 litresp. 46
approx. 340 litresp. 46
+– Coolantp. 46
– Coolantp. 46
+Mixture of water and anti-freeze agentp. 46
+Mixture of water and anti-freeze agentp. 46
see chapter "Fuels and Lubricants – Colant"p. 46
+approx. 16 litresp. 46
approx. 16 litresp. 46
+Hydraulic systemp. 46
Hydraulic systemp. 46
+Hydraulic oil (ISO), HV46, kinem. Viscosity 46 mm2/s at 40 °C with viscosity index (VI) >150 or ester based biodegradable hydraulic oilp. 46
+3. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Material: Plastic, Temperature range: down to -40 °Cp. 56
3. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Material: Plastic, Temperature range: down to -40 °Cp. 56
BOMAG part-no.: 050 100 75p. 56
+Fig. 4p. 56
Fig. 4p. 56
+4. Digital rpm-meter for petrol enginesp. 56
4. Digital rpm-meter for petrol enginesp. 56
BOMAG part-no.: 079 948 99p. 56
+Fig. 5p. 57
Fig. 5p. 57
+5. Digital rpm-meter for petrol enginesp. 57
5. Digital rpm-meter for petrol enginesp. 57
BOMAG part-no.: 059 711 12p. 57
+Fig. 6p. 57
Fig. 6p. 57
+6. Digital rpm-meter, optical/mechanical, universal usep. 57
6. Digital rpm-meter, optical/mechanical, universal usep. 57
BOMAG part-no.: 079 948 98p. 57
+Fig. 7p. 57
Fig. 7p. 57
+7. Infrared manual thermometer, -18 to 275°Cp. 57
7. Infrared manual thermometer, -18 to 275°Cp. 57
BOMAG part-no.: 057 668 06p. 57
+Fig. 8p. 57
Fig. 8p. 57
+8. Hydraulic test case, largep. 57
8. Hydraulic test case, largep. 57
BOMAG part-no.: 007 610 03p. 57
+4 X 600 bar pressure gaugesp. 57
4 X 600 bar pressure gaugesp. 57
4 X 60 bar pressure gaugesp. 57
8 pressure test hosesp. 57
+Fig. 9p. 58
Fig. 9p. 58
+9. Hydraulic test case, smallp. 58
9. Hydraulic test case, smallp. 58
BOMAG part-no.: 079 930 01p. 58
+2X 60 bar pressure gaugep. 58
2X 60 bar pressure gaugep. 58
2X 600 bar pressure gaugesp. 58
4 pressure test hosesp. 58
+Fig. 10p. 58
Fig. 10p. 58
+10. Pressure test hosesp. 58
10. Pressure test hosesp. 58
+1000 mm BOMAG part-no.: 079 930 02p. 58
1000 mm BOMAG part-no.: 079 930 02p. 58
+2500 mm BOMAG part-no.: 079 930 03p. 58
2500 mm BOMAG part-no.: 079 930 03p. 58
+Fig. 11p. 58
Fig. 11p. 58
+11. Pressure gaugep. 58
11. Pressure gaugep. 58
+60 bar BOMAG part-no.: 059 721 07p. 58
60 bar BOMAG part-no.: 059 721 07p. 58
+600 bar BOMAG part-no.: 059 721 04p. 58
600 bar BOMAG part-no.: 059 721 04p. 58
+Fig. 12p. 58
Fig. 12p. 58
+12. Adapter for pressure test hosep. 58
12. Adapter for pressure test hosep. 58
BOMAG part-no.: 055 439 02p. 58
+Fig. 13p. 59
Fig. 13p. 59
+13. Gear pump testing devicep. 59
13. Gear pump testing devicep. 59
BOMAG part-no.: 007 610 05p. 59
+Fig. 14p. 59
Fig. 14p. 59
+14. Vacuum pump for hydraulic oil tankp. 59
14. Vacuum pump for hydraulic oil tankp. 59
+BOMAG part-no.: 007 610 04 (12 Volt)p. 59
BOMAG part-no.: 007 610 04 (12 Volt)p. 59
+BOMAG part-no.: 007 610 24 (24 Volt)p. 59
BOMAG part-no.: 007 610 24 (24 Volt)p. 59
+5.2 Activate service modep. 60
5.2 Activate service modep. 60
+Fig. 1p. 60
Fig. 1p. 60
+Activate the input modep. 60
Activate the input modep. 60
+1. Set the travel lever to braking positionp. 60
1. Set the travel lever to braking positionp. 60
+The function can only be activated when the travel lever is engaged in braking position.p. 60
The function can only be activated when the travel lever is engaged in braking position.p. 60
+2. Switch on the ignition.p. 60
2. Switch on the ignition.p. 60
+3. Press both Info-buttonsp. 60
+3. Press both Info-buttonsp. 60
(Fig. 1)p. 60
+T he green buttons can be used select the values in thep. 60
+Fig. 2p. 60
Fig. 2p. 60
+Activate service modep. 60
Activate service modep. 60
+The input mode starts with flashing of the left hand digitp. 60
+The input mode starts with flashing of the left hand digitp. 60
(Fig. 2)p. 60
+The green buttons F2, F4p. 60
(Fig. 3)p. 60
+With the blue button F5, F3p. 60
(Fig. 4)p. 60
Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.p. 60
+T he green buttons can be used select the values in thep. 60
+Fig. 3p. 60
Fig. 3p. 60
+4. Enter access code "9999".p. 60
4. Enter access code "9999".p. 60
+Fig. 4p. 61
Fig. 4p. 61
+If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 61
If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 61
+Individual operating states can now be interrogated, activated or deactivated by transmitting further input codes to the control.p. 61
Individual operating states can now be interrogated, activated or deactivated by transmitting further input codes to the control.p. 61
+Deactivating the service modep. 61
Deactivating the service modep. 61
+5. Quit the service mode by switching the ignition off.p. 61
5. Quit the service mode by switching the ignition off.p. 61
+5.3 Driving against the closed brakep. 62
5.3 Driving against the closed brakep. 62
+On this machine the electric plug connection to the brake valve must not be pulled off, because the ESX-control would in this case detect a line interruption in the current path to the brake.p. 62
On this machine the electric plug connection to the brake valve must not be pulled off, because the ESX-control would in this case detect a line interruption in the current path to the brake.p. 62
+Fig. 1p. 62
Fig. 1p. 62
+Activate the input modep. 62
Activate the input modep. 62
+1. Set the travel lever to braking positionp. 62
1. Set the travel lever to braking positionp. 62
+The function can only be activated when the travel lever is engaged in braking position.p. 62
The function can only be activated when the travel lever is engaged in braking position.p. 62
+2. Switch on the ignition.p. 62
2. Switch on the ignition.p. 62
+3. Press both Info-buttonsp. 62
+3. Press both Info-buttonsp. 62
(Fig. 1)p. 62
+T he green buttons can be used select the values in thep. 62
+Fig. 2p. 62
Fig. 2p. 62
+Activate service modep. 62
Activate service modep. 62
+The input mode srats with flashing of the left hand digitp. 62
+The input mode srats with flashing of the left hand digitp. 62
(Fig. 2)p. 62
+The green buttons F2, F4p. 62
(Fig. 3)p. 62
+With the blue button F5, F3p. 62
(Fig. 4)p. 62
Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.p. 62
+T he green buttons can be used select the values in thep. 62
+Fig. 3p. 62
Fig. 3p. 62
+4. Enter code number "9999".p. 62
4. Enter code number "9999".p. 62
+Fig. 4p. 63
Fig. 4p. 63
+If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 63
If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 63
+Fig. 5p. 63
Fig. 5p. 63
+Activating the brake functionp. 63
Activating the brake functionp. 63
+5. Enter code number "0500" via the LC displayp. 63
+5. Enter code number "0500" via the LC displayp. 63
(Fig. 5)p. 63
+The brake will not be released when actuating the travel lever.p. 63
The brake will not be released when actuating the travel lever.p. 63
The warning buzzer sounds to inform the operator about this status. The brake control light in the LC display remains activated.p. 63
+Deactivating the brake functionp. 63
Deactivating the brake functionp. 63
+6. Enter code number "501" or switch the ignition off to stop this function.p. 63
6. Enter code number "501" or switch the ignition off to stop this function.p. 63
+5.4 Turn the steering against an end stop.p. 64
5.4 Turn the steering against an end stop.p. 64
+The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the electronic end stops of the angle transducer (BVC)".p. 64
The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the electronic end stops of the angle transducer (BVC)".p. 64
+Fig. 1p. 64
Fig. 1p. 64
+Activate the input modep. 64
Activate the input modep. 64
+1. Set the travel lever to braking positionp. 64
1. Set the travel lever to braking positionp. 64
+The function can only be activated when the travel lever is engaged in braking position.p. 64
The function can only be activated when the travel lever is engaged in braking position.p. 64
+2. Switch on the ignition.p. 64
2. Switch on the ignition.p. 64
+3. Press both Info-buttonsp. 64
+3. Press both Info-buttonsp. 64
(Fig. 1)p. 64
+T he green buttons can be used select the values in thep. 64
+Fig. 2p. 64
Fig. 2p. 64
+Activate service modep. 64
Activate service modep. 64
+The input mode starts with flashing of the left hand digitp. 64
+The input mode starts with flashing of the left hand digitp. 64
(Fig. 2)p. 64
+The green buttons F2, F4p. 64
(Fig. 3)p. 64
+With the blue button F5, F3p. 64
(Fig. 4)p. 64
Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.p. 64
+T he green buttons can be used select the values in thep. 64
+Fig. 3p. 64
Fig. 3p. 64
+4. Enter code number "9999".p. 64
4. Enter code number "9999".p. 64
+Fig. 4p. 65
Fig. 4p. 65
+If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 65
If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.p. 65
+Fig. 5p. 65
Fig. 5p. 65
+Activating the modep. 65
Activating the modep. 65
+5. Enter code number "2010"p. 65
+5. Enter code number "2010"p. 65
(Fig. 5)p. 65
+The steering can now be actuated against the mechanical stop.p. 65
The steering can now be actuated against the mechanical stop.p. 65
The display shows the nominated steering position (0..1000).p. 65
+Deactivating the modep. 65
Deactivating the modep. 65
+6. Enter code number "501" or switch the ignition off to stop this function.p. 65
6. Enter code number "501" or switch the ignition off to stop this function.p. 65
+5.5 Pressure tests in the travel circuitp. 66
5.5 Pressure tests in the travel circuitp. 66
+Special toolsp. 66
Special toolsp. 66
Hydraulic test casep. 66
+Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 66
Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 66
+Fig. 1p. 66
Fig. 1p. 66
+1. Block drums and wheels with suitable chocksp. 66
+1. Block drums and wheels with suitable chocksp. 66
(Fig. 1)p. 66
+Fig. 2p. 66
Fig. 2p. 66
+The closed brake mode must be activated!p. 66
The closed brake mode must be activated!p. 66
+Drive against the closed brake, see corresponding chapter.p. 66
Drive against the closed brake, see corresponding chapter.p. 66
+2. Enter code number "0500" to close the brakep. 66
+2. Enter code number "0500" to close the brakep. 66
(Fig. 2)p. 66
+Fig. 3p. 66
Fig. 3p. 66
+3. Connect 600 bar pressure gauges to the high pressure test ports for "forward travel" and "reverse travel" and a 60 bar pressure gauge to the charge pressure test portp. 66
+3. Connect 600 bar pressure gauges to the high pressure test ports for "forward travel" and "reverse travel" and a 60 bar pressure gauge to the charge pressure test portp. 66
(Fig. 3)p. 66
+4. Start the engine and run it with maximum speed.p. 66
4. Start the engine and run it with maximum speed.p. 66
+5. Read charge and high pressure gauges.p. 66
5. Read charge and high pressure gauges.p. 66
+Nominal valuep. 66
Nominal valuep. 66
see technical data of travel pump:p. 66
Charge pressure gauge = charge pressure at high idlep. 66
High pressure gauge = charge pressure at high idlep. 66
+Evaluation of testp. 66
Evaluation of testp. 66
If the nominal value is not reached, check the steering/charge pump.p. 66
+Fig. 4p. 67
Fig. 4p. 67
+6. Move the travel leverp. 67
+6. Move the travel leverp. 67
(Fig. 4)p. 67
+Nominal valuep. 67
Nominal valuep. 67
see technical data of travel pump:p. 67
Charge pressure gauge = charge pressure at high idlep. 67
High pressure gauge = pressure overridep. 67
+Evaluation of testp. 67
Evaluation of testp. 67
If the specified high pressure is not reached, check the travel pump.p. 67
If the charge pressure drops considerably during the high pressure test, check the components individually.p. 67
+Deactivate the closed brake modep. 67
Deactivate the closed brake modep. 67
+7. Quit this mode by switching the ignition off.p. 67
7. Quit this mode by switching the ignition off.p. 67
+5.6 Checking / adjusting the neutral positions of the travel pumpp. 68
5.6 Checking / adjusting the neutral positions of the travel pumpp. 68
+Special toolsp. 68
Special toolsp. 68
Hydraulic test casep. 68
+Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 68
Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 68
+Fig. 1p. 68
Fig. 1p. 68
+1. Block drums and wheels with suitable chocksp. 68
+1. Block drums and wheels with suitable chocksp. 68
(Fig. 1)p. 68
+Fig. 2p. 68
Fig. 2p. 68
+The closed brake mode must be activated!p. 68
The closed brake mode must be activated!p. 68
+Drive against the closed brake, see corresponding chapter.p. 68
Drive against the closed brake, see corresponding chapter.p. 68
+2. Enter code number "0500" to close the brakep. 68
+2. Enter code number "0500" to close the brakep. 68
(Fig. 2)p. 68
+Fig. 3p. 68
Fig. 3p. 68
+3. Connect a 600 bar pressure gauge each to the high pressure test ports for "forward travel" and "reverse travel"p. 68
+3. Connect a 600 bar pressure gauge each to the high pressure test ports for "forward travel" and "reverse travel"p. 68
(Fig. 3)p. 68
+Fig. 4p. 69
Fig. 4p. 69
+The closed brake mode must be activated!p. 69
The closed brake mode must be activated!p. 69
+Drive against the closed brake, see corresponding chapter.p. 69
Drive against the closed brake, see corresponding chapter.p. 69
+4. As a measure to avoid signal residues from the hydraulic neutral position connect both control chambers X1 and X2 with a hosep. 69
+4. As a measure to avoid signal residues from the hydraulic neutral position connect both control chambers X1 and X2 with a hosep. 69
(Fig. 4)p. 69
+5. Start the engine and run it with maximum speed.p. 69
5. Start the engine and run it with maximum speed.p. 69
+Fig. 5p. 69
Fig. 5p. 69
+6. Read the high pressure gaugesp. 69
+6. Read the high pressure gaugesp. 69
(Fig. 5)p. 69
+Nominal valuep. 69
Nominal valuep. 69
+Both pressure gaugesp. 69
(Fig. 5)p. 69
+If necessary repeat the pressure test with 60 bar pressure gauges, for more accurate readings.p. 69
If necessary repeat the pressure test with 60 bar pressure gauges, for more accurate readings.p. 69
+Fig. 6p. 69
Fig. 6p. 69
+Evaluation of testp. 69
Evaluation of testp. 69
+If pressure builds up on one side, adjust the mechanical neutral positionp. 69
(Fig. 6)p. 69
+5.7 Pressure measurements in the vibration circuitp. 70
5.7 Pressure measurements in the vibration circuitp. 70
+Special toolsp. 70
Special toolsp. 70
Hydraulic test casep. 70
+Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 70
Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 70
+Fig. 1p. 70
Fig. 1p. 70
+1. Drive the machine with both drums on an elastic base (rubber buffers)p. 70
+1. Drive the machine with both drums on an elastic base (rubber buffers)p. 70
(Fig. 1)p. 70
+2. Block the wheels with suitable chocks.p. 70
2. Block the wheels with suitable chocks.p. 70
+3. Apply the brake.p. 70
3. Apply the brake.p. 70
+Fig. 2p. 70
Fig. 2p. 70
+4. Connect a 60 bar pressure gaugep. 70
+4. Connect a 60 bar pressure gaugep. 70
(Fig. 2)p. 70
+5. Connect a 600 bar pressure gauge each to the high pressure test ports for "high amplitude" and "low amplitude".p. 70
5. Connect a 600 bar pressure gauge each to the high pressure test ports for "high amplitude" and "low amplitude".p. 70
+6. Start the engine and run it with maximum speed.p. 70
6. Start the engine and run it with maximum speed.p. 70
+7. Switch on vibration at high or low frequency and read the pressure gauge.p. 70
7. Switch on vibration at high or low frequency and read the pressure gauge.p. 70
+Nominal valuep. 70
Nominal valuep. 70
Charge pressure = charge pressure at high idle (see technical data of travel pump).p. 70
+Start-up pressure = vibration pump start-up pressure (see technical data of vibration pump).p. 70
Start-up pressure = vibration pump start-up pressure (see technical data of vibration pump).p. 70
Operating pressure = vibration pump operating pressure (see technical data of vibration pump).p. 70
+Evaluation of testp. 70
Evaluation of testp. 70
If the charge pressure drops, check the components individually.p. 70
If the starting pressure is not reached, check the vibration pump.p. 70
If the starting pressure is only reached for one frequency, check the high pressure relief valves.p. 70
+5.8 Check the leakage rate of the vibration motorp. 71
5.8 Check the leakage rate of the vibration motorp. 71
+Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 71
Perform measurements at operating temperature of the hydraulic oil (50 °C).p. 71
+Fig. 1p. 71
Fig. 1p. 71
+1. Drive the drum of the machine on an elastic base (rubber buffers)p. 71
+1. Drive the drum of the machine on an elastic base (rubber buffers)p. 71
(Fig. 1)p. 71
+1. Apply the brake.p. 71
1. Apply the brake.p. 71
+Fig. 2p. 71
Fig. 2p. 71
+2. Block the flushing pressure relief valvep. 71
+2. Block the flushing pressure relief valvep. 71
(Fig. 2)p. 71
+Fig. 3p. 71
Fig. 3p. 71
+3. Disconnect the leak oil hosep. 71
+3. Disconnect the leak oil hosep. 71
(Fig. 3)p. 71
+4. Start the engine and run it with maximum speed.p. 71
4. Start the engine and run it with maximum speed.p. 71
+5. Switch the vibration on and measure the running out leak oil during one timed minute.p. 71
5. Switch the vibration on and measure the running out leak oil during one timed minute.p. 71
+Nominal valuep. 71
Nominal valuep. 71
max. 1.5 litre/minp. 71
+Evaluation of testp. 71
Evaluation of testp. 71
If the permissible leak oil rate is exceeded, replace the vibration motor.p. 71
+5.9 Pressure test in steering circuitp. 72
5.9 Pressure test in steering circuitp. 72
+Special toolsp. 72
Special toolsp. 72
Hydraulic test case, gear pump testing equipmentp. 72
+Perform measurements at operating temperature of the hydraulic oil (approx. 50 °C).p. 72
Perform measurements at operating temperature of the hydraulic oil (approx. 50 °C).p. 72
+Measurement 1p. 72
Measurement 1p. 72
+Fig. 1p. 72
Fig. 1p. 72
+1. Connect a 600 bar pressure gauge to the steering pressure test portp. 72
+1. Connect a 600 bar pressure gauge to the steering pressure test portp. 72
(Fig. 1)p. 72
+The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the end stops of the angle transducer (BVC)".p. 72
The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the end stops of the angle transducer (BVC)".p. 72
+Fig. 2p. 72
Fig. 2p. 72
+Activate teach modep. 72
Activate teach modep. 72
+Turn the steering against the mechanical stop, see corresponding chapter.p. 72
Turn the steering against the mechanical stop, see corresponding chapter.p. 72
+2. Enter code number "2010"p. 72
+2. Enter code number "2010"p. 72
(Fig. 2)p. 72
+3. Start the engine and run it at idle speed.p. 72
3. Start the engine and run it at idle speed.p. 72
+Danger of crushing, do not access the articulation area of the machine!p. 72
Danger of crushing, do not access the articulation area of the machine!p. 72
+4. Turn the steering against an end stop.p. 72
4. Turn the steering against an end stop.p. 72
+5. Set the travel lever to neutral position (no braking function).p. 72
5. Set the travel lever to neutral position (no braking function).p. 72
+6. Read the pressure gauge.p. 72
6. Read the pressure gauge.p. 72
+Nominal valuep. 72
Nominal valuep. 72
see technical data, max. steering pressure of steering/charge pump.p. 72
+Evaluation of test 1p. 72
Evaluation of test 1p. 72
If the nominal value is reached, check the steering cylinder.p. 72
+Deactivate the steering modep. 72
Deactivate the steering modep. 72
+7. Quit the teach mode by switching the ignition off.p. 72
7. Quit the teach mode by switching the ignition off.p. 72
+Fig. 3p. 73
Fig. 3p. 73
+Measurement 2p. 73
Measurement 2p. 73
+8. Disconnect the hydraulic hoses from ports L and Rp. 73
+8. Disconnect the hydraulic hoses from ports L and Rp. 73
(Fig. 3)p. 73
+9. Start the engine and run it at idle speed.p. 73
9. Start the engine and run it at idle speed.p. 73
+10. Turn the steering wheel.p. 73
10. Turn the steering wheel.p. 73
+11. Read the pressure gauge.p. 73
11. Read the pressure gauge.p. 73
+Nominal valuep. 73
Nominal valuep. 73
see technical data for steering/charge pump.p. 73
+Evaluation of test 2p. 73
Evaluation of test 2p. 73
If the nominal value is reached, replace the steering cylinder.p. 73
If the nominal value is not reached, check the steering/charge pump.p. 73
+12. Reconnect the hydraulic hoses to the steering cylinders.p. 73
12. Reconnect the hydraulic hoses to the steering cylinders.p. 73
+Fig. 4p. 73
Fig. 4p. 73
+Measurement 3p. 73
Measurement 3p. 73
+13. Close the pump outlet portp. 73
+13. Close the pump outlet portp. 73
(Fig. 4)p. 73
+14. Crank the engine with the starterp. 73
14. Crank the engine with the starterp. 73
+Nominal valuep. 73
Nominal valuep. 73
see technical data for steering/charge pump.p. 73
+Evaluation of test 3p. 73
Evaluation of test 3p. 73
If the nominal value is reached, replace the steering valve.p. 73
If the nominal value is not reached, replace the steering/charge pump.p. 73
+6 Flushing and bleedingp. 75
6 Flushing and bleedingp. 75
+6.1 Special tools for flushingp. 76
6.1 Special tools for flushingp. 76
+Fig. 1p. 76
Fig. 1p. 76
+1. Filling and filtering unitp. 76
1. Filling and filtering unitp. 76
BOMAG part-no.: 058 240 22p. 76
+Fig. 2p. 76
Fig. 2p. 76
+2. Flushing filter (S connection)p. 76
2. Flushing filter (S connection)p. 76
BOMAG part-no.: 007 000 01p. 76
+3. Filter element 1p. 76
+3. Filter element 1p. 76
mp. 76
BOMAG part-no.: 079 930 52p. 76
+4. Flushing hose 20S – 25S (2 pieces)p. 76
4. Flushing hose 20S – 25S (2 pieces)p. 76
BOMAG part-no.: 055 509 19p. 76
+5. Screw socket R1“ – 25S (2 pieces)p. 76
5. Screw socket R1“ – 25S (2 pieces)p. 76
BOMAG part-no.: 055 400 52p. 76
+Fig. 3p. 76
Fig. 3p. 76
+6. Flushing filter (L connection)p. 76
6. Flushing filter (L connection)p. 76
BOMAG part-no.: 079 390 29p. 76
+7. Filter elementp. 76
7. Filter elementp. 76
BOMAG part-no.: 079 390 14p. 76
+8. Flushing hose 15L (2 pieces)p. 76
8. Flushing hose 15L (2 pieces)p. 76
BOMAG part-no.: 055 510 09p. 76
+9. Screw socket R3/4“ — 15L (2 pieces)p. 76
9. Screw socket R3/4“ — 15L (2 pieces)p. 76
BOMAG part-no.: 055 400 89p. 76
+Fig. 4p. 76
Fig. 4p. 76
+10. SAE-flange 1“ – 20Sp. 76
10. SAE-flange 1“ – 20Sp. 76
BOMAG part-no.: 058 142 60p. 76
+11. O-ringp. 76
11. O-ringp. 76
BOMAG part-no. 062 203 30p. 76
+Fig. 5p. 77
Fig. 5p. 77
+12. Flanged plate 1“ – 25Sp. 77
12. Flanged plate 1“ – 25Sp. 77
BOMAG part-no.: 007 160 18p. 77
+13. O-ringp. 77
13. O-ringp. 77
BOMAG part-no. 062 202 22p. 77
+Fig. 6p. 77
Fig. 6p. 77
+14. Reducing fitting 18L – 15Lp. 77
14. Reducing fitting 18L – 15Lp. 77
BOMAG part-no.: 055 422 92p. 77
+Fig. 7p. 77
Fig. 7p. 77
+15. Reducing fitting 25S – 20Sp. 77
15. Reducing fitting 25S – 20Sp. 77
BOMAG part-no.: 055 422 98p. 77
+Fig. 8p. 77
Fig. 8p. 77
+16. Reducing fitting 20S – 16Sp. 77
16. Reducing fitting 20S – 16Sp. 77
BOMAG part-no.: 055 423 26p. 77
+Fig. 9p. 78
Fig. 9p. 78
+17. Connecting socket 15Lp. 78
17. Connecting socket 15Lp. 78
BOMAG part-no.: 055 426 55p. 78
+Fig. 10p. 78
Fig. 10p. 78
+18. Connecting socket 18Lp. 78
18. Connecting socket 18Lp. 78
BOMAG part-no.: 055 426 06p. 78
+Fig. 11p. 78
Fig. 11p. 78
+19. Connecting socket 16Sp. 78
19. Connecting socket 16Sp. 78
BOMAG part-no.: 055 459 43p. 78
+Fig. 12p. 78
Fig. 12p. 78
+20. Connecting fitting 20Sp. 78
20. Connecting fitting 20Sp. 78
BOMAG part-no.: 055 459 44p. 78
+Fig. 13p. 79
Fig. 13p. 79
+21. Connecting fitting 25Sp. 79
21. Connecting fitting 25Sp. 79
BOMAG part-no.: 055 459 45p. 79
+Fig. 14p. 79
Fig. 14p. 79
+22. Angular fitting 18Lp. 79
22. Angular fitting 18Lp. 79
BOMAG part-no.: 055 421 26p. 79
+Fig. 15p. 79
Fig. 15p. 79
+23. Elbow fitting 16Lp. 79
23. Elbow fitting 16Lp. 79
BOMAG part-no.: 055 421 36p. 79
+Fig. 16p. 79
Fig. 16p. 79
+24. Elbow 20Sp. 79
24. Elbow 20Sp. 79
BOMAG part-no.: 055 421 37p. 79
+Fig. 17p. 80
Fig. 17p. 80
+25. Elbow 25Sp. 80
25. Elbow 25Sp. 80
BOMAG part-no.: 055 421 38p. 80
+Fig. 18p. 80
Fig. 18p. 80
+26. Pipe connection 16S – 16Sp. 80
26. Pipe connection 16S – 16Sp. 80
BOMAG part-no.: 493 301 01p. 80
+Fig. 19p. 80
Fig. 19p. 80
+27. Connecting hose 15Lp. 80
27. Connecting hose 15Lp. 80
BOMAG part-no.: 055 510 09p. 80
+6.10 Bleeding the vibration circuitp. 81
6.2 Flushing – generalp. 81
+Changing a componentp. 81
Changing a componentp. 81
+Always flush the complete oil circuit after you have replaced a component.p. 81
+Always flush the complete oil circuit after you have replaced a component.p. 81
Always flush the complete oil circuit after you have replaced a component.p. 81
Solid particles in the circuit will very quickly cause damage to machine components.p. 81
Fig. 1p. 81
Effect of contaminationp. 81
Coarse particles (> 15 µm)p. 81
Sudden failure of components.p. 81
Fine particle contamination (5 – 15 µm)p. 81
Wear of components, internal leaks, inaccurate controlling behaviour, blockage of valves.p. 81
Extra fine particle contamination (< 2 – 5 µm)p. 81
Silting of oil, accelerated aging of oil, corrosion.p. 81
Water in oilp. 81
Increased wear, accelerated aging of oil.p. 81
+Chips (abrasion) in the oilp. 81
Chips (abrasion) in the oilp. 81
+l Open and clean all components in the oil circuit, replace if necessary.p. 81
+l Open and clean all components in the oil circuit, replace if necessary.p. 81
l Open and clean all components in the oil circuit, replace if necessary.p. 81
l Clean all high pressure hoses in the oil circuit, replace if necessary.p. 81
l If abrasion is found in the travel circuit you should also flush the vibration circuit.p. 81
l If abrasion is found in the vibration circuit you should also flush the travel circuit.p. 81
+Before flushingp. 82
Before flushingp. 82
+Change the filter elementp. 82
Change the filter elementp. 82
Fig. 1p. 82
+Clean the hydraulic tankp. 82
Clean the hydraulic tankp. 82
Fig. 2p. 82
+Change the oil in case of excessive contamination, oil discoloration or if the oil change interval is almost due.p. 82
Change the oil in case of excessive contamination, oil discoloration or if the oil change interval is almost due.p. 82
+l Filter the tank content with the filling and filtering unit and pump it into an oil container.p. 82
l Filter the tank content with the filling and filtering unit and pump it into an oil container.p. 82
l Mark all hoses and disconnect them from the hydraulic oil tank.p. 82
l Clean the oil tank thoroughly from inside, if necessary remove the tank cover.p. 82
l Reconnect all hoses.p. 82
l Fill the hydraulic oil tank again with the filling and filtering unit.p. 82
+Bleedingp. 82
Bleedingp. 82
Fig. 3p. 82
+l Always bleed closed hydraulic circuits if lines had been removed or connected.p. 82
l Always bleed closed hydraulic circuits if lines had been removed or connected.p. 82
+Servicing the flushing filter kitp. 82
Servicing the flushing filter kitp. 82
Fig. 4p. 82
+l Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.p. 82
l Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.p. 82
l Clean hoses and connections and store the flushing kit in a clean and protected environment.p. 82
12 High pressure hose (B, drum drive motor reverse)p. 84
+13 High pressure hose (A, drum drive motor forward)p. 84
+13 High pressure hose (A, drum drive motor forward)p. 84
13 High pressure hose (A, drum drive motor forward)p. 84
14 High pressure hose (B, axle motor reverse)p. 84
15 High pressure hose (A, axle motor forward)p. 84
16 High pressure hose (B, axle motor reverse)p. 84
17 High pressure port (B, drum drive motor reverse)p. 84
18 Flushing hose 25S – 20S (tool)p. 84
19 Flushing hose 25S – 20S (tool)p. 84
+6.10 Bleeding the vibration circuitp. 85
6.4 Flushing the travel circuit (travel pump distribution)p. 85
+Flushing the drum drivep. 85
Flushing the drum drivep. 85
+Replacing the hydraulic oil filter elementp. 85
Replacing the hydraulic oil filter elementp. 85
+Cleaning the hydraulic oil tankp. 85
Cleaning the hydraulic oil tankp. 85
+Observe the chapter "Flushing – General"p. 85
Observe the chapter "Flushing – General"p. 85
+Fig. 1p. 85
Fig. 1p. 85
+Installing the flushing filterp. 85
Installing the flushing filterp. 85
+Before the installation of the filters check hoses and connections for cleanliness.p. 85
Before the installation of the filters check hoses and connections for cleanliness.p. 85
The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump in forward travel.p. 85
With the connection shown in the illustration the travel pump must therefore be actuated to forward direction.p. 85
+1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 17) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 85
1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 17) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 85
+2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump.p. 85
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump.p. 85
+Fig. 2p. 85
Fig. 2p. 85
+Disconnect the drum drive motorp. 85
Disconnect the drum drive motorp. 85
+3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 85
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 85
+Fig. 3p. 86
Fig. 3p. 86
+Bleeding the travel circuitp. 86
Bleeding the travel circuitp. 86
+Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 86
Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 86
+Fig. 4p. 86
Fig. 4p. 86
+Flushing the hosesp. 86
Flushing the hosesp. 86
+4. Block drums and wheels with suitable chocks.p. 86
4. Block drums and wheels with suitable chocks.p. 86
+Fig. 5p. 86
Fig. 5p. 86
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 86
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 86
+Fig. 6p. 86
Fig. 6p. 86
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 86
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 86
+5. Start the engine and shift the travel lever to travel direction forward.p. 86
5. Start the engine and shift the travel lever to travel direction forward.p. 86
+6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 86
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 86
+7. Shut down the engine.p. 86
7. Shut down the engine.p. 86
+8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 86
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 86
+Fig. 7p. 87
Fig. 7p. 87
+Flushing the drum drive motorp. 87
Flushing the drum drive motorp. 87
+Danger of accident!p. 87
Danger of accident!p. 87
The drum must rotate freely.p. 87
+9. Jack up the front of the machine, so that the drum can rotate freely.p. 87
9. Jack up the front of the machine, so that the drum can rotate freely.p. 87
+10. Secure the rear wheels with chocks.p. 87
10. Secure the rear wheels with chocks.p. 87
+11. Pre-select the slow speed range.p. 87
11. Pre-select the slow speed range.p. 87
+Fig. 8p. 87
Fig. 8p. 87
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 87
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 87
+Fig. 9p. 87
Fig. 9p. 87
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 87
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 87
+12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 87
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 87
+13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 87
13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 87
+14. Shut down the engine.p. 87
14. Shut down the engine.p. 87
+15. Remove the flushing filter and reconnect the high pressure lines.p. 87
15. Remove the flushing filter and reconnect the high pressure lines.p. 87
Flushing the axle drivep. 88
+Fig. 10p. 88
Fig. 10p. 88
+Installing the flushing filterp. 88
Installing the flushing filterp. 88
+16. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (18) (flushing filter inlet "IN").p. 88
16. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (18) (flushing filter inlet "IN").p. 88
+17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 88
17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 88
+Fig. 11p. 88
Fig. 11p. 88
+Disconnecting the axle motorp. 88
Disconnecting the axle motorp. 88
+18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and 15) on the axle drive motor together.p. 88
18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and 15) on the axle drive motor together.p. 88
+Fig. 12p. 88
Fig. 12p. 88
+Bleeding the travel circuitp. 88
Bleeding the travel circuitp. 88
+Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 88
Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 88
+Fig. 13p. 89
Fig. 13p. 89
+Flushing the hosesp. 89
Flushing the hosesp. 89
+19. Block drums and wheels with suitable chocks.p. 89
19. Block drums and wheels with suitable chocks.p. 89
+Fig. 14p. 89
Fig. 14p. 89
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 89
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 89
+Fig. 15p. 89
Fig. 15p. 89
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 89
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 89
+20. Start the engine and shift the travel lever to travel direction forward.p. 89
20. Start the engine and shift the travel lever to travel direction forward.p. 89
+21. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 89
21. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 89
+22. Shut down the engine.p. 89
22. Shut down the engine.p. 89
+23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor.p. 89
23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor.p. 89
+Fig. 16p. 89
Fig. 16p. 89
+Flushing the axle motorp. 89
Flushing the axle motorp. 89
+Danger of accident!p. 89
Danger of accident!p. 89
Both wheels must be off the ground. The wheels must be able to rotate freely.p. 89
+24. Jack up the rear of the machine, so that the wheels can rotate freely.p. 89
24. Jack up the rear of the machine, so that the wheels can rotate freely.p. 89
+25. Secure the drum with wheel chocks.p. 89
25. Secure the drum with wheel chocks.p. 89
+26. Pre-select the slow speed range.p. 89
26. Pre-select the slow speed range.p. 89
+Fig. 17p. 90
Fig. 17p. 90
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 90
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 90
+Fig. 18p. 90
Fig. 18p. 90
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 90
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 90
+27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 90
27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 90
+28. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 90
28. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 90
+29. Shut down the engine.p. 90
29. Shut down the engine.p. 90
+30. Remove the flushing filter and reconnect the high pressure lines.p. 90
30. Remove the flushing filter and reconnect the high pressure lines.p. 90
+Bleeding the travel circuitp. 90
Bleeding the travel circuitp. 90
+31. Bleed the travel circuit (see corresponding chapter).p. 90
31. Bleed the travel circuit (see corresponding chapter).p. 90
+Keep circulating the tank content.p. 90
Keep circulating the tank content.p. 90
+32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 90
32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 90
+Fig. 19p. 90
Fig. 19p. 90
+Function testp. 90
Function testp. 90
+33. Check the hydraulic oil level in the tank, fill up if necessary.p. 90
33. Check the hydraulic oil level in the tank, fill up if necessary.p. 90
+34. Check all connections for leaks with the engine running (visual inspection).p. 90
34. Check all connections for leaks with the engine running (visual inspection).p. 90
+35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 90
35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 90
+36. Check all ports and connections for leak tightness (visual inspection).p. 90
36. Check all ports and connections for leak tightness (visual inspection).p. 90
12 High pressure hose (drum drive motor reverse)p. 95
+13 High pressure hose (drum drive motor forward)p. 95
+13 High pressure hose (drum drive motor forward)p. 95
13 High pressure hose (drum drive motor forward)p. 95
14 High pressure hose (B, axle motor reverse)p. 95
15 High pressure hose (A, axle motor forward)p. 95
16 High pressure hose (B, axle motor reverse)p. 95
17 not usedp. 95
18 Flushing hose 25S – 20S (tool)p. 95
19 Flushing hose 25S – 20S (tool)p. 95
+6.10 Bleeding the vibration circuitp. 96
6.6 Flushing the travel circuit (axle motor distribution)p. 96
+Flushing the drum drivep. 96
Flushing the drum drivep. 96
+Replacing the hydraulic oil filter elementp. 96
Replacing the hydraulic oil filter elementp. 96
+Cleaning the hydraulic oil tankp. 96
Cleaning the hydraulic oil tankp. 96
+Observe the chapter "Flushing – General"p. 96
Observe the chapter "Flushing – General"p. 96
+Fig. 1p. 96
Fig. 1p. 96
+Installing the flushing filterp. 96
Installing the flushing filterp. 96
+Before the installation of the filters check hoses and connections for cleanliness.p. 96
Before the installation of the filters check hoses and connections for cleanliness.p. 96
The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump in forward travel.p. 96
With the connection shown in the illustration the travel pump must therefore be actuated to forward direction.p. 96
+1. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (19) (flushing filter inlet "IN").p. 96
1. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (19) (flushing filter inlet "IN").p. 96
+2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 96
2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 96
+Fig. 2p. 96
Fig. 2p. 96
+Disconnect the drum drive motorp. 96
Disconnect the drum drive motorp. 96
+3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 96
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 96
+Fig. 3p. 97
Fig. 3p. 97
+Bleeding the travel circuitp. 97
Bleeding the travel circuitp. 97
+Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 97
Bleeding the travel circuit, see chapter "Bleeding the travel circuit".p. 97
+Fig. 4p. 97
Fig. 4p. 97
+Flushing the hosesp. 97
Flushing the hosesp. 97
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 97
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 97
+Fig. 5p. 97
Fig. 5p. 97
+4. Block drums and wheels with suitable chocks.p. 97
4. Block drums and wheels with suitable chocks.p. 97
+Fig. 6p. 97
Fig. 6p. 97
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 97
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 97
+5. Start the engine and shift the travel lever to travel direction forward.p. 97
5. Start the engine and shift the travel lever to travel direction forward.p. 97
+6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 97
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 97
+7. Shut down the engine.p. 97
7. Shut down the engine.p. 97
+8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 97
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 97
+Fig. 7p. 98
Fig. 7p. 98
+Flushing the drum drive motorp. 98
Flushing the drum drive motorp. 98
+Danger of accident!p. 98
Danger of accident!p. 98
The drum must rotate freely.p. 98
+9. Jack up the front of the machine, so that the drum can rotate freely.p. 98
9. Jack up the front of the machine, so that the drum can rotate freely.p. 98
+10. Secure the rear wheels with chocks.p. 98
10. Secure the rear wheels with chocks.p. 98
+11. Pre-select the slow speed range.p. 98
11. Pre-select the slow speed range.p. 98
+Fig. 8p. 98
Fig. 8p. 98
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 98
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 98
+Fig. 9p. 98
Fig. 9p. 98
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 98
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 98
+12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 98
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 98
+13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 98
13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 98
+14. Shut down the engine.p. 98
14. Shut down the engine.p. 98
Flushing the axle motorp. 99
+Fig. 10p. 99
Fig. 10p. 99
+Danger of accident!p. 99
Danger of accident!p. 99
Both wheels must be off the ground. The wheels must be able to rotate freely.p. 99
+15. Jack up the rear of the machine, so that the wheels can rotate freely.p. 99
15. Jack up the rear of the machine, so that the wheels can rotate freely.p. 99
+16. Secure the drum with wheel chocks.p. 99
16. Secure the drum with wheel chocks.p. 99
+17. Pre-select the slow speed range.p. 99
17. Pre-select the slow speed range.p. 99
+Fig. 11p. 99
Fig. 11p. 99
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 99
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 99
+Fig. 12p. 99
Fig. 12p. 99
+Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 99
Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 99
+18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 99
18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 99
+19. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 99
19. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 99
+20. Shut down the engine.p. 99
20. Shut down the engine.p. 99
+21. Remove the flushing filter and reconnect the high pressure lines.p. 99
21. Remove the flushing filter and reconnect the high pressure lines.p. 99
+Bleeding the travel circuitp. 99
Bleeding the travel circuitp. 99
+22. Bleed the travel circuit (see corresponding chapter).p. 99
22. Bleed the travel circuit (see corresponding chapter).p. 99
+Keep circulating the tank content.p. 99
Keep circulating the tank content.p. 99
+23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 99
23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 99
+Fig. 13p. 100
Fig. 13p. 100
+Function testp. 100
Function testp. 100
+24. Check the hydraulic oil level in the tank, fill up if necessary.p. 100
24. Check the hydraulic oil level in the tank, fill up if necessary.p. 100
+25. Check all connections for leaks with the engine running (visual inspection).p. 100
25. Check all connections for leaks with the engine running (visual inspection).p. 100
+26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 100
26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 100
+27. Check all ports and connections for leak tightness (visual inspection).p. 100
27. Check all ports and connections for leak tightness (visual inspection).p. 100
+6.10 Bleeding the vibration circuitp. 101
Flushing schematic for vibration drive
+1 Elbow union (tool)p. 101
+1 Elbow union (tool)p. 101
1 Elbow union (tool)p. 101
2 Connecting union (tool)p. 101
3 Vibration motorp. 101
4 Vibration pumpp. 101
5 Screw socket R1 – 25S (tool)p. 101
6 Flushing hose 25S – 20S (tool)p. 101
+7 Flushing hose 25S – 20S (tool)p. 101
+7 Flushing hose 25S – 20S (tool)p. 101
7 Flushing hose 25S – 20S (tool)p. 101
+8 Flushing filter with filter element 1p. 101
mp. 101
9 SAE flange (tool)p. 101
10 High pressure hose (B, high frequency)p. 101
11 High pressure hose (A, low frequency)p. 101
+6.10 Bleeding the vibration circuitp. 102
6.8 Flushing the vibration circuitp. 102
+Replacing the hydraulic oil filter elementp. 102
Replacing the hydraulic oil filter elementp. 102
+Cleaning the hydraulic oil tankp. 102
Cleaning the hydraulic oil tankp. 102
+Observe the chapter "Flushing – General"p. 102
Observe the chapter "Flushing – General"p. 102
+Fig. 1p. 102
Fig. 1p. 102
+Installing the flushing filterp. 102
Installing the flushing filterp. 102
+Before the installation of the filters check hoses and connections for cleanliness.p. 102
Before the installation of the filters check hoses and connections for cleanliness.p. 102
The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the vibration pump in high frequency.p. 102
For the connection schematic shown here the vibration must always be filtered with "high frequency / low amplitude".p. 102
+1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic – vibration circuit") from the vibration pump (4) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 102
1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic – vibration circuit") from the vibration pump (4) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 102
+2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump.p. 102
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump.p. 102
+Fig. 2p. 102
Fig. 2p. 102
+Disconnect the vibration motorp. 102
Disconnect the vibration motorp. 102
+3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together.p. 102
3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together.p. 102
+Fig. 3p. 103
Fig. 3p. 103
+Bleeding the vibration circuitp. 103
Bleeding the vibration circuitp. 103
+Bleeding the vibration circuit, see chapter "Bleeding the vibration circuit".p. 103
Bleeding the vibration circuit, see chapter "Bleeding the vibration circuit".p. 103
+Fig. 4p. 103
Fig. 4p. 103
+Flushing the hosesp. 103
Flushing the hosesp. 103
+4. Block drums and wheels with suitable chocks.p. 103
4. Block drums and wheels with suitable chocks.p. 103
+Fig. 5p. 103
Fig. 5p. 103
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 103
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 103
+Fig. 6p. 103
Fig. 6p. 103
+Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 103
Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 103
+5. Switch on vibration with high frequency.p. 103
5. Switch on vibration with high frequency.p. 103
+6. Start the engine and run it with maximum speed.p. 103
6. Start the engine and run it with maximum speed.p. 103
+7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds.p. 103
7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds.p. 103
+8. Shut down the engine.p. 103
8. Shut down the engine.p. 103
+9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.p. 103
9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.p. 103
+Fig. 7p. 104
Fig. 7p. 104
+Flushing the vibration motorp. 104
Flushing the vibration motorp. 104
+10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.p. 104
10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.p. 104
+Fig. 8p. 104
Fig. 8p. 104
+Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 104
Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.p. 104
+Fig. 9p. 104
Fig. 9p. 104
+Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 104
Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 104
+11. Start the engine and run it with maximum speed.p. 104
11. Start the engine and run it with maximum speed.p. 104
+12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.p. 104
12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.p. 104
+13. Shut down the engine.p. 104
13. Shut down the engine.p. 104
+14. Remove the flushing filter and reinstall the vibration motor.p. 104
14. Remove the flushing filter and reinstall the vibration motor.p. 104
+Bleeding the vibration circuitp. 104
Bleeding the vibration circuitp. 104
+15. Bleed the vibration circuit (see corresponding chapter).p. 104
15. Bleed the vibration circuit (see corresponding chapter).p. 104
+Keep circulating the tank content.p. 104
Keep circulating the tank content.p. 104
+16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 104
16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 104
+Fig. 10p. 105
Fig. 10p. 105
+Function testp. 105
Function testp. 105
+17. Check the hydraulic oil level in the tank, fill up if necessary.p. 105
17. Check the hydraulic oil level in the tank, fill up if necessary.p. 105
+18. Test drive.p. 105
18. Test drive.p. 105
+19. Check all ports and connections for leak tightness (visual inspection).p. 105
19. Check all ports and connections for leak tightness (visual inspection).p. 105
+6.10 Bleeding the vibration circuitp. 106
+6.9 Bleeding the travel circuitp. 106
+Catch hydraulic oil and dispose of environmentally.p. 106
Catch hydraulic oil and dispose of environmentally.p. 106
+1. Install a pressure test hose to the charge pressure test port.p. 106
1. Install a pressure test hose to the charge pressure test port.p. 106
+2. Install a pressure test hose each to the high pressure test ports.p. 106
2. Install a pressure test hose each to the high pressure test ports.p. 106
+Fig. 1p. 106
Fig. 1p. 106
+3. Actuate the emergency stop switch.p. 106
3. Actuate the emergency stop switch.p. 106
+The engine should not start.p. 106
The engine should not start.p. 106
+Fig. 2p. 106
Fig. 2p. 106
+4. Hold the open ends of the pressure test hosesp. 106
+4. Hold the open ends of the pressure test hosesp. 106
(Fig. 2)p. 106
+5. Operate the starter motor for approx. 30 seconds. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.p. 106
5. Operate the starter motor for approx. 30 seconds. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.p. 106
+6. Remove the pressure test hoses.p. 106
6. Remove the pressure test hoses.p. 106
+Fig. 3p. 106
Fig. 3p. 106
+7. Unlock the emergency stop switchp. 106
7. Unlock the emergency stop switchp. 106
+Fig. 4p. 107
Fig. 4p. 107
+8. Connect a 60 bar pressure gauge to the charge pressure test portp. 107
+8. Connect a 60 bar pressure gauge to the charge pressure test portp. 107
(Fig. 4)p. 107
+9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.p. 107
9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.p. 107
+Fig. 5p. 107
Fig. 5p. 107
+With the flushing filter installed shift the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 107
With the flushing filter installed shift the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 107
+Run the engine with idle speed.p. 107
Run the engine with idle speed.p. 107
+10. Start the engine.p. 107
10. Start the engine.p. 107
+11. Shift the travel leverp. 107
+11. Shift the travel leverp. 107
(Fig. 5)p. 107
+12. After approx. 1 to 2 minutes shut down the engine for a minute.p. 107
12. After approx. 1 to 2 minutes shut down the engine for a minute.p. 107
+This waiting time is necessary to allow air bubbles to escape through the leak oil return line.p. 107
This waiting time is necessary to allow air bubbles to escape through the leak oil return line.p. 107
+13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 107
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 107
+6.10 Bleeding the vibration circuitp. 108
+6.10 Bleeding the vibration circuitp. 108
+Catch hydraulic oil and dispose of environmentally.p. 108
Catch hydraulic oil and dispose of environmentally.p. 108
+1. Install a pressure test hose to the charge pressure test port.p. 108
1. Install a pressure test hose to the charge pressure test port.p. 108
+2. Install a pressure test hose each to the high pressure test ports.p. 108
2. Install a pressure test hose each to the high pressure test ports.p. 108
+Fig. 1p. 108
Fig. 1p. 108
+3. Actuate the emergency stop switch.p. 108
3. Actuate the emergency stop switch.p. 108
+Fig. 2p. 108
Fig. 2p. 108
+4. Hold the open ends of the pressure test hosesp. 108
+4. Hold the open ends of the pressure test hosesp. 108
(Fig. 2)p. 108
+5. Crank the engine approx. 10 seconds with the starter motor. Wait one minute and keep repeating this procedure, until oil starts to run out from the pressure test hoses.p. 108
5. Crank the engine approx. 10 seconds with the starter motor. Wait one minute and keep repeating this procedure, until oil starts to run out from the pressure test hoses.p. 108
+6. Remove the pressure test hoses.p. 108
6. Remove the pressure test hoses.p. 108
+Fig. 3p. 108
Fig. 3p. 108
+7. Unlock the emergency stop switchp. 108
7. Unlock the emergency stop switchp. 108
+Fig. 4p. 109
Fig. 4p. 109
+8. Connect a 60 bar pressure gauge to the charge pressure test portp. 109
+8. Connect a 60 bar pressure gauge to the charge pressure test portp. 109
(Fig. 4)p. 109
+9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.p. 109
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.p. 109
+Fig. 5p. 109
Fig. 5p. 109
+With the flushing filter installed use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 109
With the flushing filter installed use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.p. 109
+10. For bleeding switch on vibration with high frequencyp. 109
+10. For bleeding switch on vibration with high frequencyp. 109
(Fig. 5)p. 109
+11. Start the engine.p. 109
11. Start the engine.p. 109
+12. After running the engine 1 to 2 minutes pause for approx. one minute.p. 109
12. After running the engine 1 to 2 minutes pause for approx. one minute.p. 109
+This waiting time is necessary to allow air bubbles to escape through the leak oil return line.p. 109
This waiting time is necessary to allow air bubbles to escape through the leak oil return line.p. 109
+13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 109
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 109
+7 Caddy wiring diagramsp. 111
+7 Caddy wiring diagramsp. 111
7.1 Understanding circuit diagramsp. 112
+Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry logics.p. 112
Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry logics.p. 112
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 112
+l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 112
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, …p. 112
l The sequence in which current flows through the individual elements in the electric circuit.p. 112
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.p. 112
l Pin assignment of plug-and-socket connections.p. 112
+Structurep. 112
Structurep. 112
+l Table of contentsp. 112
+l Table of contentsp. 112
(Fig. 6)p. 112
+l Function groupsp. 112
(Fig. 7)p. 112
+l List of componentsp. 112
(Fig. 9)p. 112
+Potential cross referencesp. 113
+Table of contentsp. 113
(Fig. 6)p. 113
The table of contents lists all function groups.p. 113
Fig. 6 Table of contentsp. 113
Example:p. 113
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.p. 113
+Potential cross referencesp. 114
+Function groupsp. 114
(Fig. 7)p. 114
On the individual pages the electric circuits are combined to function groups.p. 114
Arrangement of current pathsp. 114
The individual current paths must be read as follows:p. 114
+l From top (plus potential) to bottom (minus potential).p. 114
l From top (plus potential) to bottom (minus potential).p. 114
l From left to right.p. 114
l From function group to function group.p. 114
l Via cross references for potentials and relays.p. 114
Fig. 7 Function groupsp. 114
+Potential cross referencesp. 114
Potential cross referencesp. 114
+Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 114
Potential cross references serve the purpose of tracking signals, which are transmitted from one function group to another.p. 114
Example:p. 114
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page no. 8 in current path "1“.p. 114
+Relay cross referencep. 114
Relay cross referencep. 114
+Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 114
Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.p. 114
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally attached to the bottom of each contactor coil.p. 114
Example:p. 114
The coil of relay (K99) is located on page no. 8 in current path "6".p. 114
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is triggered.p. 114
The changeover contact can be found on page no. 8 in current path "3".p. 114
+Current pathsp. 115
Current pathsp. 115
+The pages of a circuit diagram are sub-divided into current pathsp. 115
(Fig. 8)p. 115
Fig. 8 Current pathsp. 115
+Component cross referencesp. 116
+List of componentsp. 116
(Fig. 9)p. 116
Here you find all components used in alphabetical order, related to the name of the component (A01, A02….).p. 116
Fig. 9 List of componentsp. 116
+Component cross referencesp. 116
Component cross referencesp. 116
+Example:p. 116
Example:p. 116
The warning horn "B 11" is located on page no. 8 in current path 3.p. 116
7.2 Circuit symbols in the circuit diagramp. 117
+Circuit symbolp. 117
Circuit symbolp. 117
+l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in complianc…p. 117
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in complianc…p. 117
Fig. 1 Example: Circuit symbolp. 117
+1 Current sourcep. 117
1 Current sourcep. 117
2 Conductorp. 117
3 Switchp. 117
4 Groundp. 117
5 Filament lampp. 117
6 Filament lamp with two luminous elementsp. 117
7 Voltmeterp. 117
8 Amperemeterp. 117
9 Resistancep. 117
10 Backupp. 117
11 Line connection (fixed)p. 117
12 Line connection (separable)p. 117
7.3 Identification of switch blocks in the Caddy wiring diagramp. 118
+Switches of modular designp. 118
Switches of modular designp. 118
+l For normally open contacts the contact symbols "_3/_4" are used.p. 118
l For normally open contacts the contact symbols "_3/_4" are used.p. 118
l For normally closed contacts the contact symbols "_1/_2" are used.p. 118
In combination with the contact block numbering described above each individual connection is clearly defined.p. 118
+Example of terminal designationsp. 118
Example of terminal designationsp. 118
Fig. 2 Terminal designationsp. 118
+l Normally open contact 23 located on block 2p. 118
l Normally open contact 23 located on block 2p. 118
l Normally open contact 24 located on block 2p. 118
l Normally closed contact 12 located on block 1p. 118
l Normally closed contact 11 located on block 1p. 118
l Normally open contact 34 located on block 3p. 118
l Normally open contact 33 located on block 3p. 118
l Normally open contact 63 located on block 6p. 118
l Normally open contact 64 located on block 6p. 118
l Normally open contact 43 located on block 4p. 118
l Normally open contact 44 located on block 4p. 118
+If e.g. block 5 is not needed to design a switch, the numbering for blocks 1,2,3,4 and 6 remains unchanged.p. 118
If e.g. block 5 is not needed to design a switch, the numbering for blocks 1,2,3,4 and 6 remains unchanged.p. 118
+8 E-Plan wiring diagramsp. 119
+8 E-Plan wiring diagramsp. 119
8.1 Understanding wiring diagramsp. 120
+Electric circuit diagramsp. 120
Electric circuit diagramsp. 120
+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. 120
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. 120
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information:p. 120
+l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 120
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc.p. 120
l The sequence in which current flows through the individual elements in the electric circuit.p. 120
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.p. 120
l Pin assignment of plug-and-socket connections.p. 120
+Structure of a wiring diagramp. 120
Structure of a wiring diagramp. 120
+l Cover sheet, see section "Cover sheet"p. 120
l Cover sheet, see section "Cover sheet"p. 120
l Table of contents, see section "Table of contents"p. 120
l Structuring symbol overview, see section "Structuring symbol overview"p. 120
+The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 120
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification!p. 120
+l Sheets with illustration of function, see section"Sheets with illustration of function"p. 120
l Sheets with illustration of function, see section"Sheets with illustration of function"p. 120
l List of fuels and lubricants, see "List of fuels and lubricants"p. 120
l Terminal strip overview, see section "Terminal strip overview"p. 120
l Plug overview, see section "Plug overview"p. 120
l Pin overview, see section "Pin overview"p. 120
Cover sheetp. 121
+The cover sheet, see examplep. 121
(Fig. 3)p. 121
Fig. 3 Example: Cover sheetp. 121
Table of contentsp. 122
+The table of contents, see examplep. 122
(Fig. 4)p. 122
Fig. 4 Example: Table of contentsp. 122
Sheets with representations of functionsp. 123
+l The main reading direction is sheet by sheet, from top to bottom and from right to left.p. 123
l The main reading direction is sheet by sheet, from top to bottom and from right to left.p. 123
l All sheets are successively numbered.p. 123
+l BOMAG used the resolved type of representation. In this case parts and components with different functions, which belong to the same components (e.g. relay coil and relay contact), can be represented on different sheets. Cross-references, which ref…p. 123
(Fig. 5)p. 123
Fig. 5 Example: Sheet with functionsp. 123
+Current pathsp. 123
+Current pathsp. 123
(Fig. 5)p. 123
+l Current paths are successively numbered from 0 to 9.p. 123
l Current paths are successively numbered from 0 to 9.p. 123
+Potential cross referencesp. 123
+Potential cross referencesp. 123
(Fig. 5)p. 123
+l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 123
l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them.p. 123
+Example: Potentialp. 123
+Example: Potentialp. 123
®p. 123
~p. 123
+SEATp. 123
+Relay cross referencesp. 124
+Relay cross referencesp. 124
(Fig. 5)p. 124
+l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta…p. 124
l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta…p. 124
+Example: The relay cross-reference (p. 124
Example:p. 124
-K61/4.2p. 124
List of componentp. 125
+The list of components, see examplep. 125
(Fig. 6)p. 125
Fig. 6 Example: List of componentsp. 125
An electric component is a part, assembly or device in an electrical installation.p. 125
+l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the …p. 125
l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN – EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same component. In this context the …p. 125
l The component identifications are alphabetically sorted in the list of components. Each component has the corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which installation location it is assigned t…p. 125
+Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 125
Component identifications are used in both the electrical and the hydraulic documentation and are identical.p. 125
Overview of terminal stripsp. 126
+The overview of terminal strips, see axamplep. 126
(Fig. 7)p. 126
Fig. 7 Example: Terminal strip overview X1p. 126
Overview of plugsp. 127
+The overview of plugs, see examplep. 127
(Fig. 8)p. 127
The following information is listed for each plug:p. 127
+l Contact numberingp. 127
l Contact numberingp. 127
l Structuring symbolsp. 127
l Function textp. 127
l Use in wiring diagram.p. 127
Fig. 8 Example: Plug overview X0p. 127
Overview of pinsp. 128
+The overview of pins, see examplep. 128
(Fig. 9)p. 128
Fig. 9 Example: Overview of pins, control A66p. 128
8.2 Circuit symbols in the circuit diagramp. 129
+Circuit symbolsp. 129
Circuit symbolsp. 129
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. 129
Fig. 10 Example: Circuit symbolp. 129
+1 Current sourcep. 129
1 Current sourcep. 129
2 Conductorp. 129
3 Switchp. 129
4 Groundp. 129
5 Filament lampp. 129
6 Filament lamp with two luminous elementsp. 129
7 Voltmeterp. 129
8 Amperemeterp. 129
9 Resistancep. 129
10 Fusep. 129
11 Terminal stripp. 129
12 Plugp. 129
+Different symbols are used to simplify the differentiation of terminal strips 11p. 129
(Fig. 10)p. 129
+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. 129
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. 129
Representation of electric devicesp. 130
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. 130
+Black-Box representationp. 130
+Black-Box representationp. 130
(Fig. 11)p. 130
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. 130
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is available.p. 130
Fig. 11 Example: Central lubrication systemp. 130
+Identification of externally supplied documentationp. 130
(Fig. 12)p. 130
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. 130
Fig. 12 Example: Identification of externally supplied documentationp. 130
+PLC representationp. 130
+PLC representationp. 130
(Fig. 13)p. 130
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. 130
Fig. 13 PLC representationp. 131
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. 131
Identification of similar, adjacent switching symbolsp. 131
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. 131
+Example: -X0 36 and -X0 37p. 131
(Fig. 13)p. 131
In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol.p. 131
8.3 Identification of switch blocks in the wiring diagramp. 132
+Switches of modular designp. 132
Switches of modular designp. 132
+l For normally open contacts the contact symbols "_3/_4" are used.p. 132
l For normally open contacts the contact symbols "_3/_4" are used.p. 132
l For normally closed contacts the contact symbols "_1/_2" are used.p. 132
In combination with the contact block numbering described above each individual connection is clearly defined.p. 132
Fig. 14p. 132
Example:p. 132
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. 132
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. 132
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. 132
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. 132
+9 Electricsp. 133
9 Electricsp. 133
+9.23 Battery servicep. 134
9.1 Designation of components in the wiring diagramp. 134
+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. 134
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. 134
Control lights, warning buzzer, warning lightp. 134
+Kp. 134
Kp. 134
+Relaysp. 134
Relaysp. 134
+Mp. 134
Mp. 134
+Starter, pumps, motorsp. 134
Starter, pumps, motorsp. 134
+Pp. 134
Pp. 134
+Operating hour meter, general gaugesp. 134
Operating hour meter, general gaugesp. 134
+Rp. 134
Rp. 134
+Transducers, resistorsp. 134
Transducers, resistorsp. 134
+Sp. 134
Sp. 134
+Switches, momentary contact switchesp. 134
Switches, momentary contact switchesp. 134
+Vp. 134
Vp. 134
+Diodep. 134
Diodep. 134
+Xp. 134
Xp. 134
+Terminalp. 134
Terminalp. 134
+Yp. 134
Yp. 134
+Solenoid valvesp. 134
Solenoid valvesp. 134
+9.23 Battery servicep. 135
9.2 Terminal designations in wiring diagramp. 135
+l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 135
+l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 135
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following …p. 135
+Terminal designationp. 135
Terminal designationp. 135
+Meaningp. 135
Meaningp. 135
+15p. 135
15p. 135
+Switch plus (after battery) : Output of ignition switchp. 135
Switch plus (after battery) : Output of ignition switchp. 135
+15ap. 135
15ap. 135
+Output from dropping resistor to ignition coil and starterp. 135
Output from dropping resistor to ignition coil and starterp. 135
+Battery changeover relay 12V / 24V return line to battery 2 minusp. 135
Battery changeover relay 12V / 24V return line to battery 2 minusp. 135
+31bp. 135
31bp. 135
+Return line to battery minus or ground via switch or relay (switched minus)p. 135
Return line to battery minus or ground via switch or relay (switched minus)p. 135
+31cp. 135
31cp. 135
+Battery changeover relay 12V / 24V return line to battery 1 minusp. 135
Battery changeover relay 12V / 24V return line to battery 1 minusp. 135
+49p. 135
49p. 135
+Input flasher relayp. 135
Input flasher relayp. 135
+49ap. 135
49ap. 135
+Output flasher relayp. 135
Output flasher relayp. 135
+49bp. 135
49bp. 135
+Flasher relay output 2nd flasher circuitp. 135
Flasher relay output 2nd flasher circuitp. 135
+49cp. 135
49cp. 135
+Flasher relay output 3rd flasher circuitp. 135
Flasher relay output 3rd flasher circuitp. 135
+50p. 135
50p. 135
+Starter, starter controlp. 135
Starter, starter controlp. 135
+50ap. 135
50ap. 135
+Battery changeover relay, output for starter controlp. 135
Battery changeover relay, output for starter controlp. 135
+53p. 135
53p. 135
+Wiper motor input (+)p. 135
Wiper motor input (+)p. 135
+53ap. 135
53ap. 135
+Wiper motor (+) end limit shut downp. 135
Wiper motor (+) end limit shut downp. 135
+53bp. 135
53bp. 135
+Wiper shunt windingp. 135
Wiper shunt windingp. 135
+56p. 135
56p. 135
+Head lightp. 135
Head lightp. 135
+56ap. 135
56ap. 135
+Head light, travel light and travel light controlp. 135
Head light, travel light and travel light controlp. 135
+56bp. 135
56bp. 135
+Head lights, dimmed head lightp. 135
Head lights, dimmed head lightp. 135
+56dp. 135
56dp. 135
+Head lights, flash lightp. 135
Head lights, flash lightp. 135
+57p. 135
57p. 135
+Parking light for motor cycles (abroad also for cars and trucks)p. 135
Parking light for motor cycles (abroad also for cars and trucks)p. 135
+57ap. 135
57ap. 135
+Parking lightp. 135
Parking lightp. 135
+57Lp. 135
57Lp. 135
+Parking light leftp. 135
Parking light leftp. 135
+57Rp. 135
57Rp. 135
+Parking light rightp. 135
Parking light rightp. 135
+58p. 135
58p. 135
+Side lights, tail light, number plate light, dashboard lightp. 135
Side lights, tail light, number plate light, dashboard lightp. 135
+58bp. 135
58bp. 135
+Tail light changeover for single axle trailersp. 135
Tail light changeover for single axle trailersp. 135
+58cp. 135
58cp. 135
+Trailer plug for single core wired and trailer fused tail lightp. 135
Trailer plug for single core wired and trailer fused tail lightp. 135
+58dp. 135
58dp. 135
+Adjustable dashboard light, tail light and side lightp. 135
Adjustable dashboard light, tail light and side lightp. 135
+58Lp. 135
58Lp. 135
+Side light, leftp. 135
Side light, leftp. 135
+58Rp. 135
58Rp. 135
+Side light, rightp. 135
Side light, rightp. 135
+61p. 135
61p. 135
+Generator controlp. 135
Generator controlp. 135
+75p. 135
75p. 135
+Radio, cigarette lighterp. 135
Radio, cigarette lighterp. 135
+76p. 135
76p. 135
+Loudspeakerp. 135
Loudspeakerp. 135
+87p. 135
87p. 135
+Relay contact on breaker and two-way contact, inputp. 135
Relay contact on breaker and two-way contact, inputp. 135
+87ap. 136
87ap. 136
+Relay contact on breaker and two-way contact, output 1 (breaker side)p. 136
Relay contact on breaker and two-way contact, output 1 (breaker side)p. 136
+87bp. 136
87bp. 136
+Relay contact on breaker and two-way contact, output 2p. 136
Relay contact on breaker and two-way contact, output 2p. 136
+87cp. 136
87cp. 136
+Relay contact on breaker and two-way contact, output 3p. 136
Relay contact on breaker and two-way contact, output 3p. 136
+87zp. 136
87zp. 136
+Relay contact on breaker and two-way contact, input 1p. 136
Relay contact on breaker and two-way contact, input 1p. 136
+87yp. 136
87yp. 136
+Relay contact on breaker and two-way contact, input 2p. 136
Relay contact on breaker and two-way contact, input 2p. 136
+87xp. 136
87xp. 136
+Relay contact on breaker and two-way contact, input 3p. 136
Relay contact on breaker and two-way contact, input 3p. 136
+88p. 136
88p. 136
+Relay contact for makerp. 136
Relay contact for makerp. 136
+88ap. 136
88ap. 136
+Relay contact on maker and two-way contact, (maker side) output 1p. 136
Relay contact on maker and two-way contact, (maker side) output 1p. 136
+88bp. 136
88bp. 136
+Relay contact on maker and two-way contact, (maker side) output 2p. 136
Relay contact on maker and two-way contact, (maker side) output 2p. 136
+88cp. 136
88cp. 136
+Relay contact on maker and two-way contact, (maker side) output 3p. 136
Relay contact on maker and two-way contact, (maker side) output 3p. 136
+88zp. 136
88zp. 136
+Relay contact on maker, input 1p. 136
Relay contact on maker, input 1p. 136
+88yp. 136
88yp. 136
+Relay contact on maker, input 2p. 136
Relay contact on maker, input 2p. 136
+88xp. 136
88xp. 136
+Relay contact on maker, input 3p. 136
Relay contact on maker, input 3p. 136
+B+p. 136
B+p. 136
+Battery positivep. 136
Battery positivep. 136
+B-p. 136
B-p. 136
+Battery minusp. 136
Battery minusp. 136
+D+p. 136
D+p. 136
+Dynamo Plusp. 136
Dynamo Plusp. 136
+D-p. 136
D-p. 136
+Dynamo Minusp. 136
Dynamo Minusp. 136
+DFp. 136
DFp. 136
+Dynamo field (generator excitation current)p. 136
Dynamo field (generator excitation current)p. 136
+DF1p. 136
DF1p. 136
+Dynamo field 1 (generator excitation current)p. 136
Dynamo field 1 (generator excitation current)p. 136
+DF2p. 136
DF2p. 136
+Dynamo field 2 (generator excitation current)p. 136
Dynamo field 2 (generator excitation current)p. 136
+9.23 Battery servicep. 137
9.3 Battery ground and analog groundp. 137
+GND, battery groundp. 137
GND, battery groundp. 137
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. 137
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. 137
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. 137
Terminal designation for GND = terminale 31p. 137
+AGND, analog groundp. 137
AGND, analog groundp. 137
Apart from the "normal" battery ground there is also the analog ground, which is solely reserved for sensors.p. 137
+9.23 Battery servicep. 137
9.4 Current and voltagep. 137
+Generalp. 137
Generalp. 137
If one wants to describe electric current, this can most simply be accomplished by means of a comparison:p. 137
One simply compares electric current with water.p. 137
+Voltagep. 137
Voltagep. 137
Fig. 1p. 137
+1 (Fig. 1) Chargep. 137
+1 (Fig. 1) Chargep. 137
1 (Fig. 1)p. 137
2 Voltagep. 137
3 Currentp. 137
+The equalization attempt between different electric charges is referred to as electric voltage.p. 137
The equalization attempt between different electric charges is referred to as electric voltage.p. 137
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. 137
Fig. 2p. 137
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.p. 137
Plus pole= lack of electronsp. 137
Minus pole = excess of electronsp. 137
The following statements concerning electric voltage can be madep. 138
+l electric voltage is the pressure or force applied to free electrons.p. 138
l electric voltage is the pressure or force applied to free electrons.p. 138
l the electric voltage is the cause of electric currentp. 138
l electric voltage is a result of the equalization attempt of electric charges.p. 138
Voltage is measured with a Voltmeter.p. 138
Unit, Voltp. 138
The electric voltage (U) is measured in Volt (V).p. 138
Currentp. 138
+Electric current generally describes the directed movement of charge carriers.p. 138
Electric current generally describes the directed movement of charge carriers.p. 138
+l The charge carriers may either be electrons or ions.p. 138
l The charge carriers may either be electrons or ions.p. 138
l Electric current can only flow if there is a sufficient amount of free moving charge carriers.p. 138
l The higher the number of electrons flowing through a conductor per second, the higher the amperage.p. 138
Current is measured with an ammeter.p. 138
Unit, Amperep. 138
The electric amperage (I) is measured in Ampere (A).p. 138
The technical flow direction is specified from PLUS to MINUS.p. 138
+Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 138
Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons.p. 138
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. 138
+Circuitp. 138
Circuitp. 138
Fig. 3 Circuitp. 138
+A simple circuit consists of a current source 1p. 138
(Fig. 3)p. 138
When the circuit is closed, current can flow.p. 138
The circuit can be interrupted or closed with a switch (2).p. 138
The system is protected by a fuse (4).p. 138
Types of currentp. 139
+Direct current (D.C.)p. 139
Direct current (D.C.)p. 139
Fig. 1 Direct current (D.C.)p. 139
Direct current flows with steady voltage and amperage from the plus to the minus pole.p. 139
Pure D.C.-voltages are only delivered by accumulators or batteries.p. 139
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. 139
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off.p. 139
+Alternating current (A.C.)p. 139
Alternating current (A.C.)p. 139
Fig. 2 Alternating current (A.C.)p. 139
Alternating current not only changes its direction, but also its amperage.p. 139
+9.23 Battery servicep. 140
9.5 Pulse Width Modulation (PWM)p. 140
+Pulse width modulation (PWM)p. 140
Pulse width modulation (PWM)p. 140
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. 140
The following applies:p. 140
+l The signal voltage cannot be measured.p. 140
l The signal voltage cannot be measured.p. 140
l The current can be measured.p. 140
+PWM-solenoid valves must not be interference suppressed with suppressor diodes.p. 140
PWM-solenoid valves must not be interference suppressed with suppressor diodes.p. 140
What does a PWM-output do?p. 140
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. 140
Fig. 1p. 140
+(Fig. 1)Course of PWM-voltage U and coil current I at 10 % duty cycle The effective coil current Ieff is also 10 %.p. 140
(Fig. 1)p. 140
Fig. 1p. 140
+(Fig. 1) Course of PWM-voltage U and coil current I at 50 % duty cycle The effective coil current Ieff is also 50 %.p. 140
(Fig. 1)p. 140
Fig. 1p. 141
+(Fig. 1) Course of PWM-voltage U and coil current I at 100 % duty cycle The effective coil current Ieff is also 100 %.p. 141
(Fig. 1)p. 141
+What does Dither mean?p. 141
What does Dither mean?p. 141
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. 141
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. 141
Advantage: The hydraulic cylinder actuated this way can be controlled with a much higher sensitivity.p. 141
Disadvantage: With dither the valves becomes noticeably warmer, because the valve spool is permanently in action.p. 141
+9.23 Battery servicep. 142
9.6 Resistancep. 142
+Resistance and voltage dropp. 142
Resistance and voltage dropp. 142
+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. 142
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. 142
Fig. 1 Various size resistorsp. 142
+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. 142
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. 142
The resistance can only be measured with a Multimeter.p. 142
Symbol, Rp. 142
+Unit, Ohmp. 142
Wp. 142
+The electric resistance (R) is measured in Ohmp. 142
Wp. 142
Rule of thumb:p. 142
+l The thicker the cable cross-section, the lower the voltage loss.p. 142
l The thicker the cable cross-section, the lower the voltage loss.p. 142
l The shorter the cable, the better the current.p. 142
l The cleaner the contacts, the better the current.p. 142
l The quality of the ground cable is of the same importance as the supply line.p. 142
+Unnecessary resistancesp. 142
Unnecessary resistancesp. 142
+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. 142
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. 142
Badp. 142
Fig. 1 Screw-type terminalsp. 142
Copper wires are squashed and thus become faulty.p. 142
+Betterp. 142
Betterp. 142
Fig. 2 Spring clampsp. 142
Connecting clamps for flexible conductorsp. 142
BOMAG No. 057 565 72p. 142
Ampacity up to 20 Amp.p. 142
Cable cross-section 0.08 to 2.5 qmmp. 142
Fig. 3p. 143
+In many cases it is better to replace the contact. Soiled or oxidized contacts should be cleaned with Ballistolp. 143
(Fig. 4)p. 143
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. 143
Fig. 4 Balistol oilp. 143
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. 143
Fig. 5p. 143
Hint for practice:p. 143
A tool you cannot buy. The pliers were converted, the nail is permanently present.p. 143
+9.23 Battery servicep. 144
9.7 Series / parallel connectionp. 144
+Series connectionp. 144
Series connectionp. 144
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. 144
Fig. 1 Series connectionp. 144
Currentp. 144
In series connection the current is identical at every point.p. 144
Itotal = I1 = I2 = I3p. 144
Voltagep. 144
The sum of all partial voltages is identical with the total voltage.p. 144
Utotal = U1 + U2 + U3p. 144
Resistancep. 144
The sum of all partial resistances is identical with the total resistance.p. 144
Rtotal = R1 + R2 + R3p. 144
+Series connection of batteriesp. 144
Series connection of batteriesp. 144
Fig. 2p. 144
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. 144
+l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 144
l In series connection the plus pole of the first battery must be connected with the minus pole of the second battery.p. 144
l The sum of all individual voltages is applied to the free poles.p. 144
l The total capacity (Ah) is identical with the capacity of the individual battery.p. 144
+Parallel connection of batteriesp. 145
Parallel connectionp. 145
In parallel connection all resistances (consumers) are connected between feed and return line.p. 145
+l All resistances (consumers) are supplied with the same voltage.p. 145
l All resistances (consumers) are supplied with the same voltage.p. 145
l Each of the resistances (consumers) draws as much current as required.p. 145
Fig. 3 Parallel connectionp. 145
Currentp. 145
The total current is the sum of all currents.p. 145
Itotal = I1 + I2 + I3p. 145
Voltagep. 145
The voltage values are identical at every resistance (consumer).p. 145
Utotal = U1 = U2 = U3p. 145
Resistancep. 145
The total resistance is less than the lowest individual resistance.p. 145
+Parallel connection of batteriesp. 145
Parallel connection of batteriesp. 145
Fig. 4p. 145
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. 145
+l In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 145
l In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery.p. 145
l Plus and minus poles have the voltage of the single battery applied.p. 145
l The total capacity (Ah) is identical with the sum of all battery capacities.p. 145
The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of charging.p. 145
+9.23 Battery servicep. 146
9.8 Ohm's lawp. 146
+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. 146
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. 146
Fig. 1p. 146
+According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohmp. 146
Wp. 146
Advicep. 146
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. 146
Voltage U = I multiplied with Rp. 146
Resistance R = U divided by Ip. 146
Amperage I = U divided by Rp. 146
U = Voltage in Voltp. 146
I = Current in Amperep. 146
+R = Resistance in OHMp. 146
Wp. 146
+9.23 Battery servicep. 146
9.9 Electrical energyp. 146
Fig. 1p. 146
In a closed electric circuit current and voltage generate energy.p. 146
If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced.p. 146
Advicep. 146
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. 146
Energy P = I multiplied with Up. 146
Amperage I = P divided by Up. 146
Voltage U = P divided by Ip. 146
U = Voltage in Voltp. 146
I = Current in Amperep. 146
P = Power in Wattp. 146
+9.23 Battery servicep. 147
9.10 Formula diagramp. 147
+Description:p. 147
Description:p. 147
+l Select the desired value from the inner circle.p. 147
l Select the desired value from the inner circle.p. 147
l Determine the formula variables in the quarter circlep. 147
l Calculatep. 147
Example:p. 147
P = 150 Wattp. 147
U = 24 Voltp. 147
Sought for = Current in Amperep. 147
I = P : U = 150 W : 24 Volt = 6.25 Amperep. 147
Fig. 1 Formula diagramp. 147
+Resistance, R Ohmp. 147
Wp. 147
Voltage, U Voltp. 147
Current, I Amperep. 147
Power, P Wattp. 147
+9.23 Battery servicep. 148
9.11 Metrologyp. 148
+Test lampsp. 148
Test lampsp. 148
+Test lampp. 148
Test lampp. 148
Fig. 1 Test lampp. 148
+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. 148
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. 148
+Diode test lampp. 148
Diode test lampp. 148
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. 148
Fig. 2 Diode test lampp. 148
If voltage is present, the corresponding light emitting diode will light up.p. 148
Multimeterp. 148
+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. 148
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. 148
Fig. 1 Multimeterp. 148
In order to avoid damage:p. 148
+l the range selector switch must be correctly set for the corresponding measurement.p. 148
l the range selector switch must be correctly set for the corresponding measurement.p. 148
l the test cable must be plugged into the correct socket.p. 148
l the voltage type (AC/DC) must be set.p. 148
l In case of direct voltage the correct polarity must be assured.p. 148
l the measuring range should be chosen higher at the beginning of the test.p. 148
l In order to avoid any influence on the circuitry to be measured, the internal resistance of the voltage tester should be as high as possible.p. 148
Resistance and continuity measurement with multimeterp. 149
Fig. 2p. 149
The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points.p. 149
Fig. 3p. 149
The following information should be observed when measuring resistance and continuity:p. 149
+l The component to be measured must not be connected to the power supply during the measurement.p. 149
l The component to be measured must not be connected to the power supply during the measurement.p. 149
l At least one side of the component to be measured must be disconnected from the circuitry, as otherwise the measuring result may be influenced by parallel components.p. 149
l Polarity is of no significance.p. 149
Voltage and voltage drop measurement with multimeterp. 149
Fig. 4 Measuring voltagep. 149
+l Measurement at the voltage source measures the currently available Voltage.p. 149
l Measurement at the voltage source measures the currently available Voltage.p. 149
l The meter is always connected parallel to consumer, component or power source.p. 149
Fig. 5 Voltage measurementp. 149
+l A measurement at the consumer measures the voltage drop at this component.p. 149
l A measurement at the consumer measures the voltage drop at this component.p. 149
Current measurement with the multimeterp. 150
Fig. 6 Measuring currentp. 150
+l The meter is connected in series with the consumer.p. 150
l The meter is connected in series with the consumer.p. 150
l During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened.p. 150
Fig. 7 Current measurementp. 150
Advicep. 150
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. 150
The current value can then be calculated with the help of Ohm's law.p. 150
Clip-on measuring instrumentp. 150
+The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 150
The clip-on measuring instrument can be used to measure current, voltage and resistance.p. 150
Fig. 1 Clip-on measuring instrumentp. 150
Fig. 2p. 150
+l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 150
l For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.p. 150
Magnet testerp. 151
Fig. 1 Magnet testerp. 151
The magnet tester is used to test solenoid valves and magnetic coils.p. 151
The test lamp responds to the magnetic fields of A.C- voltage, D.C.-voltage and permanent magnets.p. 151
+l The component to be tested does not need to be removed.p. 151
l The component to be tested does not need to be removed.p. 151
l The magnetic coil can also be tested under a protective cap.p. 151
Power measurementp. 151
The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage.p. 151
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. 151
Fig. 2p. 151
+9.23 Battery servicep. 152
9.12 Diodes, relays, fusesp. 152
+Diodesp. 152
Diodesp. 152
Fig. 1p. 152
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. 152
Plus-voltage on diode:p. 152
+l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 152
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.p. 152
Negative voltage on diode:p. 152
+l The diode does not allow current to pass through.p. 152
l The diode does not allow current to pass through.p. 152
Fig. 2 Marking of the cathodep. 152
Diodes are used:p. 152
+l For rectifying A.C. voltage.p. 152
l For rectifying A.C. voltage.p. 152
l For absorbing voltage peaks (free-wheeling diode).p. 152
l For construction of logical circuits.p. 152
+Diode logics and free-wheeling diodep. 152
Diode logics and free-wheeling diodep. 152
Fig. 3 Diode circuitryp. 152
+l The solenoid valve Y48p. 152
+l The solenoid valve Y48p. 152
(Fig. 3)p. 152
l Solenoid valve Y20 is supplied, if the switch is in position "1".p. 152
l Solenoid valve Y21 is supplied, if the switch is in position "2".p. 152
The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.p. 152
+Light emitting diodesp. 153
Light emitting diodesp. 153
Fig. 4 LEDp. 153
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. 153
Relaysp. 153
Fig. 1 Relaysp. 153
Relays are commonly used to realize switching processes.p. 153
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. 153
With the possibility of using breaker – maker contacts the effect of an information can be reversed.p. 153
Fig. 2 Relay circuitryp. 153
+The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric currentp. 153
(Fig. 2)p. 153
86 = Positive supply for coilp. 153
85 = Ground supply for coilp. 154
30 = Supply voltagep. 154
87 = Normally open contactp. 154
87a= Normally closed contactp. 154
Fusesp. 154
Fig. 1p. 154
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. 154
+Fuses must not be repaired or bridged.p. 154
Fuses must not be repaired or bridged.p. 154
The melting time at 23 °C is:p. 154
+l approx. 1 hour with 1.5 times the rated currentp. 154
l approx. 1 hour with 1.5 times the rated currentp. 154
l approx. 1 minute with 2.5 times the rated current.p. 154
A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours.p. 154
Yellow = 5 Ap. 154
Brown = 7.5 Ap. 154
White = 8 Ap. 154
Red = 16 Ap. 154
Blue = 25 Ap. 154
+9.23 Battery servicep. 155
9.13 Telemecanique switchp. 155
+Disassemblyp. 155
Disassemblyp. 155
Fig. 1 Disassemblyp. 155
+l Lift up the interlock (5).p. 155
l Lift up the interlock (5).p. 155
Fig. 2 Folding down the switch blockp. 155
+l Fold down the switch block (4).p. 155
l Fold down the switch block (4).p. 155
l Loosen screw (1).p. 155
Fig. 3 Pulling out the front elementp. 155
+l Lift up the interlock (2) and pull out the front element (3).p. 155
l Lift up the interlock (2) and pull out the front element (3).p. 155
Assemblyp. 156
Fig. 4 Assemblyp. 156
+l Insert the front element (3) into the bore in the control panel.p. 156
l Insert the front element (3) into the bore in the control panel.p. 156
Fig. 5 Observe the marks.p. 156
+l Clip the fastening adapter (6) onto the front element (3).p. 156
l Clip the fastening adapter (6) onto the front element (3).p. 156
+Watch the marls on front elementp. 156
+Watch the marls on front elementp. 156
(Fig. 5)p. 156
+l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 156
l Tighten the screw (1) with a tightening torque of 0.6 Nm.p. 156
Fig. 6 Assemble the switch blockp. 156
+l Clip on the switch block (4).p. 156
l Clip on the switch block (4).p. 156
+Hook in the switch block at the bottom firstp. 156
+Hook in the switch block at the bottom firstp. 156
(Fig. 6)p. 156
+9.23 Battery servicep. 157
9.14 Plug connectorsp. 157
+Duties and requirementsp. 157
Duties and requirementsp. 157
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. 157
+Examples for these loads are:p. 157
Examples for these loads are:p. 157
+l Vibration accelerationp. 157
l Vibration accelerationp. 157
l Temperature fluctuations, high and low temperaturesp. 157
l Dampnessp. 157
l Micro movements of the contact with resulting friction corrosion.p. 157
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. 157
+l Low transition resistances of the conductive parts.p. 157
l Low transition resistances of the conductive parts.p. 157
l High insulation strength between conductive parts with different voltage potentials.p. 157
l Excellent leak tightness against water and moisture.p. 157
+9.23 Battery servicep. 158
Magnetic coil plugp. 158
+Magnetic coil plug with LED and suppressor diodep. 158
Magnetic coil plug with LED and suppressor diodep. 158
The plug is equipped with a polarized function display and a suppressor diode as protection against overvoltages.p. 158
Fig. 7p. 158
The plug is polarized, it does not matter whether Pin1 or Pin 2 is supplied with current, Pin 3 is not used. The LED lights if voltage is applied to the solenoid valve.p. 158
Fig. 8p. 158
Fig. 9 Switching symbol in circuit diagramp. 158
Magnetic coil plug without LED and without supressor diodep. 158
The plug has no LED and no suppressor diode as protection against overvoltages.p. 158
Assembly of magnetic coil plugsp. 159
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. 159
Fig. 10 Solenoid valve plug with pointed cablep. 159
Fig. 11p. 159
+l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 159
l Connect the plug with the coil connection and press it firmly onto the connecting housing.p. 159
Fig. 12p. 159
+l Fasten the screw with a suitable screwdriver.p. 159
l Fasten the screw with a suitable screwdriver.p. 159
Fig. 13p. 159
+l Press the plug firmly on again.p. 159
l Press the plug firmly on again.p. 159
Fig. 14p. 159
+l Retighten the screw.p. 159
l Retighten the screw.p. 159
Fig. 15p. 160
+There should be no gap between plug and solenoid coil!p. 160
There should be no gap between plug and solenoid coil!p. 160
Fig. 16 Correctly installed plug without gapp. 160
+9.23 Battery servicep. 160
9.16 Deutsch plug, series DT and DTMp. 160
+Generalp. 160
Generalp. 160
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. 160
Fig. 17 Crimp connectionsp. 160
+Do not crimp more than one lead per pin or per socket.p. 160
Do not crimp more than one lead per pin or per socket.p. 160
Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics).p. 160
When connecting sockets and plugs these must engage with a noticeable click when both halves interlock.p. 160
The plug connection should not be separable (without loosening the interlock).p. 160
Pulling testp. 160
This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing.p. 160
+l Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 160
l Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.p. 160
+DT Seriesp. 161
DT Seriesp. 161
Fig. 1 DT plug connectionp. 161
Fig. 2 DT Seriesp. 161
Fig. 3 Sectional drawingp. 161
+9.23 Battery servicep. 162
DT Seriesp. 162
+Installing DT contactsp. 162
Installing DT contactsp. 162
Fig. 4p. 162
+l Insert the contacts through the rubber grommet until they click into place.p. 162
l Insert the contacts through the rubber grommet until they click into place.p. 162
l Insert the orange wedge in direction of arrow.p. 162
+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. 162
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. 162
+Use the same method when assembling the socket.p. 162
Use the same method when assembling the socket.p. 162
+Disassembling DT contactsp. 162
Disassembling DT contactsp. 162
Fig. 5p. 162
+l Pull the orange wedge out with long nose pliers.p. 162
l Pull the orange wedge out with long nose pliers.p. 162
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 162
l Pull the contact out of the socket.p. 162
+Use the same method when assembling the socket.p. 162
Use the same method when assembling the socket.p. 162
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 162
+9.23 Battery servicep. 163
DTM Seriesp. 163
Fig. 6 DTM plug connectionp. 163
Fig. 7 DTM Seriesp. 163
Fig. 8 Sectional drawingp. 163
+Disassembling DTM contactsp. 164
Installing DTM contactsp. 164
Fig. 9p. 164
+l Insert the contacts through the rubber grommet until they click into place.p. 164
l Insert the contacts through the rubber grommet until they click into place.p. 164
l Insert the orange wedge, until it clicks into place.p. 164
+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. 164
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. 164
+Use the same method when assembling the socket.p. 164
Use the same method when assembling the socket.p. 164
+Disassembling DTM contactsp. 164
Disassembling DTM contactsp. 164
Fig. 10p. 164
+l Pull the orange wedge (interlock) out with long nose pliers.p. 164
l Pull the orange wedge (interlock) out with long nose pliers.p. 164
l Slightly pull the lead and unlock the interlocking hook with a screw driver.p. 164
l Pull the contact out of the socket.p. 164
+Use the same method when assembling the socket.p. 164
Use the same method when assembling the socket.p. 164
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.p. 164
+9.23 Battery servicep. 165
9.17 Plugs and terminals in spring clamping technologyp. 165
+Generalp. 165
Generalp. 165
Fig. 1p. 165
+The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 165
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp!p. 165
+Spring clamp technologyp. 165
(Fig. 1)p. 165
+Connecting terminal for quick repairsp. 165
Connecting terminal for quick repairsp. 165
Fig. 2 That's how it worksp. 165
BOMAG part-no.: 057 565 72p. 165
+The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mmp. 165
2p. 165
2p. 165
2p. 165
(Fig. 2)p. 165
That's how it worksp. 165
+l Strip 9-10 mm of the lead.p. 165
l Strip 9-10 mm of the lead.p. 165
l Open the actuating lever and insert the strand.p. 165
l Return the actuating lever to initial position.p. 165
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 165
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 165
+X-COM plug clampp. 166
Series clampp. 166
Fig. 3 That's how it worksp. 166
That's how it worksp. 166
+l Insert a screw driver into the actuating opening until it bottoms.p. 166
l Insert a screw driver into the actuating opening until it bottoms.p. 166
l Strip 9-10 mm of the lead and insert it into the clamp.p. 166
l Pull out the screw driver.p. 166
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 166
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 166
Measuring signalsp. 166
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. 166
Fig. 4 Test adapterp. 166
+X-COM plug clampp. 167
X-COM Systemp. 167
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. 167
+X-COM plug clampp. 167
X-COM plug clampp. 167
Fig. 5 That's how it worksp. 167
That's how it worksp. 167
+l Insert a screw driver into the actuating opening until it bottoms.p. 167
l Insert a screw driver into the actuating opening until it bottoms.p. 167
l Strip 9-10 mm of the lead and insert it into the plug.p. 167
l Pull out the screw driver.p. 167
+Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 167
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.p. 167
Fig. 6 X-COM plug with measuring cablep. 167
+l The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 167
l The most reliable measurements on the plug can be made when using the measuring and connecting cable with 2mm plug (see special tools for electrics).p. 167
Measuring signalsp. 168
Fig. 7 X-COM plug plugged onto the series clampp. 168
+9.23 Battery servicep. 169
9.18 Inductive proximity switchesp. 169
+Generalp. 169
Generalp. 169
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. 169
+Working principlep. 169
Working principlep. 169
Fig. 8p. 169
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. 169
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. 169
+PNP circuitryp. 169
PNP circuitryp. 169
Fig. 9 PNP circuitryp. 169
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. 169
+NPN circuitryp. 169
NPN circuitryp. 169
Fig. 10 NPN circuitryp. 169
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. 169
+Breaking and making contactsp. 169
Breaking and making contactsp. 169
Fig. 11p. 169
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. 169
+The LEDp. 169
(Fig. 11)p. 169
Fig. 12 Circuit diagram, making contactp. 170
+The circuit diagramp. 170
(Fig. 12)p. 170
Brown = voltage supplyp. 170
Blue = ground supplyp. 170
Black = switching outputp. 170
The initiator switches the relay (K05)p. 170
+9.23 Battery servicep. 170
9.19 Angle sensorsp. 170
+Sensor with current outputp. 170
Sensor with current outputp. 170
Fig. 1 Angle sensorp. 170
+The the function of the angle sensorp. 170
(Fig. 1)p. 170
The advantage of the Hall sensor lies in the fact that, in contrast to the potentiometer, there is no dragging contact and thus no wear by abrasion.p. 170
The Hall sensor generates an electric voltage, the Hall voltage. The necessary electric and magnetic processes take place in a very confined space inside the Hall-IC. Since a vast variety of electronic elements work together in highly complicated cir…p. 170
The Hall effect is based on the phenomenon that electrons are deflected to one side when they pass through a magnetic field that acts from the outside. In this case an excess of electrons is created on the side used by the electrons, because the nega…p. 170
+Situation without external magnetic fieldp. 171
Situation without external magnetic fieldp. 171
Fig. 2p. 171
I = Current in semi-conductor of Hall-ICp. 171
W = Semi-conductor as current conductor in Hall-ICp. 171
+Current passes through the semi-conductor W in the Hall-IC. Since there is no other magnetic force, the electrons pass evenly through the semi-conductor. There is no measureable Hall voltage (Up. 171
Hallp. 171
+Situation with external magnetic fieldp. 171
Situation with external magnetic fieldp. 171
Fig. 3p. 171
+Current passes through the semi-conductor W in the Hall-IC. Since there is the effect of an external magnetic field, the electrons are deflected to the left. There is an excess of electrons on the left, and a lack of electrons on the right. Hall volt…p. 171
Hallp. 171
Fig. 4 Connection diagramp. 171
+The angle sensor has 3 electric connectionsp. 171
(Fig. 4)p. 171
Ub, supply voltage (+ 8.5 Volt)p. 171
Gnd, groundp. 171
Out, output current 4-20 mA.p. 171
+l at -35° = 4 mA output currentp. 171
l at -35° = 4 mA output currentp. 171
l at 0° = 12 mA output currentp. 171
l at +35° = 20 mA output current.p. 171
+9.23 Battery servicep. 172
Sensor with voltage outputp. 172
The design is almost identical with the angle sensor on the new single drum rollers of generation -4 with electronic steering wheel, where a sensor with a voltage output of 0-8.5 V is mounted on the articulated joint. The potentiometer inside the sen…p. 172
+9.23 Battery servicep. 173
Acceleration transducer
Fig. 1p. 173
BVC machines and machines with E-VIB meter are equipped with two piezo-electric acceleration transducers, which are mounted to the drum.p. 173
During operation these transducers transmit the acceleration signals to the measuring ESX.p. 173
The function of the piezo electric acceleration transducer is based on the self-charging effect of quartz crystals under mechanical load (pressure, tension, torsion) in vertical direction to the polar axes, which was discovered in 1880 by J. and P. C…p. 173
Mode of actionp. 173
The piezo electric acceleration transducer consists of two basic components:p. 173
+l Piezo electric materialp. 173
l Piezo electric materialp. 173
l Seismic massp. 173
Once side of the piezo disc is connected with the so- called seismic mass, the other one with a rigid carrier. When this combination is set to oscillate, the seismic (sluggish) mass transfers a force to the piezo disc. According to NewtonsLawtheresul…p. 173
A small wire connects the piezo element with the sensor socket.p. 173
The piezo electric effect generates a charge on the electrodes, which is proportional to the force and thus also to the acceleration.p. 173
Fig. 1p. 174
+1 Seismic massp. 174
1 Seismic massp. 174
2 Piezo electric materialp. 174
3 Accelerationp. 174
+9.23 Battery servicep. 174
9.21 Potentiometer on the slewing motor, B62p. 174
+The potentiometer is directly connected with the control shaft of the slewing motor via a small coupling. This enables to control and approach the exciter position.p. 174
The potentiometer is directly connected with the control shaft of the slewing motor via a small coupling. This enables to control and approach the exciter position.p. 174
+Disassembling the potentiometerp. 174
Disassembling the potentiometerp. 174
Fig. 1p. 174
+l Unscrew the fastening screws and remove the protection hoodp. 174
+l Unscrew the fastening screws and remove the protection hoodp. 174
(Fig. 1)p. 174
Fig. 2p. 174
+l Remove the protective hood 1p. 174
+l Remove the protective hood 1p. 174
(Fig. 2)p. 174
Fig. 3p. 175
+l Cut the cable strapsp. 175
+l Cut the cable strapsp. 175
(Fig. 3)p. 175
l Disconnect the plug connection.p. 175
Fig. 4p. 175
+l Unscrew the fastening screws.p. 175
+l Unscrew the fastening screws.p. 175
(Fig. 4)p. 175
Fig. 5p. 175
+l Pull out the potentiometer housingp. 175
+l Pull out the potentiometer housingp. 175
(Fig. 5)p. 175
Installing the potentiometerp. 175
Fig. 1p. 175
+The potentiometer must only be assembled in vertical position.p. 175
The potentiometer must only be assembled in vertical position.p. 175
+If the slewing motor is incorrectly positionedp. 175
(Fig. 1)p. 175
+l …. for this purpose connect the new potentiometer to plug (electrically).p. 175
l …. for this purpose connect the new potentiometer to plug (electrically).p. 175
l Start the engine and run it at idle speed.p. 175
+The slewing motor swivels to vertical position.p. 175
The slewing motor swivels to vertical position.p. 175
+l Shut down the engine again.p. 175
l Shut down the engine again.p. 175
Fig. 2p. 175
+(Fig. 2) shows the correct installation position.p. 175
+(Fig. 2) shows the correct installation position.p. 175
(Fig. 2)p. 175
Fig. 3p. 176
+If necessary rotate the potentiometer shaft and insert it carefully into the blue coupling.p. 176
If necessary rotate the potentiometer shaft and insert it carefully into the blue coupling.p. 176
+l Assemble the new potentiometer with loop ringp. 176
+l Assemble the new potentiometer with loop ringp. 176
(Fig. 3)p. 176
Fig. 4p. 176
+l Tighten the fastening screwsp. 176
+l Tighten the fastening screwsp. 176
(Fig. 4)p. 176
Checking the potentiometer installationp. 176
Fig. 1p. 176
+l Start the engine, run it with idle speed and watch the displayp. 176
+l Start the engine, run it with idle speed and watch the displayp. 176
(Fig. 1)p. 176
+If the potentiometer has been installed correctly, the effective amplitude will be a "0"p. 176
+If the potentiometer has been installed correctly, the effective amplitude will be a "0"p. 176
(Fig. 1)p. 176
Fig. 2p. 176
+If the potentiometer had been mounted incorrectly (offset by 180°) the effective amplitude will be at "0,9"p. 176
+If the potentiometer had been mounted incorrectly (offset by 180°) the effective amplitude will be at "0,9"p. 176
(Fig. 2)p. 176
+In this case the potentiometer needs to be turned by 180°p. 176
(Fig. 3)p. 176
Fine-tuning the potentiometerp. 177
Fig. 1p. 177
+l Park the machine on a firm base (asphalt or concrete)p. 177
+l Park the machine on a firm base (asphalt or concrete)p. 177
(Fig. 1)p. 177
+Soft ground is not suitable.p. 177
Soft ground is not suitable.p. 177
+Secure the wheels with chocks.p. 177
Secure the wheels with chocks.p. 177
+l Start the engine and run it with high speed.p. 177
l Start the engine and run it with high speed.p. 177
l Switch the vibration on .p. 177
l Release the brake.p. 177
+Turn the potentiometer housing clockwise, the drum will rotate slowly forward.p. 177
Turn the potentiometer housing clockwise, the drum will rotate slowly forward.p. 177
Turn the potentiometer housing anti-clockwise, the drum will rotate slowly backward.p. 177
+l Turn the potentiometer housing anti-clockwise or clockwisep. 177
+l Turn the potentiometer housing anti-clockwise or clockwisep. 177
(Fig. 1)p. 177
Fig. 2p. 177
+l Tighten the fastening screws.p. 177
+l Tighten the fastening screws.p. 177
(Fig. 2)p. 177
l Shut down the engine.p. 177
l Fasten with new cable straps.p. 177
l Assemble the protection hood.p. 177
+9.23 Battery servicep. 178
9.22 Batteriesp. 178
+Battery – accumulatorp. 178
Battery – accumulatorp. 178
Fig. 1p. 178
In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries.p. 178
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.p. 178
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. 178
All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.p. 178
Fig. 2p. 178
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.p. 178
Capacityp. 178
is a synonym for the amount of current taken up and discharged by a battery over a specified period of time.p. 178
+Battery maintenancep. 178
Battery maintenancep. 178
+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. 178
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. 178
If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself.p. 178
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. 178
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.p. 178
The following therefore applies for longer downtimes:p. 178
+l Remove the battery and store it in a cool, dry and frost protected room.p. 178
l Remove the battery and store it in a cool, dry and frost protected room.p. 178
l Check the open circuit voltage on the battery at regular intervals (at least once every month).p. 178
l Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).p. 178
+The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 178
The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge.p. 178
+Battery test in generalp. 178
Battery test in generalp. 178
+l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 178
l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area?p. 178
l Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar.p. 178
+9.23 Battery servicep. 179
Testing batteries without screw plugsp. 179
On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:p. 179
Fig. 3 Battery and generator testerp. 179
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. 179
+Before testing clean the poles and ensure good connection between clamps and poles.p. 179
Before testing clean the poles and ensure good connection between clamps and poles.p. 179
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. 179
The starting power can exceed 100%.p. 179
+9.23 Battery servicep. 180
Charge condition with hydrometerp. 180
Fig. 4 Charge conditionp. 180
Green = Charge condition >65%p. 180
Dark = Charge conditionp. 180
Light = Electrolyte level too lowp. 180
+Danger of explosion!!! If the electrolyte level is too low, the battery must no longer be charged.p. 180
Danger of explosion!!! If the electrolyte level is too low, the battery must no longer be charged.p. 180
9.23 Battery servicep. 180
+9.23 Battery servicep. 181
9.23 Battery servicep. 181
+Danger of cauterisation ! Danger of explosion!p. 181
+Danger of cauterisation ! Danger of explosion!p. 181
Danger of cauterisation ! Danger of explosion!p. 181
When working on the battery do not use open fire, do not smoke!p. 181
The battery contains acid. Do not let acid come in contact with skin or clothes!p. 181
Wear protective clothing!p. 181
Do not lay any tools on the battery!p. 181
For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.p. 181
+Dispose of the old battery environmentally.p. 181
Dispose of the old battery environmentally.p. 181
+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. 181
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. 181
The following therefore applies for the service life:p. 181
+l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 181
l Switch off all consumers (e.g. ignition, light, inside light, radio).p. 181
l Check open-circuit voltage of the battery at regular intervals. At least once per month.p. 181
Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.p. 181
+l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 181
l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging.p. 181
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.p. 181
+l After each charging process allow the battery to rest for one hour before taking it into service.p. 181
l After each charging process allow the battery to rest for one hour before taking it into service.p. 181
l For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.p. 181
+Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty!p. 181
Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty!p. 181
+l Open the engine hood and remove the coveringp. 181
l Open the engine hood and remove the coveringp. 181
Fig. 5p. 181
+l Remove the batteryp. 181
+l Remove the batteryp. 181
(Fig. 5)p. 181
l Clean the outside of the battery.p. 181
l Clean battery poles and pole clamps and grease them with pole grease (Vaseline).p. 181
l Check the fastening of the battery.p. 181
l On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.p. 181
9.24 Main battery fusep. 182
Fig. 6p. 182
+125Ap. 182
125Ap. 182
(F00) Main fusep. 182
125Ap. 182
(F48) Fuse for glow plugsp. 182
+Battery with main fuse is located in the engine compartmentp. 182
Battery with main fuse is located in the engine compartmentp. 182
+9.25 Starting with jump wiresp. 182
9.25 Starting with jump wiresp. 182
Fig. 7p. 182
+A wrong connection will cause severe damage in the electric system.p. 182
A wrong connection will cause severe damage in the electric system.p. 182
+l Bridge the machine only with a 12 Volt auxiliary battery.p. 182
l Bridge the machine only with a 12 Volt auxiliary battery.p. 182
l When jump starting with an external battery connect both plus poles first.p. 182
+l 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. 182
+l 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. 182
(Fig. 7)p. 182
l Start as described under 'Starting the engine'.p. 182
+l Once the engine is running switch on a powerful consumer (working light, etc.).p. 182
l Once the engine is running switch on a powerful consumer (working light, etc.).p. 182
+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. 182
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. 182
+l After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 182
l After starting disconnect the negative poles (ground cable) first and the positive poles after.p. 182
l Switch off the consumer.p. 182
Overview of electric componentsp. 183
+1) Wiring loom cabinp. 183
1) Wiring loom cabinp. 183
1) Wiring loom enginep. 184
+1) Wiring loom enginep. 184
1) Wiring loom enginep. 184
22) Wiring loom, battery-fusesp. 185
+22) Wiring loom, battery-fusesp. 185
22) Wiring loom, battery-fusesp. 185
23) Wiring loom ground, battery-framep. 185
24) Wiring loom ground, engine-framep. 185
25) Wiring loom ground, battery-batteryp. 185
26) Wiring loom supply central electricsp. 185
27) Wiring loom starterp. 185
1) Wiring loom rear framep. 186
+1) Wiring loom rear framep. 186
1) Wiring loom rear framep. 186
1) Wiring loom, central electrics-engine control unitp. 187
+1) Wiring loom, central electrics-engine control unitp. 187
1) Wiring loom, central electrics-engine control unitp. 187
2) Wiring loom transducer for vibration frequencyp. 187
15 S127, Rotary momentary contact switch for engine speedp. 198
16 S37, Rotary switch for direction indicators left/right*p. 198
17 S14, rotary switch for hazard light system*p. 198
18 S15, Rotary switch for lighting (StVZO)*p. 198
19 S53, Rotary switch for working lights*p. 198
20 S139, Rotary switch for drum frequencyp. 198
21 Steering wheel adjustment leverp. 198
9.27 Cabinp. 198
Fig. 9p. 198
a = S38, toggle switch for flashing beaconp. 198
b = S20, toggle switch for front windscreen wiper/ washerp. 198
+upp. 198
upp. 198
windscreen wiper moves to end position and stops.p. 198
+downp. 198
downp. 198
Switches on front windscreen wiping.p. 198
+Push buttonp. 198
Push buttonp. 198
Front windscreen is sprayed during wiping.p. 198
c = S21, toggle switch for rear windscreen wiper/ washerp. 198
+upp. 198
upp. 198
windscreen wiper moves to end position and stops.p. 198
+downp. 198
downp. 198
Switches on wiping of rear windscreen.p. 198
+Push buttonp. 198
Push buttonp. 198
Rear windscreen is sprayed during wiping.p. 198
d = S163, toggle switch for rear windscreen heatingp. 198
Fig. 10p. 199
g = E29, Reading and dashboard lightp. 199
h = S45, Toggle switch for cabin lampp. 199
i = S158, Toggle switch for reading and dashboard lightp. 199
j = E70, Cabin lampp. 199
9.28 Electronic control unitsp. 199
+Control unitsp. 199
Control unitsp. 199
+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. 199
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. 199
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. 199
Fig. 1 Electronic control (ESX)p. 199
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. 199
Modulesp. 200
+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. 200
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. 200
Fig. 2 Modulep. 200
The modules have control lights on inputs and outputs to monitor the applied signals.p. 200
Signalsp. 200
+Analog signalsp. 200
Analog signalsp. 200
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. 200
+Binary signalsp. 200
Binary signalsp. 200
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. 200
CAN-bus, Controller Area Networkp. 201
+created by Bosch at the end of the eighties for automobile applications.p. 201
created by Bosch at the end of the eighties for automobile applications.p. 201
Development objectives:p. 201
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. 201
Fig. 3p. 201
Why CAN?p. 201
+l Networking of control units for the realization of complex functions.p. 201
+l Networking of control units for the realization of complex functions.p. 201
l Networking of control units for the realization of complex functions.p. 201
l Reduction of the extend of wiring and plug connections.p. 201
l Better diagnostic possibilities (central diagnostics socket).p. 201
Characteristics of CANp. 201
+It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 201
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.p. 201
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. 201
Wire (+) = cable colour bluep. 201
Wire (-) = cable colour yellowp. 201
+Measuring on the CANp. 201
Measuring on the CANp. 201
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. 201
9.29 Checking the voltage supply for the control unitp. 202
+Power supply for a control unit, generalp. 202
Power supply for a control unit, generalp. 202
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. 202
+The following describes the electric power supply for the ESX-control.p. 202
The following describes the electric power supply for the ESX-control.p. 202
+(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. 202
(Fig. 4)p. 202
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. 202
Fig. 4 Circuitry examplep. 202
+1p. 202
1p. 202
Engine blockp. 202
+ESXp. 202
ESXp. 202
Control unitp. 202
+F00p. 202
F00p. 202
Main fusep. 202
+Fx,Fxxp. 202
Fx,Fxxp. 202
Fuses potential 30p. 202
+Fxxxp. 202
Fxxxp. 202
Fuses potential 15p. 202
+Gp. 202
Gp. 202
Generatorp. 202
+G01p. 202
G01p. 202
Batteryp. 202
+GNDp. 202
GNDp. 202
Housing earthp. 202
+H08p. 202
H08p. 202
Charge control lightp. 202
+S00p. 202
S00p. 202
Ignition switchp. 202
+S01p. 202
S01p. 202
Emergency stop switchp. 202
+Pin 28p. 202
Pin 28p. 202
Voltage supply for controlp. 202
+Pin 54p. 202
Pin 54p. 202
if the signal (12/24 Volt) is applied, the control is switched onp. 202
+Pin 55p. 202
Pin 55p. 202
Ground supply for controlp. 202
+Pin 56 to 60p. 202
Pin 56 to 60p. 202
Voltage supply for outputsp. 202
+GNDp. 202
GNDp. 202
Housing earthp. 202
Fault in current supply, generalp. 203
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. 203
Fig. 5 Circuitry examplep. 203
The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply voltage.p. 203
The following faults may occur:p. 203
+l Line interruption in a plus supply linep. 203
l Line interruption in a plus supply linep. 203
l high voltage drop in a plus supply linep. 203
l line interruption on the minus sidep. 203
Measuring principle for line testingp. 204
+When a line conducts an electric current, a voltage drop will occur in the line (Up. 204
Vp. 204
Vp. 204
+l the available amperage (I) andp. 204
l the available amperage (I) andp. 204
+l the electric resistance (Rp. 204
linep. 204
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. 204
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.p. 204
12 V / 21 W – lamp as load in a 12 Volt vehicle network.p. 204
24 V / 21 W – lamp as load in a 24 Volt vehicle network.p. 204
+Test stepsp. 204
Test stepsp. 204
1. Switch off the ignition.p. 204
2. Unplug the control unit from wiring loom.p. 204
+3. If available connect the Pinboxp. 204
(Fig. 6)p. 204
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. 204
+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. 204
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. 204
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.p. 204
Fig. 6 Pinbox for 68 pole ESX controlp. 204
General measuring setup to check a supply line (plus side)p. 205
Fig. 7 Measuring arrangement 12 Voltp. 205
+1p. 205
1p. 205
Supply line, plus sidep. 205
+2p. 205
2p. 205
+Plug contact in wiring loom plug on control or Pinboxp. 205
(Fig. 6)p. 205
+Ep. 205
Ep. 205
Lamp, 12V / 21 Wattp. 205
+Pp. 205
Pp. 205
Multimeterp. 205
+G01p. 205
G01p. 205
Battery as voltage source, 12Vp. 205
+Up. 205
+Up. 205
Vp. 205
Voltage drop caused by the lamp currentp. 205
Setpointp. 205
+The voltage drop Up. 205
Vp. 205
Setpointp. 205
£p. 205
General measuring setup to check a return line (minus side)p. 206
Fig. 8 Measuring arrangement 12 Voltp. 206
+1p. 206
1p. 206
Return line, minus sidep. 206
+2p. 206
2p. 206
+Plug contact in wiring loom plug on control or Pinboxp. 206
(Fig. 6)p. 206
+Ep. 206
Ep. 206
Lamp, 12V / 21 Wattp. 206
+Pp. 206
Pp. 206
Multimeterp. 206
+G01p. 206
G01p. 206
Battery as voltage source, 12Vp. 206
+Up. 206
+Up. 206
Vp. 206
Voltage drop caused by the lamp currentp. 206
Setpointp. 206
+The voltage drop Up. 206
Vp. 206
Setpointp. 206
£p. 206
Connection example to check the plus line between battery and plug pin 28p. 207
Fig. 9p. 207
+Xp. 207
Xp. 207
+Wiring loom plug disconnected from control unit or Pinboxp. 207
(Fig. 6)p. 207
+Pp. 207
Pp. 207
Multimeterp. 207
+S00p. 207
S00p. 207
+Ignition switched on. Setpoint : E is bright. Up. 207
Vp. 207
+S00p. 207
S00p. 207
+Ignition switched off. Setpoint : E is dark. Up. 207
Vp. 207
Connection example to check the minus line between battery and plug pin 55p. 208
Fig. 10p. 208
+Pp. 208
Pp. 208
Multimeterp. 208
+Xp. 208
Xp. 208
+Wiring loom plug disconnected from control unit or Pinboxp. 208
(Fig. 6)p. 208
+Ep. 208
Ep. 208
+Setpoint : E is bright. Up. 208
Vp. 208
Test protocol for ESXp. 209
+E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 209
E lamp 12V / 21W in 12V vehicle network, to load the current branches.p. 209
E lamp 24V / 21W in 24V vehicle network, to load the current branches.p. 209
G01, batteryp. 209
P multimeter, measuring range: DCp. 209
+Plug pinp. 209
Plug pinp. 209
+Notep. 209
Notep. 209
+Setpointsp. 209
Setpointsp. 209
+28p. 209
28p. 209
+Ignition ONp. 209
Ignition ONp. 209
E between plug pin 28 and battery minusp. 209
P between battery plus and plug pin 28p. 209
E is bright,p. 209
+Up. 209
Vp. 209
+28p. 209
28p. 209
+Ignition OFFp. 209
Ignition OFFp. 209
E between plug pin 28 and battery plusp. 209
P between battery minus and plug pin 28p. 209
E is dark,p. 209
+Up. 209
Vp. 209
+54p. 209
54p. 209
+Ignition OFF, emergency stop not operatedp. 209
Ignition OFF, emergency stop not operatedp. 209
E between plug pin 54 and battery minusp. 209
P between battery plus and plug pin 54p. 209
E is bright,p. 209
+Up. 209
Vp. 209
+54p. 209
54p. 209
+Ignition OFF, emergency stop operatedp. 209
Ignition OFF, emergency stop operatedp. 209
E between plug pin 54 and battery minusp. 209
P between battery plus and plug pin 54p. 209
E is dark,p. 209
+Up. 209
Vp. 209
+55p. 209
55p. 209
+Ignition OFFp. 209
Ignition OFFp. 209
E between plug pin 55 and battery minusp. 209
P between battery plus and plug pin 55p. 209
E is bright,p. 209
+Up. 209
Vp. 209
+56, 57, 58, 59, 60p. 209
56, 57, 58, 59, 60p. 209
+Ignition OFFp. 209
Ignition OFFp. 209
E between plug pin 56, 57, 58, 59, 60 and battery minusp. 209
P between battery plus and plug pin 56, 57, 58, 59, 60p. 209
E is bright,p. 209
+Up. 209
Vp. 209
+If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 209
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram.p. 209
Example 1:p. 209
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. 209
Example 2:p. 209
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. 209
9.30 Diagnostics conceptp. 210
+Introductionp. 210
Introductionp. 210
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. 210
+Fault description and questioning of the customerp. 210
Fault description and questioning of the customerp. 210
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. 210
Fig. 11p. 210
+(1) Fault memorized in error logp. 210
(1) Fault memorized in error logp. 210
+Clear cause?p. 210
Clear cause?p. 210
+l If the fault message leaves no doubt, repair work may be started immediately.p. 210
l If the fault message leaves no doubt, repair work may be started immediately.p. 210
Line or component?p. 211
Fig. 12p. 211
+l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 211
l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the…p. 211
l Checking the voltage supply for the control unitp. 211
l Checking the sensor linesp. 211
l Checking the actor linesp. 211
Sequence after the fault is foundp. 211
Fig. 13p. 211
(2) No fault memorized in the error log at the time of initial questioningp. 212
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. 212
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. 212
+Consideration, when the error log has not recorded a faultp. 212
Consideration, when the error log has not recorded a faultp. 212
+l What could be the cause of the complaint?p. 212
l What could be the cause of the complaint?p. 212
l Which measuring possibilities are available?p. 212
+3. Pull the wiring loom carefully out of the dashboardp. 214
+3. Pull the wiring loom carefully out of the dashboardp. 214
(Fig. 3)p. 214
+Fig. 4p. 214
Fig. 4p. 214
+4. Attach the new gasket to the back of the operating consolep. 214
+4. Attach the new gasket to the back of the operating consolep. 214
(Fig. 4)p. 214
+Pull the adhesive strip off the gasket and stick on the gasket.p. 214
Pull the adhesive strip off the gasket and stick on the gasket.p. 214
+Fig. 5p. 215
Fig. 5p. 215
+5. Pull the dust protection bag over the operating consolep. 215
+5. Pull the dust protection bag over the operating consolep. 215
(Fig. 5)p. 215
(Fig. 6)p. 215
(Fig. 7)p. 215
+Fig. 6p. 215
Fig. 6p. 215
+Fig. 7p. 215
Fig. 7p. 215
+Fig. 8p. 215
Fig. 8p. 215
+6. Tighten the screws for the operating console hand tightp. 215
+6. Tighten the screws for the operating console hand tightp. 215
(Fig. 8)p. 215
+Ensure the seal/gasket is fitted correctly.p. 215
Ensure the seal/gasket is fitted correctly.p. 215
+Fig. 9p. 216
Fig. 9p. 216
+7. Disassemble the dashboard, for this purpose unscrew the fastening screws (4X), take off spacers and washersp. 216
+7. Disassemble the dashboard, for this purpose unscrew the fastening screws (4X), take off spacers and washersp. 216
(Fig. 9)p. 216
+Fig. 10p. 216
Fig. 10p. 216
+8. Lift the dashboard upp. 216
+8. Lift the dashboard upp. 216
(Fig. 10)p. 216
+Fig. 11p. 216
Fig. 11p. 216
+9. … fold it backp. 216
+9. … fold it backp. 216
(Fig. 11)p. 216
+Fig. 12p. 216
Fig. 12p. 216
+10. Wrap the dust protection bag around the wiring looms and fasten it with cable strapsp. 216
+10. Wrap the dust protection bag around the wiring looms and fasten it with cable strapsp. 216
(Fig. 12)p. 216
+Fig. 13p. 217
Fig. 13p. 217
+11. Assemble the dashboardp. 217
+11. Assemble the dashboardp. 217
(Fig. 13)p. 217
+Fig. 14p. 217
Fig. 14p. 217
+12. Fasten the dashboard with fastening screws (4X), spacers and washersp. 217
+12. Fasten the dashboard with fastening screws (4X), spacers and washersp. 217
(Fig. 14)p. 217
+Fig. 15p. 217
Fig. 15p. 217
+13. Tighten the fastening screwsp. 217
+13. Tighten the fastening screwsp. 217
(Fig. 15)p. 217
+Check the function of control switches.p. 217
Check the function of control switches.p. 217
+11 Engine electricsp. 219
+11 Engine electricsp. 219
11.1 EMR3 system componentsp. 220
+Engine control unitp. 220
Engine control unitp. 220
+It is strictly prohibited to interchange control units from one production series or against another engine serial number. The warranty will in this case become null and void.p. 220
+It is strictly prohibited to interchange control units from one production series or against another engine serial number. The warranty will in this case become null and void.p. 220
It is strictly prohibited to interchange control units from one production series or against another engine serial number. The warranty will in this case become null and void.p. 220
Sensors and actuators must not be connected to external power sources for testing, but must solely be operated in combination with the EMR3. Otherwise components may be permanently damaged.p. 220
Disconnecting the control unit plug connectors with the control unit switched on (i.e. with power supply to terminal 15), is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition switch), wait until the ma…p. 220
+The engine control unit is the central component of the EMR3-system. It has the function to assure optimal engine performance with the objectivesp. 220
The engine control unit is the central component of the EMR3-system. It has the function to assure optimal engine performance with the objectivesp. 220
+l good exhaust characteristic,p. 220
l good exhaust characteristic,p. 220
l low fuel consumption,p. 220
l smooth running of engine,p. 220
l long lifetime of engine,p. 220
l efficient servicep. 220
. For this purpose the engine control unit runs a number of calculations using the detected measuring values and the parameters saved in the database, which for the basis for all functions provided. The most important functions include:p. 220
+l exact control of injection process (among others the number, start and duration of injection processes),p. 220
l exact control of injection process (among others the number, start and duration of injection processes),p. 220
l idle speed control,p. 220
l control of the exhaust gas recirculation quantity,p. 220
l optimization of smooth running (by means of correcting the injection quantity),p. 220
l engine monitoring,p. 220
l system diagnose.p. 220
+Replacing the control unitp. 220
Replacing the control unitp. 220
Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you mu…p. 220
+The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 220
The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.p. 220
Replacing the EMR or DCR componentsp. 220
+l On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control uni…p. 220
l On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control uni…p. 220
l Any other EMR components (sensors etc) must under no circumstances be repaired, but must be replaced if they are defective.p. 220
Fig. 16p. 221
+The engine control unit EMR3-S (TCD 2012 and TCD 2013)p. 221
(Fig. 16)p. 221
+l the socket D2.1 to connect the engine wiring loom,p. 221
l the socket D2.1 to connect the engine wiring loom,p. 221
l the socket D2.2 to connect the vehicle wiring loom.p. 221
Fig. 17p. 221
+The engine control unit EMR3-E (TCD 2015)p. 221
(Fig. 17)p. 221
+l the socket D2.1 to connect the vehicle wiring loom,p. 221
l the socket D2.1 to connect the vehicle wiring loom,p. 221
l the socket D2.2 to connect the engine wiring loom for sensors and actuators,p. 221
l the socket D2.3 to connect the engine wiring loom for fuel metering unit and injection valves.p. 221
EMR3-system in connection with injection system and electronicsp. 222
Fig. 1p. 222
+1 Fuel tankp. 222
1 Fuel tankp. 222
2 Pre-filterp. 222
3 Fuel lift pumpp. 222
4 Fuel filterp. 222
5 High pressure fuel pumpp. 222
6 Fuel metering unit ZMEp. 222
7 Control unitp. 222
8 High pressure accumulator, railp. 222
9 Injectorp. 222
10 Rail pressure sensorp. 222
11 Exhaust gas turbochargerp. 222
12 Engine transfer plugp. 222
13 Exhaust gas recirculation, optionp. 222
14 Engine sensorsp. 222
15 Diagnostics lampp. 222
16 Ignition switchp. 222
17 Pedalp. 222
18 Diagnostics buttonp. 222
19 Pressure relief valvep. 222
20 Battery, terminal 31 and 30p. 222
21 Connecting cable between control unit and enginep. 222
22 Connecting line for engine wiring loomp. 222
23 Engine wiring harnessp. 222
24 Sensor, water in fuelp. 222
Sensors TCD 2012 / 2013p. 223
Fig. 1p. 223
+1 Fuel metering unit ZMEp. 223
1 Fuel metering unit ZMEp. 223
2 Coolant temperature sensorp. 223
3 Sensor for charge air temperature and charge air pressurep. 223
4 Connecting line for engine wiring loomp. 223
5 Engine control unitp. 223
6 Rotary speed sensor for crankshaftp. 223
7 Rail pressure sensorp. 223
8 Oil level sensor, optionp. 223
9 Oil pressure sensorp. 223
10 Fuel pressure sensorp. 223
11 Rotary speed sensor for camshaftp. 223
12 Central plugp. 223
Sensors TCD 2015p. 223
Fig. 1p. 223
+1 Oil pressure sensorp. 223
1 Oil pressure sensorp. 223
2 Fuel temperature sensorp. 223
3 Sensor for charge air temperature and charge air pressurep. 223
4 Engine control unitp. 223
5 Coolant temperature sensorp. 223
6 Oil level sensor, optionp. 223
7 Central plugp. 223
8 Rotary speed sensor for crankshaftp. 223
9 Rotary speed sensor for camshaftp. 223
10 Connecting line for engine wiring loomp. 223
Shutting down the enginep. 224
+The engine is shut down by disconnecting the electronics from terminal 15 by means of the ignition switch The injectors are closed immediately, the rail pressure is reduced in a controlled manner and the counter status data are saved in the non-volat…p. 224
+The engine is shut down by disconnecting the electronics from terminal 15 by means of the ignition switch The injectors are closed immediately, the rail pressure is reduced in a controlled manner and the counter status data are saved in the non-volat…p. 224
battp. 224
+The main relay has the function of releasing the vehicle power supply for the EMR3-system.p. 224
The main relay has the function of releasing the vehicle power supply for the EMR3-system.p. 224
+l The engine control unit EMR3-S requires an external main relay (K41, see circuit diagram).p. 224
l The engine control unit EMR3-S requires an external main relay (K41, see circuit diagram).p. 224
l The engine control unit EMR3-E has an internal electronic main relay.p. 224
The following applies for both control units: once terminal 15 is no longer connected to battery (+) (i.e. after the ignition has been switched off), the main relay is switched off after approx. 10 seconds.p. 224
The main relay disconnects the control unit from terminal 30 battery (+), whereby is becomes de-energized.p. 224
The switching state of the main relay can be directly observed on Pin72 of the EMR3-S and on Pin13 of the EMR3-E.p. 224
11.2 Pin assignment of engine control EDC16 / EMR3p. 225
11.3 Rotary speed sensor for camshaftp. 230
+Speed sensor, B114p. 230
Speed sensor, B114p. 230
+l Inductive sensorp. 230
l Inductive sensorp. 230
l Determination of TDCp. 230
l Limp-home function in case of crankshaft sensor failurep. 230
Fig. 2p. 230
+Disassembling the speed sensorp. 230
Disassembling the speed sensorp. 230
Fig. 3p. 230
+l Remove the cable strapp. 230
+l Remove the cable strapp. 230
(Fig. 3)p. 230
l Disconnect the cable plug.p. 230
Fig. 4p. 230
+l Unscrew the screwp. 230
+l Unscrew the screwp. 230
(Fig. 4)p. 230
l Remove the speed sensorp. 230
+Installing the speed sensorp. 230
Installing the speed sensorp. 230
Fig. 5p. 230
+l Clean the sealing faces on speed transducer and timing gear cover.p. 230
l Clean the sealing faces on speed transducer and timing gear cover.p. 230
+l Assemble a new O-ringp. 230
(Fig. 5)p. 230
l Cover the O-ring slightly with oil.p. 230
Fig. 6p. 231
+l Insert the speed sensorp. 231
+l Insert the speed sensorp. 231
(Fig. 6)p. 231
l Tighten the screw.p. 231
+Assemble the screw with screw retention agent.p. 231
Assemble the screw with screw retention agent.p. 231
Fig. 7p. 231
+l Plug in the cable plugp. 231
+l Plug in the cable plugp. 231
(Fig. 7)p. 231
l Route the cable.p. 231
l Fasten the cable with cable straps.p. 231
11.4 Crankshaft speed sensorp. 231
+Speed sensor, B130p. 231
Speed sensor, B130p. 231
+l Inductive sensorp. 231
l Inductive sensorp. 231
l Exact determination of engine speedp. 231
l Limp-home function in case of camshaft sensor failurep. 231
+RPM-meterp. 231
RPM-meterp. 231
+The rotary speed is detected by the EMR control and passed on to the LC-Display (A81)p. 231
(Fig. 8)p. 231
Fig. 8 A81, multi-function LC-Displayp. 231
+xp. 231
+xp. 231
xp. 231
Engine rpm-meterp. 231
Fig. 9 Crankshaft speed sensorp. 231
Check the gap measurementp. 232
Fig. 10p. 232
+1 Toothed disc on crankshaftp. 232
1 Toothed disc on crankshaftp. 232
2 Speed sensorp. 232
+l Check gap measurement with a feeler gauge cp. 232
+l Check gap measurement with a feeler gauge cp. 232
(Fig. 10)p. 232
+Nominal value: 0,6p. 232
± 0,5p. 232
+The feeler gauge must fit with only little resistance through the gap between toothed disc and speed sensor (crankshaft).p. 232
The feeler gauge must fit with only little resistance through the gap between toothed disc and speed sensor (crankshaft).p. 232
11.5 Rail pressure sensorp. 232
+Pressure sensor, B93p. 232
Pressure sensor, B93p. 232
+l Pressure sensorp. 232
l Pressure sensorp. 232
l Monitoring the injection pressurep. 232
Fig. 11p. 232
+Disassembling the pressure sensorp. 232
Disassembling the pressure sensorp. 232
+After shutting down the engine wait 30 seconds, before starting work in the fuel system.p. 232
After shutting down the engine wait 30 seconds, before starting work in the fuel system.p. 232
+Ensure strict cleanliness when working on the fuel system.p. 232
Ensure strict cleanliness when working on the fuel system.p. 232
Thoroughly clean the areas around the affected components. Dry off moist locations with compressed air.p. 232
Do not allow foreign particles to enter into the rail.p. 232
Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 232
Follow the safety regulations and the country specific instructions concerning the handling of fuel.p. 232
Close any opened connection immediately with new and clean plugs/caps.p. 232
Remove plugs/caps only just before assembly.p. 232
Do not touch the pin contacts of the rail pressure sensor with bare hands to avoid electrostatic discharge.p. 232
+Catch running out fuel and dispose of environmentally.p. 232
Catch running out fuel and dispose of environmentally.p. 232
Fig. 12p. 233
+l Unlock and pull out the cable plugp. 233
+l Unlock and pull out the cable plugp. 233
(Fig. 12)p. 233
l Unscrew the rail pressure sensor with a socket wrenchp. 233
Fig. 13p. 233
+l Visually examine the thread and the sealing edge (arrows)p. 233
+l Visually examine the thread and the sealing edge (arrows)p. 233
(Fig. 13)p. 233
+Installing the rail pressure sensorp. 233
Installing the rail pressure sensorp. 233
Fig. 14p. 233
+Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 233
Ensure strict cleanliness. Particularly on the thread and the sealing surface of the rail.p. 233
+l Apply a little bit of grease to the thread and the sealing edge of the rail pressure sensor.p. 233
l Apply a little bit of grease to the thread and the sealing edge of the rail pressure sensor.p. 233
+l Turn in the rail pressure sensor (2)p. 233
(Fig. 14)p. 233
+Tightening torque: 40p. 233
+Tightening torque: 40p. 233
+ 5p. 233
+l Plug on the cable plug.p. 233
l Plug on the cable plug.p. 233
11.6 Fuel pressure sensorp. 234
+Pressure sensor, B145p. 234
Pressure sensor, B145p. 234
+l Pressure sensorp. 234
l Pressure sensorp. 234
l Monitoring of input pressurep. 234
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 234
Fig. 15p. 234
+Disassembling the pressure sensorp. 234
Disassembling the pressure sensorp. 234
+Ensure strict cleanliness when working on the fuel system.p. 234
Ensure strict cleanliness when working on the fuel system.p. 234
Thoroughly clean the areas around the affected components. Dry off moist locations with compressed air.p. 234
Follow the safety regulations and the country specific instructions concerning the handling of fuel.p. 234
Close any opened connection immediately with new and clean plugs/caps.p. 234
Remove plugs/caps only just before assembly.p. 234
+Catch running out fuel and dispose of environmentally.p. 234
Catch running out fuel and dispose of environmentally.p. 234
Fig. 16p. 234
+l Unscrew the locking ringp. 234
+l Unscrew the locking ringp. 234
(Fig. 16)p. 234
l Pull out the cable plug.p. 234
l Unscrew the fuel pressure sensor with a socket wrench.p. 234
+Assembling the pressure sensorp. 234
Assembling the pressure sensorp. 234
Fig. 17p. 234
+l Install and tighten the fuel pressure sensor with a new seal ringp. 234
+l Install and tighten the fuel pressure sensor with a new seal ringp. 234
(Fig. 17)p. 234
+Tightening torque: 30p. 234
+Tightening torque: 30p. 234
± 5p. 234
Fig. 18p. 235
+l Push the cable plug onto the fuel level sensorp. 235
+l Push the cable plug onto the fuel level sensorp. 235
(Fig. 18)p. 235
l Screw in the locking ring, until it locks in place.p. 235
+Ensure matching of the contacts.p. 235
Ensure matching of the contacts.p. 235
Bleed the fuel system via the manual fuel pump on the fuel pre-filter.p. 235
11.7 Fuel control unitp. 235
+Control unit, Y137p. 235
Control unit, Y137p. 235
Fig. 19p. 235
+Functionp. 235
Functionp. 235
Here the fuel flowing into the pump elements is metered by a infinitely controllable solenoid valve (referred to as fuel control unit).p. 235
This valve is mounted on the control block FCU (Fuel Control Unit) and adapts the fuel quantity delivered to the Rail to the system requirements. The solenoid valve is triggered by means of a pulse width modulated signal (PWM-signal). When the valve …p. 235
+The injectors are installed in the cylinder head. They have the same function as nozzle and nozzle holder in conventional injection systems. The injectors are connected with the pressure accumulator (Rail) by high pressure linesp. 237
(Fig. 23)p. 237
A valve determines the start of injection and the end of injection of the nozzle. The actuating forces to open and close the valve are generated by an solenoid. The injectors work with 50 to 70 V instead of the 12 V on- board voltage, which opens the…p. 237
+The forces required to open and close the nozzle needle cannot be generated by a solenoid valve on its own. The nozzle needle is therefore indirectly triggered via an hydraulic power booster system in the injectorp. 237
(Fig. 24)p. 237
Fig. 23p. 237
Fig. 24p. 237
11.9 Oil pressure sensorp. 238
+Pressure sensor, B88p. 238
Pressure sensor, B88p. 238
Oil pressure monitoringp. 238
The operator is warned ifp. 238
+l the oil pressure falls short of the warning limit and/orp. 238
l the oil pressure falls short of the warning limit and/orp. 238
l the power is reduced by the EMR after a pre-warning time, orp. 238
l the oil pressure falls short of the shut-down limit and the engine is shut down after a pre-warning time.p. 238
Fig. 25 Oil pressure sensorp. 238
+Engine oil pressure warning lightp. 238
Engine oil pressure warning lightp. 238
+The inductive sensor is monitored by the EMR-control (A48). In case of a fault a message is sent through the CAN-bus connection to the LC-Display (A81)p. 238
(Fig. 26)p. 238
Fig. 26 A81, multi-function LC-Displayp. 238
+e redp. 238
+e redp. 238
ep. 238
+flashes if the oil pressure is too low. The warning buzzer sounds, codesp. 238
5100 and 5112p. 238
+If the engine is shut down by the EMR control the codesp. 238
5101 and 5112p. 238
+A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 238
A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 238
The warning buzzer (H07) is triggered by the travel control (A34).p. 238
+Installing the pressure sensorp. 239
Disassembling the pressure sensorp. 239
+Ensure absolute cleanliness when working in the lubrication oil system.p. 239
Ensure absolute cleanliness when working in the lubrication oil system.p. 239
Thoroughly clean the area around the affected component. Dry off wet locations with compressed air.p. 239
Immediately close all connections and openings with new and clean plugs/caps.p. 239
Only remove plugs/caps just before assembling.p. 239
+Catch engine oil and dispose of environmentally.p. 239
Catch engine oil and dispose of environmentally.p. 239
Fig. 27p. 239
+l Unlock and pull out the cable plugp. 239
+l Unlock and pull out the cable plugp. 239
(Fig. 27)p. 239
l Unscrew the coolant temperature sensor.p. 239
+Installing the pressure sensorp. 239
Installing the pressure sensorp. 239
Fig. 28p. 239
+l Insert the oil pressure sensor with a new seal ring and tighten.p. 239
l Insert the oil pressure sensor with a new seal ring and tighten.p. 239
+Tightening torque: 20Nmp. 239
Tightening torque: 20Nmp. 239
11.10 Sensor for charge air temperature and charge air pressurep. 240
+Sensor, B133p. 240
Sensor, B133p. 240
+Combined charge air pressure / temperature sensorp. 240
Combined charge air pressure / temperature sensorp. 240
Fig. 29p. 240
This sensor unites two functions in one housing. The one function measures the charge air pressure in the and adapts the injection quantity in dependence on the measured pressure. On the other hand the EMR now detects the temperature of the passing a…p. 240
+With a faulty sensor the engine continues to run with charge pressure simulation.p. 240
With a faulty sensor the engine continues to run with charge pressure simulation.p. 240
With a defective temperature sensor the engine also carries on running.p. 240
Charge air temperature monitoringp. 240
The operator is warned ifp. 240
+l the temperature exceeds the warning limit and/orp. 240
l the temperature exceeds the warning limit and/orp. 240
l the power is reduced by the EMR 3 after a pre- warning time, orp. 240
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 240
+Disassembling the sensorp. 240
Disassembling the sensorp. 240
Fig. 30p. 240
+l Unscrew fastening screw 1p. 240
+l Unscrew fastening screw 1p. 240
(Fig. 30)p. 240
l Remove the cover plate.p. 240
Fig. 31p. 240
+l Unlock and pull out the cable plugp. 240
+l Unlock and pull out the cable plugp. 240
(Fig. 31)p. 240
l Remove the pressure/temperature sensor.p. 240
+Assembling the sensorp. 241
Assembling the sensorp. 241
Fig. 32p. 241
+l Assemble a new O-ringp. 241
+l Assemble a new O-ringp. 241
(Fig. 32)p. 241
l Slightly cover the O-ring with grease.p. 241
Fig. 33p. 241
+l Carefully insert the pressure/temperature sensorp. 241
+l Carefully insert the pressure/temperature sensorp. 241
(Fig. 33)p. 241
l Plug in and lock the cable plug.p. 241
Fig. 34p. 241
+l Attach the cover platep. 241
+l Attach the cover platep. 241
(Fig. 34)p. 241
l Tighten the screw (1).p. 241
11.11 EMR coolant temperature sensorp. 242
+Temperature sensor, B113p. 242
Temperature sensor, B113p. 242
The coolant temperature has an effect on the calculated injection quantity and the preheating behaviour of the glow plugs.p. 242
Coolant temperature monitoringp. 242
The operator is warned ifp. 242
+l the temperature exceeds the warning limit and/orp. 242
l the temperature exceeds the warning limit and/orp. 242
l the power is reduced by the EMR after a pre-warning time, orp. 242
l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time.p. 242
Fig. 35 Coolant temperature sensorp. 242
+Warning light engine overheatingp. 242
Warning light engine overheatingp. 242
+The coolant temperature is detected by the EMR control (A48). In case of a fault a message is sent through the CAN-bus connection to the LC-Display (A81)p. 242
(Fig. 36)p. 242
Fig. 36 A81, multi-function LC-Displayp. 242
+f redp. 242
+f redp. 242
fp. 242
+flashes if the engine is overheating The warning buzzer sounds, codesp. 242
5100 and 5116p. 242
+If the engine is shut down by the EMR control the codesp. 242
5101 and 5116p. 242
+A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 242
A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 242
The warning buzzer (H07) is triggered by the travel control (A34).p. 242
+Coolant temperature gaugep. 242
Coolant temperature gaugep. 242
+cp. 242
+cp. 242
cp. 242
upper display field, shows either the time or the coolant temperature.p. 242
+Installing the temperature sensorp. 243
Disassembling the temperature sensorp. 243
+Catch running out fluids in a suitable vessel and dispose of environmentally.p. 243
Catch running out fluids in a suitable vessel and dispose of environmentally.p. 243
+Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 243
Follow the corresponding documentation in the operating instructions to drain and fill the cooling system.p. 243
Fig. 37p. 243
+l Unlock and pull out the cable plugp. 243
+l Unlock and pull out the cable plugp. 243
(Fig. 37)p. 243
Fig. 38p. 243
+l Unscrew the coolant temperature sensorp. 243
+l Unscrew the coolant temperature sensorp. 243
(Fig. 38)p. 243
+Counter the adapter piece.p. 243
Counter the adapter piece.p. 243
+Installing the temperature sensorp. 243
Installing the temperature sensorp. 243
Fig. 39p. 243
+l Tighten the coolant temperature sensorp. 243
+l Tighten the coolant temperature sensorp. 243
(Fig. 39)p. 243
+Make sure that the seal rings are present .p. 243
Make sure that the seal rings are present .p. 243
+Tightening torque: 22p. 243
±2p. 243
Fig. 40p. 243
+l Push on the cable plugp. 243
+l Push on the cable plugp. 243
(Fig. 40)p. 243
11.12 Glow plugsp. 244
+R81 to R86p. 244
R81 to R86p. 244
+The engines are equipped with glow plugs for cold starting as standard. Preheating the glow plugs in the combustion chamber of the diesel engine ensures perfect cold starting and post-heating of the glow plugs has a positive effect on the emissions f…p. 244
The engines are equipped with glow plugs for cold starting as standard. Preheating the glow plugs in the combustion chamber of the diesel engine ensures perfect cold starting and post-heating of the glow plugs has a positive effect on the emissions f…p. 244
+Pre-heating control lightp. 244
Pre-heating control lightp. 244
+Pre- and after-heating is passed on via the CAN-bus connection to the LC-Display (A81)p. 244
(Fig. 41)p. 244
Fig. 41 A81, LC-Displayp. 244
+k yellowp. 244
+k yellowp. 244
kp. 244
lights when temperatures are low (pre- heating for starting).p. 244
+Triggering of glow plugsp. 244
Triggering of glow plugsp. 244
During cold starting the EMR-control (Pin24 ground, Pin 34 plus) switches, whereby the coil of relay (K14) is excited. The switch contact of relay (K14) supplies the glow plugs with battery current.p. 244
+Fuse for glow plugsp. 244
Fuse for glow plugsp. 244
Fig. 42p. 244
+125Ap. 244
125Ap. 244
(F48) Fuse for glow plugsp. 244
125Ap. 244
(F00) Main fusep. 244
11.13 Sensor, water in fuelp. 244
+Sensor, B124p. 244
Sensor, B124p. 244
Fig. 43p. 244
+1 Water separator sensor connection (B124)p. 244
1 Water separator sensor connection (B124)p. 244
+2 Fuel pre-heating connectionp. 244
Optionp. 244
+Warning light water in fuelp. 244
Warning light water in fuelp. 244
+The sensor data are detected by the EMR control (A48) and passed on to the LC-Display (A81)p. 244
(Fig. 44)p. 244
Fig. 44 A81, multi-function LC-Displayp. 244
+m redp. 244
+m redp. 244
mp. 244
+Lights when the water proportion in the transparent section of the fuel filter reaches the contacts. The warning buzzer sounds, codesp. 244
5100 and 5119p. 244
+A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 245
A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 245
The warning buzzer (H07) is triggered by the travel control (A34). The travel control receives the signal from the data collector (A80) via the CAN-bus connection.p. 245
11.14 Fuel pre-heatingp. 245
+Fuel pre-heating (option)p. 245
Fuel pre-heating (option)p. 245
+The preheating system is not monitored by the engine control unit.p. 245
+The preheating system is not monitored by the engine control unit.p. 245
The preheating system is not monitored by the engine control unit.p. 245
In diesel engines the pre-heating of the fuel prevents malfunctions caused by the formation of jelly (paraffin separation) in the fuel under low temperatures.p. 245
The heater is activated when the ignition is switched on, this should take place at least 5 minutes before starting the engine.p. 245
The generated heat works directly under the filter element and melts the wax crystals that have formed, so that the fuel can flow through the filter element without restriction. The 200W heating is supplied with 12V D.C-current.p. 245
11.15 Rotary switch for engine speedp. 246
Fig. 1p. 246
Rotary switch for engine speed, S127p. 246
The switch position is detected by the LC-Display (A81) and passed on to the EMR-control (A48) via the CAN-bus connection.p. 246
+Position leftp. 246
Position leftp. 246
Idle speed positionp. 246
+Position middlep. 246
Position middlep. 246
„ECO“ -mode. The engine speed adapts automatically to the power requirements. This enables economical operation.p. 246
+Position rightp. 246
Position rightp. 246
Full throttle position, operating position for driving and vibrationp. 246
+Always drive and vibrate with max. engine speed or in ECO-mode! Control the travel speed with the travel lever.p. 246
Always drive and vibrate with max. engine speed or in ECO-mode! Control the travel speed with the travel lever.p. 246
11.16 Data collectorp. 246
+The data collector (A80) is an electronic device which records various machine signals and supplies these in form of a CAN-message to the machine system, mainly the display module.p. 246
The data collector (A80) is an electronic device which records various machine signals and supplies these in form of a CAN-message to the machine system, mainly the display module.p. 246
Fig. 1p. 246
The electric evaluation of the signals takes place in analog mode.p. 246
In the data collector various signals are recorded, processed and, with the help of a micro-processor, passed on to the collective display via a CAN bus connection.p. 246
The superordinate control sends a machine specific parameter string via CAN bus, which enables the calibration of data in the collective display.p. 246
+Type and number of inputs:p. 247
Type and number of inputs:p. 247
+l 11 digital inputs.p. 247
l 11 digital inputs.p. 247
l 2 analog 4-20 mA current inputs to groundp. 247
l 1 analog measuring input for temperature sensor.p. 247
l 2 analog inputs for fuel and water level gaugep. 247
l 1 CAN busp. 247
+Digital inputsp. 247
Digital inputsp. 247
The 11 inputs are (HIGH- and LOW-active) inputs, which may be differently equipped, depending on the machine type.p. 247
+One of these digital inputs serves for direct connection of a signal output from a Sepa filter for water separation in the fuel filter.p. 247
One of these digital inputs serves for direct connection of a signal output from a Sepa filter for water separation in the fuel filter.p. 247
+Analog inputsp. 247
Analog inputsp. 247
The 4-20 mA inputs work against reference ground.p. 247
Vacuum switch, B03p. 247
+The vacuum is not monitored by the engine control unit.p. 247
+The vacuum is not monitored by the engine control unit.p. 247
The vacuum is not monitored by the engine control unit.p. 247
Fig. 2p. 247
+Air filter warning lightp. 247
Air filter warning lightp. 247
At a vacuum of > 50 mbar the vacuum switch will switch to ground.p. 247
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 247
(Fig. 3)p. 247
Fig. 3 A81, multi-function LC-Displayp. 247
+g yellowp. 247
+g yellowp. 247
gp. 247
+lights (with a 5 second delay) if the combustion air filter cartridge is contaminated. The warning buzzer sounds and the codep. 247
5026p. 247
5027p. 247
+The warning buzzer (H07) is triggered by the travel control (A34).p. 247
The warning buzzer (H07) is triggered by the travel control (A34).p. 247
Float switch, B55p. 248
Fig. 4p. 248
+Coolant level warning lightp. 248
Coolant level warning lightp. 248
In case of a too low coolant level the float switch will switch to ground.p. 248
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 248
(Fig. 5)p. 248
Fig. 5 A81, multi-function LC-Displayp. 248
+h redp. 248
+h redp. 248
hp. 248
+flashes (with a 5 second delay) if the coolant level is too low. The warning buzzer sounds and the codep. 248
5024p. 248
5025p. 248
+The warning buzzer (H07) is triggered by the travel control (A34).p. 248
The warning buzzer (H07) is triggered by the travel control (A34).p. 248
Charge control lightp. 248
+The generator is not monitored by the engine control unit.p. 248
The generator is not monitored by the engine control unit.p. 248
Fig. 6p. 248
+1 Terminal B+p. 248
1 Terminal B+p. 248
2 Terminal Wp. 248
3 Terminal D+p. 248
+If the battery is not being charged, a ground signal is applied to D+ terminal 3p. 248
(Fig. 6)p. 248
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 248
(Fig. 7)p. 248
Fig. 7 A81, multi-function LC-Displayp. 248
+l yellowp. 248
+l yellowp. 248
lp. 248
Charge control lamp, lights if the battery is not being charged. Check V-belt, if necessary repair the generator.p. 248
Level sensor in diesel tank (R03)p. 249
+The immersion pipe sensor is not monitored by the engine control unit.p. 249
The immersion pipe sensor is not monitored by the engine control unit.p. 249
Fig. 8p. 249
The fluid of the level to be measured carries a float, which lowers or rises with the fluid level. Contact springs mounted on the float thereby slide along two resistor wires arranged parallel to the movement of the float and generate a resistance va…p. 249
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 249
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 249
(Fig. 9)p. 249
Fig. 9 A81, multi-function LC-Displayp. 249
+bp. 249
+bp. 249
bp. 249
Fuel level gaugep. 249
Differential pressure switch for hydraulic oil filter, B21p. 249
Fig. 1p. 249
+l The differential pressure switchesp. 249
+l The differential pressure switchesp. 249
(Fig. 1)p. 249
Dp. 249
+The switching state is detected by the data collector and passed on to the multi-function LC-Display (A81)p. 249
(Fig. 2)p. 249
Fig. 2 A81, multi-function LC-Displayp. 249
+i yellowp. 249
+i yellowp. 249
ip. 249
lights if the hydraulic oil filter is contaminated, the engine is shut down after 2 minutes. Warning buzzer sounds. Check hydraulic system, replace hydraulic oil filter.p. 249
+The warning buzzer (H07) is triggered by the travel control (A34). The travel control receives the signal from the data collector via the CAN-bus connection.p. 249
The warning buzzer (H07) is triggered by the travel control (A34). The travel control receives the signal from the data collector via the CAN-bus connection.p. 249
Fault displayp. 250
Fig. 1 Displayp. 250
+All detected faults are displayedp. 250
All detected faults are displayedp. 250
Fault codes 5000 – 5499 are diesel engine related.p. 250
A detailed reading out of fault codes for the diesel engine is only possible with Deutz-Serdiap. 250
+A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 250
A detailed description of how to read out fault codes can be found in the Service Training Electrics.p. 250
11.18 Diagnose with SERDIAp. 251
+SERDIAp. 251
SERDIAp. 251
+With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 251
With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of the control unit.p. 251
Fig. 1 Service-Software TCD 2012 / 2013p. 251
The SERDIA software is first choice for any diagnostics task.p. 251
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log.p. 251
This displays information onp. 251
+l Location of fault (e.g. ’coolant temperature sensor’)p. 251
l Location of fault (e.g. ’coolant temperature sensor’)p. 251
l Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)p. 251
l Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)p. 251
l Number of fault locations and frequency of faultp. 251
l Fault status (active – fault present / passive- fault no longer present)p. 251
l Fault messages for non-present / rectified faults can be deleted with SERDIA.p. 251
Function testp. 251
The control outputs can be activated with the engine shut down.p. 251
Assignment of inputs/outputsp. 251
Display of the current input and output assignment of the EMR-control.p. 251
Representation of measuring valuesp. 252
Fig. 2p. 252
There is a vast variety of measuring values available for selection which can even be used if no EMR-fault is present (start behaviour, engine sawing, lack of power).p. 252
Representation of fault logp. 253
Fig. 3p. 253
When looking for the cause of a fault in the EMR3-system examining the fault log of the engine control unit usually provides useful information.p. 253
11.19 Diagnose with CAN-busp. 254
+The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 254
The CAN-bus is used to transfer standard messages of the SAE J 1939.p. 254
The display is a compact, robust and integratable modules which enables the user to invoke engine data and to display these in the following formats:p. 254
+l Analog displayp. 254
l Analog displayp. 254
l Digital datap. 254
l Multi data (a combination of analog and digital data)p. 254
l Alarm messages currently presentp. 254
The different diagnostic screens enable detailed examination of the engine data flowp. 254
Fig. 1p. 254
+Display for EMR controlp. 254
(Fig. 1)p. 254
11.20 Diagnostics interfacep. 255
Fig. 1 Control unit under driver's standp. 255
Fig. 2 Serdia connection socket in electrics cabinetp. 256
Fig. 3 Diagnostic linkp. 256
+Ap. 256
Ap. 256
Battery plus (+)p. 256
Bp. 256
Battery minus (-)p. 256
Fp. 256
CAN2 lowp. 256
Gp. 256
CAN1 lowp. 256
Hp. 256
CAN1 highp. 256
Kp. 256
K-Linep. 256
Mp. 256
CAN2 highp. 256
SERDIA connectionp. 257
Fig. 4p. 257
+The KWP-protocol with encrypted dataflow is used via the K-line. For this purpose the PC or laptopp. 257
(Fig. 4)p. 257
Operation of SERDIA is described in a separate operation manual.p. 257
CAN-bus display connectionp. 257
Operation of the display is described in a separate operation manual.p. 257
Fig. 5p. 257
+Display for EMR controlp. 257
(Fig. 5)p. 257
BOMAG part-no.: 057 189 94p. 257
Fig. 6p. 257
The display is connected to the diagnostic interface by means of a special cable.p. 257
+Wiring loom for displayp. 257
(Fig. 6)p. 257
BOMAG part-no.: 079 900 19p. 257
EMR3 List of fault codesp. 258
11.22 Generatorp. 329
+Generalp. 329
Generalp. 329
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. 329
Terminal designationsp. 329
+l B61, L = charge controlp. 329
l B61, L = charge controlp. 329
l B+, B = battery plus, also with the designation "30"p. 329
l B- = battery minus, also with the designation "31"p. 329
l D+ = dynamo plus corresponds with terminal "61" and "L"p. 329
l D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed)p. 329
l DF = dynamo field (this designation is only found on D.C. generators or A.C. generators with regulator removed). Note: The designation DF is also found on older alternators with externally arranged regulator on the connection of the exciting coil t…p. 329
l DF1 = dynamo field 1p. 329
l DF2 = dynamo field 2p. 329
l IG = "15" ignition switchp. 329
Three-phase generatorp. 329
+The AC-generator first of all produces AC-voltage / AC-current.p. 329
The AC-generator first of all produces AC-voltage / AC-current.p. 329
Why does AC-current need to be rectified?p. 329
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. 329
This includes :p. 329
+l Incandescent lampsp. 329
l Incandescent lampsp. 329
l Fluorescent lampsp. 329
l Glow lampsp. 329
l Electric heating elements.p. 329
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. 329
This includes :p. 329
+l Electric motorsp. 329
l Electric motorsp. 329
l Relays.p. 329
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.p. 329
This includes :p. 329
+l Accumulatorsp. 329
l Accumulatorsp. 329
l Control unitsp. 329
l All electronicsp. 329
l Communication equipment.p. 329
+Design and functionp. 329
Design and functionp. 329
Fig. 7p. 329
+1 Fanp. 329
1 Fanp. 329
2 Holding platep. 329
3 Stator corep. 329
4 Stator windingp. 329
5 Brushp. 329
6 Brush holderp. 330
7 Rectifierp. 330
8 Bearing coverp. 330
9 Rotor windingp. 330
10 Rotorp. 330
11 V-belt pulleyp. 330
Fig. 8 Rotor with claw polesp. 330
+In the generator the armature windings are located inside the stationary statorp. 330
(Fig. 9)p. 330
(Fig. 8)p. 330
Fig. 9 Statorp. 330
+The three stator windingsp. 330
(Fig. 9)p. 330
Fig. 10 3-phase currentp. 330
+The wiring diagramp. 330
(Fig. 10)p. 330
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. 330
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. 330
Charge control lightp. 331
The charge control light has two duties:p. 331
+l Indication of the correct generator functionp. 331
l Indication of the correct generator functionp. 331
l External excitation of the generator during the starting phasep. 331
Fig. 11 plus controlled charging regulatorp. 331
+(Fig. 11) shows the current flow with the ignition switched on, engine stopped.p. 331
(Fig. 11)p. 331
Fig. 12 plus controlled charging regulatorp. 331
+(Fig. 12) shows the current flow with the ignition switched on, engine running.p. 331
(Fig. 12)p. 331
+1 Batteryp. 331
1 Batteryp. 331
2 Charge controllerp. 331
3 Ignition switchp. 331
4 Charge control lightp. 331
5 Rectifierp. 331
6 Rotorp. 331
7 Sliprings / carbon brushp. 331
8 Auxiliary rectifierp. 331
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. 331
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. 331
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. 331
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. 331
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. 331
Charge controllerp. 332
The charge controller has the following functionsp. 332
+l To regulate the voltage generated by the generatorp. 332
l To regulate the voltage generated by the generatorp. 332
l To protect against overloads caused by too high output currentp. 332
l Protection against reverse currentp. 332
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. 332
+Electronic charge regulatorp. 332
Electronic charge regulatorp. 332
Fig. 13p. 332
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. 332
Fig. 14 plus controlled regulatorp. 332
Fig. 15 minus controlled regulatorp. 332
Checking the generatorp. 333
+First one must check whether the generator is actually defective.p. 333
First one must check whether the generator is actually defective.p. 333
+l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 333
l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt.p. 333
l When the engine is at rest, the charge control light must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously also possible.p. 333
The following points allow to contain faults in the voltage supply within certain limits.p. 333
+l Cable connections on the generator OK?p. 333
l Cable connections on the generator OK?p. 333
l V-belt OK?p. 333
l Generator ground (engine ground) OK?p. 333
l Pre-excitation from vehicle electronics OK?p. 333
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. 333
Checking the pre-exciter circuit, D+ generatorp. 333
The most common reason for a 3-phase alternator not charging is a too low pre-excitation current. The pre- excitation current through connection D+ depends on the connected consumer (resistance), e.g. charge control light or relay of a MD+ engine con…p. 333
The pre-excitation current should be approx. 250 mA at 12 Volt. This corresponds with a 3 Watt light bulb or an equivalent combination of light bulb + resistance or an LED + resistance.p. 333
The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm.p. 333
In case of faults likep. 333
+l charge control light stays onp. 333
l charge control light stays onp. 333
l no voltage increase, e.g. from 12 V to 14 Vp. 333
one should check that the correct resistance is assured.p. 333
Fig. 16 Connections on the three-phase alternator (exemplary design)p. 333
If the charge control light or LED stays on when the engine is running, you should proceed as follows:p. 333
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 333
+l Temporarily bridge connections D+ and B+ on the three-phase alternatorp. 333
(Fig. 16)p. 333
If this measure does not clear the fault, the alternator must be defective.p. 333
+Measuring the charge currentp. 334
Measuring the charge currentp. 334
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 334
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 334
l The generator ground connection must be OK.p. 334
l During the measurement switch on as many consumers as possible.p. 334
+1 Attach the clip-on ammeter around the B+ line.p. 334
1 Attach the clip-on ammeter around the B+ line.p. 334
2 Gradually increase the engine speed.p. 334
3 The generator current must be at least as high as the total current of all switched on consumers.p. 334
Checking the rotorp. 334
+The rotor coils can only be measured in disassembled state.p. 334
The rotor coils can only be measured in disassembled state.p. 334
Fig. 17p. 334
+l Measure the resistance between the sliprings.p. 334
l Measure the resistance between the sliprings.p. 334
l If the resistance does not comply with the factory specification, replace the rotor.p. 334
l Use the resistance range of the continuity tester to check the continuity between slipring and core.p. 334
l Replace the rotor if no infinite value is indicated.p. 334
+Factory specification for resistance: 2.8 to 5 OHM.p. 334
Factory specification for resistance: 2.8 to 5 OHM.p. 334
Checking the statorp. 335
+The stator coils can only be measured in disassembled state.p. 335
The stator coils can only be measured in disassembled state.p. 335
Fig. 18p. 335
+l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 335
l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding.p. 335
l If the measuring value does not comply with the factory specification, replace the stator.p. 335
l Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core.p. 335
l Replace the stator if no infinite value is indicated.p. 335
+Factory specification for resistance: Less than 1 OHM.p. 335
Factory specification for resistance: Less than 1 OHM.p. 335
Checking the bearingsp. 335
Fig. 19p. 335
+l Check whether the bearing rotates without obstruction.p. 335
l Check whether the bearing rotates without obstruction.p. 335
l Replace the bearing if it does not rotate properly.p. 335
Checking the regulator voltage with the generator testerp. 336
The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) thermal printer.p. 336
Fig. 20p. 336
The generator test assesses the regulator voltage and the ripple factor of the generator voltage.p. 336
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 336
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 336
l The generator ground connection must be OK.p. 336
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 336
l If possible switch off all consumers.p. 336
l Perform the measurement at raised engine speed.p. 336
Checking the regulator voltage with the multimeterp. 336
Fig. 21p. 336
+l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 336
l All plug-and-socket connectors must be free of corrosion and intermittent contact.p. 336
l The generator ground connection must be OK.p. 336
l The battery should be in good condition – the idle voltage of the battery should be at least 12.6 Volt.p. 336
l If possible switch off all consumers.p. 336
l Perform the measurement at raised engine speed.p. 336
l The voltage (B+) should adjust itself at 13 to 14 Volt.p. 336
Checking the regulator in disassembled statep. 337
+On ap. 337
Bosch generatorp. 337
+Thep. 337
Delco-Remy generatorp. 337
+When testing the regulator one should be aware that there are 2 different types of regulators:p. 337
When testing the regulator one should be aware that there are 2 different types of regulators:p. 337
+l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon …p. 337
l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon …p. 337
D+ (vehicle wiring system)p. 337
D- (ground contact, mostly located on one of the fastening screws)p. 337
DF (Dynamo Field)p. 337
Fig. 22p. 337
+l If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush i…p. 337
l If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush i…p. 337
The basic function of a disassembled regulator can be easily tested with a 12V lamp and an adjustable D.C. power supply unit (0V … 20V).p. 337
Fig. 23p. 337
E.g minus controlled regulatorp. 337
+One connects the regulatorp. 337
(Fig. 23)p. 337
With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-.p. 337
Fig. 24p. 337
Fig. 25p. 337
+The illustrationsp. 337
(Fig. 24)p. 337
(Fig. 25)p. 337
Replacing carbon brushesp. 338
+l On ap. 338
+l On ap. 338
Bosch generatorp. 338
5 mmp. 338
+l For replacing the carbon brushes in thep. 338
Delco- Remy generatorp. 338
11.23 Replacing the voltage regulatorp. 338
+Disassembling the regulatorp. 338
Disassembling the regulatorp. 338
Fig. 1p. 338
+l Loosen the hexagon nuts M5p. 338
+l Loosen the hexagon nuts M5p. 338
(Fig. 1)p. 338
l Take off hexagon nuts and washers.p. 338
l Remove the plastic cover.p. 338
+Optional:p. 338
Optional:p. 338
Unscrew the hexagon nut M5 from terminal W, take off washer and flat plug connector.p. 338
Fig. 2p. 338
+l Check whether washers are present. Take off the washers (3x)p. 338
+l Check whether washers are present. Take off the washers (3x)p. 338
(Fig. 2)p. 338
Fig. 3p. 339
+l Slacken the screws M3 (A)p. 339
+l Slacken the screws M3 (A)p. 339
(Fig. 3)p. 339
l Loosen the hexagon nuts M5 (B).p. 339
l Remove screw and hexagon nuts.p. 339
l Take off the voltage regulator.p. 339
+Assembling the voltage regulatorp. 339
Assembling the voltage regulatorp. 339
Fig. 1p. 339
+l Check for correct fit of sealing ring on protective coverp. 339
+l Check for correct fit of sealing ring on protective coverp. 339
(Fig. 1)p. 339
Fig. 2p. 339
+l Check whether the rubber seal is present on the brush holderp. 339
+l Check whether the rubber seal is present on the brush holderp. 339
l Tighten the screw M3 (A).- Tightening torque 0.7- 1.0 Nm.p. 339
l Tighten the screw M5 (B).- Tightening torque 3.5- 4.5 Nm.p. 339
Fig. 4p. 339
+l Install the washersp. 339
+l Install the washersp. 339
(Fig. 4)p. 339
Fig. 5p. 340
+l Assemble the coverp. 340
+l Assemble the coverp. 340
(Fig. 5)p. 340
l Install the washers.p. 340
l Fasten the protective cover with the hexagon nuts.- Tightening torque for hexagon nut M5 2.1-3.1 Nm.p. 340
+Optional:p. 340
Optional:p. 340
Assemble flat plug connector, washer and hexagon nut M5 to connection W.p. 340
Tightening torque for hexagon nut 2.7-3.8 Nm.p. 340
11.24 Electric starterp. 340
+Generalp. 340
Generalp. 340
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. 340
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. 340
Duties of the starter:p. 340
+l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 340
l to accelerate the combustion engine to start speed with lowest possible current consumption.p. 340
l establish the gear connection between starter and combustion engine.p. 340
l to maintain this connection.p. 340
l to switch on the starter current.p. 340
After starting the engine:p. 340
+l to return the starter pinion to initial position.p. 340
l to return the starter pinion to initial position.p. 340
l to switch off the starter current.p. 340
Directly acting electric starterp. 341
+This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 341
This shows the design of this starter. It consists of a starter motor and a magnetic switch.p. 341
Fig. 6p. 341
+1 Magnetic switchp. 341
1 Magnetic switchp. 341
2 Armaturep. 341
3 Actuating leverp. 341
4 Freewheeling clutchp. 341
5 Resetting springp. 341
6 Brushp. 341
7 Exciting windingp. 341
8 Armaturep. 341
9 Collectorp. 341
+Ignition switch in position "START"p. 341
Ignition switch in position "START"p. 341
Fig. 7 Magnetic switch openp. 341
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. 341
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. 341
+1 Armaturep. 341
1 Armaturep. 341
2 Holding windingp. 341
3 Pick-up windingp. 341
4 Magnetic switchp. 341
5 Ignition switchp. 341
6 Actuating leverp. 341
7 Ring gearp. 341
8 Pinionp. 341
9 Freewheeling clutchp. 341
10 (Batteryp. 341
+Pinion meshes with the ring gearp. 341
Pinion meshes with the ring gearp. 341
Fig. 8 Magnetic switch closedp. 341
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. 341
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. 341
+1 Pick-up windingp. 341
1 Pick-up windingp. 341
2 Magnetic switchp. 341
3 Pinionp. 341
4 Ring gearp. 341
5 Armaturep. 341
6 Exciting windingp. 341
7 Batteryp. 341
+Engine runningp. 342
Engine runningp. 342
Fig. 9p. 342
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. 342
+1 Pinionp. 342
1 Pinionp. 342
2 (Ring gearp. 342
3 Freewheeling clutchp. 342
4 Armaturep. 342
+Ignition switch releasedp. 342
Ignition switch releasedp. 342
Fig. 10p. 342
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. 342
This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops.p. 342
+1 Armaturep. 342
1 Armaturep. 342
2 Holding windingp. 342
3 Pick-up windingp. 342
4 Resetting springp. 342
5 Magnetic switchp. 342
6 Ignition switchp. 342
7 Pinionp. 342
8 Ring gearp. 342
9 Batteryp. 342
Magnetic switchp. 343
Fig. 1 Direct acting electric motorp. 343
Fig. 2 Geared motorp. 343
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. 343
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. 343
+1 Holding windingp. 343
1 Holding windingp. 343
2 Pick-up windingp. 343
3 Contact platep. 343
4 Armaturep. 343
5 Resetting springp. 343
6 Armature guidep. 343
Freewheeling clutchp. 343
Fig. 1 Freewheeling clutchp. 343
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. 343
This makes sure that the armature will only drive the ring gear, but can never be driven by the engine.p. 343
+1 Freewheeling ringp. 343
1 Freewheeling ringp. 343
2 Rollerp. 343
3 Roller springp. 343
4 Splined shaftp. 343
5 Pinionp. 343
6 Pinionp. 343
Trouble shooting "Starter"p. 344
+The most frequent fault is definitely a fully discharged battery.p. 344
+The most frequent fault is definitely a fully discharged battery.p. 344
The most frequent fault is definitely a fully discharged battery.p. 344
+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. 344
If the starter rotates too slowlyp. 344
+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. 344
If the starter only emits a clicking soundp. 344
Frequently a jammed return mechanism is the reason for a starter failure.p. 344
Occasionally worn contacts are found on the magnetic return switchp. 344
Defects on the actual starter motor including pinion and carbon brushes are very rare.p. 344
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. 344
+l Immobilizer deactivated?p. 344
l Immobilizer deactivated?p. 344
l Ignition switch OK?p. 344
l Travel lever in correct position?p. 344
l Emergency stop not actuated?p. 344
l Battery sufficiently charged?p. 344
l Battery poles OK?p. 344
l Main battery fuse OK?p. 344
l Main battery switch closed?p. 344
l Main starter cable (terminal 30) OK?p. 344
l Starter control cable (terminal 50) OK, voltage drop?p. 344
l Ground cable OK?p. 344
l Switching of magnetic switches OK?p. 344
The sequence of these tests is generally of no significance. It mainly depends on:p. 344
+l the experience of the specialistp. 344
l the experience of the specialistp. 344
l the failure probability of the component to be tested and the testing effort for the respective part.p. 344
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. 344
Testing and measuring the starterp. 344
+The highest current flows when the starter is blocked! (Short circuit current in starter). This is the case when the pinion is engaged and the starter has the duty to accelerate the flywheel to starting speed.p. 344
+The highest current flows when the starter is blocked! (Short circuit current in starter). This is the case when the pinion is engaged and the starter has the duty to accelerate the flywheel to starting speed.p. 344
The highest current flows when the starter is blocked! (Short circuit current in starter). This is the case when the pinion is engaged and the starter has the duty to accelerate the flywheel to starting speed.p. 344
+Function control with the starter installedp. 344
Function control with the starter installedp. 344
+l Initiate the starting process and measure the voltage on the pickup solenoid switch (50a). At least 10.8 Volt should be applied.p. 344
l Initiate the starting process and measure the voltage on the pickup solenoid switch (50a). At least 10.8 Volt should be applied.p. 344
l When operating the starter switch the magnetic switch must engage in the flywheel ring gear (noticeable clicking sound) and release the starting current to the starter. On most magnetic switches the voltage can be measured with the multimeter. If t…p. 344
Testing and measuring the starterp. 345
+Function control with the starter removedp. 345
Function control with the starter removedp. 345
+Fasten the starter to make sure that it will not come loose during the test.p. 345
Fasten the starter to make sure that it will not come loose during the test.p. 345
Fig. 2p. 345
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 345
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 345
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 345
+If the motor does not start, the starter is defective. Repair or replace the starter.p. 345
If the motor does not start, the starter is defective. Repair or replace the starter.p. 345
+Checking the magnetic switchp. 345
Checking the magnetic switchp. 345
Fig. 3p. 345
+l Connect a jumper lead between start terminal (1) and battery plus (2).p. 345
l Connect a jumper lead between start terminal (1) and battery plus (2).p. 345
l Connect a jumper cable instantaneously between starter housing and battery minus (3).p. 345
+If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 345
If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter.p. 345
+Continuity test for the magnetic switchp. 345
Continuity test for the magnetic switchp. 345
Fig. 4p. 345
+l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 345
l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed.p. 345
l Replace the magnetic switch if no continuity is detected.p. 345
Removing and assembling the starterp. 346
+Removing the starterp. 346
Removing the starterp. 346
Fig. 5p. 346
+l Switch the main battery switch to position "0"p. 346
+l Switch the main battery switch to position "0"p. 346
(Fig. 5)p. 346
Fig. 6p. 346
+l Disconnect the cable connections (terminal 30 and 50).p. 346
l Disconnect the cable connections (terminal 30 and 50).p. 346
+l Unscrew the screws (arrows)p. 346
(Fig. 6)p. 346
l Take off the starter.p. 346
+Assembling the starterp. 346
Assembling the starterp. 346
Fig. 7p. 346
+l Insert the starter.p. 346
l Insert the starter.p. 346
+l Tighten the screws (arrows)p. 346
(Fig. 7)p. 346
l Connect the cables (terminal 30 and 50).p. 346
+Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 346
Please comply with the following tightening torques when tightening the cable connections, in order to avoid damage to the starter terminals or other components.p. 346
+Terminal 30, 24p. 346
±4p. 346
Terminal 50, 1 – 1,3 Nmp. 346
To tightly tightened nuts can cause damage to starter components (e.g. cracks in the cover of the magnetic switch). Moisture entering into the starter can cause short circuit – or even cable fire.p. 346
Insufficiently tightened nuts can cause cable connections to come loose and thus short circuit – or even cable fire.p. 346
+12 Electronic modulesp. 347
12 Electronic modulesp. 347
12.1 Machine related electricsp. 349
12.2 Electrics MESXp. 443
12.3 Electric module A72p. 507
12.4 Electric module A108p. 513
+13 Service Trainingp. 517
13 Service Trainingp. 517
13.1 Service Trainingp. 519
13.2 Service Training BVCp. 611
+14 Enginep. 667
14 Enginep. 667
+14.10 Check the engine oil levelp. 668
14.1 Diesel enginep. 668
+Series 4 single drum rollers are powered by 4 or 6 cylinder Deutz diesel engines type TCD 2013 or a 6-cylinder engine TCD 2012.p. 668
Series 4 single drum rollers are powered by 4 or 6 cylinder Deutz diesel engines type TCD 2013 or a 6-cylinder engine TCD 2012.p. 668
The engines are water cooled in-line engines with EMR3 electronics.p. 668
The engines are mainly designed in two-valve technology with turbo charging and intercooler. They are highly compact and come with a Deutz-Common-Rail injection system, called DCR in short.p. 668
All engines are designed with exhaust gas recirculation and thus reach emission values complying with EPA/ COM/ Tier/ stage lllp. 668
The engines are characterized by the following positive features:p. 668
+l compact designp. 668
l compact designp. 668
l low noise levelp. 668
l almost vibration free operationp. 668
l low fuel consumptionp. 668
l low exhaust emission EPA/COM IIlp. 668
l high power densityp. 668
l excellent access to all service locations.p. 668
l high reliabilityp. 668
l low running costs,p. 668
l long lifetimep. 668
Fig. 1 Deutz diesel engine TCD 2012 and 2013p. 668
+14.10 Check the engine oil levelp. 669
14.2 Engine description TCD 2012p. 669
Fig. 1 Deutz diesel engine TCD 2012, right hand sidep. 669
+1 Lubrication oil filling neckp. 669
1 Lubrication oil filling neckp. 669
2 Combustion air inletp. 669
3 Coverp. 669
4 Fanp. 669
5 Generatorp. 669
6 Fuel lift pumpp. 669
7 Idler pulleyp. 669
8 Lubrication oil coolerp. 669
9 Fuel filterp. 669
10 Replaceable lubrication oil filterp. 669
11 Lubrication oil sumpp. 669
12 Possible installation of hydraulic pump or compressor (optional)p. 669
13 Flywheel or (transmission connection SAE)p. 669
14 Crankcase ventilation valvep. 669
15 Transport devicep. 669
16 Charge air linep. 669
17 Fuel control unitp. 669
Fig. 2 Deutz diesel engine TCD 2012, left hand sidep. 670
+1 Exhaust manifoldp. 670
1 Exhaust manifoldp. 670
2 Exhaust turbo chargerp. 670
3 Lubrication oil filling neck (optional)p. 670
4 Engine mountsp. 670
5 Lubrication oil return line from exhaust gas turbo chargerp. 670
6 Relay (starter)p. 670
7 Ribbed V-beltp. 670
8 Coolant inletp. 670
9 Coolant outletp. 670
10 Coolant pumpp. 670
11 Connection cabin heater ort compensation linep. 670
12 Internally switched exhaust gas recirculationp. 671
13 Crankshaft bearingsp. 671
14 Conrod bearingsp. 671
15 Camshaft bearingsp. 671
16 Line to spray nozzlep. 671
17 Piston cooling nozzle with pressure maintaining valvep. 671
18 Plunger with rocker arm pulse lubricationp. 671
19 Push rod, lubrication oil supply for rocker arm lubricationp. 671
20 Rocker armp. 671
21 Return line to lubrication oil sumpp. 671
22 Lubrication oil flow to exhaust turbo chargerp. 671
23 Exhaust turbo chargerp. 671
24 Return line from compressor / hydraulic pump to crankcasep. 671
25 Compressor or hydraulic pumpp. 671
26 Lubrication oil line to crankshaft and camshaft, compressor / hydraulic pumpp. 671
27 Return flow from exhaust turbo chargerp. 671
+14.10 Check the engine oil levelp. 672
14.4 Coolant circuit TCD 2012 / 2013p. 672
Fig. 1 Fuel diagramp. 672
+1 Coolant outlet on radiatorp. 672
1 Coolant outlet on radiatorp. 672
2 Thermostatp. 672
3 Coolant – supply to water pumpp. 672
4 Coolant pumpp. 672
5 Lubrication oil coolerp. 672
6 Cylinder coolingp. 672
7 Cylinder liner / head coolingp. 672
8 Coolant flow to heaterp. 672
9 Cabin heater (optional)p. 672
10 Coolant to thermostatp. 672
11 Connection for cabin heaterp. 672
12 Compensation linep. 672
13 Ventilation line to compensation tankp. 672
14 Coolant outlet to radiatorp. 672
15 Compensation tankp. 672
16 Compensation line to heat exchangerp. 672
+14.10 Check the engine oil levelp. 673
14.5 Fuel system TCD 2012 / 2013p. 673
Fig. 1 Coolant diagramp. 673
+1 Fuel tank A= minimum distance 500 mmp. 673
1 Fuel tank A= minimum distance 500 mmp. 673
2 Fuel pre-filter with pre-pressure pumping possibility to fill the low pressure section (provided by customer)p. 673
3 Line to fuel lift pumpp. 673
4 Fuel lift pumpp. 673
5 Fuel filterp. 673
6 Fuel supply line to fuel control unitp. 673
7 Railp. 673
8 High pressure pumpp. 673
9 Fuel supply line to injectorp. 673
10 Injectorp. 673
11 FCU (Fuel Control Unit)p. 673
12 Fuel return flow on cylinder headp. 673
13 Fuel return line to fuel tankp. 673
14 Fuel lines from fuel control unit to high pressure pumps and railp. 673
15 Fuel lift pump 2013p. 673
+Fuel pre-filterp. 674
Fuel pre-filterp. 674
Fig. 2 Fuel pre-filterp. 674
+1 Fuel supply to pumpp. 674
1 Fuel supply to pumpp. 674
2 Fuel return flow from FCU (Fuel Control Unit)p. 674
3 Manual fuel pump with bayonet lock to lock and unlockp. 674
4 Thermostat valve with shut-down leverp. 674
5 Filter cartridgep. 674
6 Possibility to connect an electric water level sensorp. 674
7 Drain tapp. 674
8 Water collecting bowlp. 674
9 Fuel inlet from fuel tankp. 674
10 Fuel return flow to fuel tankp. 674
A Electric water level sensorp. 674
TCD 2013 Fuel filter systemp. 675
Fig. 3 TCD 2013 Fuel systemp. 675
+1 Fuel pre-filterp. 675
1 Fuel pre-filterp. 675
2 Hand pumpp. 675
3 Fuel pressure filter min. 3µmp. 675
4 Input fuel control unitp. 675
5 Fuel low pressure sensorp. 675
TCD 2012 Fuel filter systemp. 676
Fig. 4 TCD 2012 Fuel systemp. 676
+1 Fuel pre-filterp. 676
1 Fuel pre-filterp. 676
2 Hand pumpp. 676
3 Fuel pressure filter min. 3µmp. 676
4 Input fuel control unitp. 676
5 Fuel low pressure sensorp. 676
+14.10 Check the engine oil levelp. 677
14.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013p. 677
+The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" injection system, DCR in short.p. 677
The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" injection system, DCR in short.p. 677
The English term "Common Rail" indicates that the system is based on a common rail. It describes the use of a common high pressure fuel line with corresponding branches to supply all cylinders with fuel.p. 677
The "Common Rail" injection is an injection system for combustion engines, in which a high pressure pump pressurizes the fuel to a high pressure level. The pressurized fuel fills a piping system, which is permanently under pressure while the engine i…p. 677
The general idea is the total isolation of the pressure generation from the actual injection process. An injection solely controlled by mapping is only possible under this condition. Injection timing and injection quantity are controlled by the engin…p. 677
The electric control is accomplished by the electronic control unit (EDC16) with EMR3, in dependence on the operating parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a r…p. 677
Fig. 1 TCD 2012 and 2013p. 677
Fig. 2 Schematic of the Deutz Common Rail System "DCR"p. 678
Under normal conditions the rail pressure is between 300 and 1350 barp. 678
The PRV is set to 1600 barp. 678
If the PRV is defective or always open, the pressure in the rail will only build up to max. 700 bar.p. 678
The rail pressure must be at least 1.5 bar to start the diesel enginep. 678
The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar.p. 678
The solenoid valve of the Fuel Control Unit (FCU) is dead, open towards the tank.p. 678
The voltage applied to the injectors is normally approx. 40 V.p. 678
FCU Fuel Control Unit (Y137)p. 679
Fig. 3 Fuel Control Unit FCUp. 679
Two high pressure pumpsp. 679
Fig. 4 High pressure pumpp. 679
Injector ( Y148 )p. 680
Fig. 5 Injectorp. 680
Wiring diagram page 4p. 680
Fig. 6 Excerpt from the wiring diagramp. 680
TCD 2013p. 681
Fig. 7 TCD 2013p. 681
+1 Fuel pre-filterp. 681
1 Fuel pre-filterp. 681
2 Hand pumpp. 681
3 Fuel filterp. 681
4 FCU Fuel Control Unit (Y137)p. 681
5 Railp. 681
6 Fuel low pressure sensor (B145)p. 681
7 Connecting plug EMR3p. 681
TCD 2012p. 682
Fig. 8 Diesel engine TCD 2012p. 682
+1 Rail pressure sensor (B93)p. 682
1 Rail pressure sensor (B93)p. 682
2 Rail pressure PRVp. 682
3 Fuel filterp. 682
4 FCU Fuel Control Unit (Y137)p. 682
5 Railp. 682
6 Fuel low pressure sensor (B145)p. 682
7 Connecting plug EMR3p. 682
+14.10 Check the engine oil levelp. 683
14.7 Exhaust gas recirculation TCD 2012 / 2013p. 683
+In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 683
In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation.p. 683
On 4-cylinder engines TCD 2012/2013 the exhaust gas recirculation has been realized internally through the intake valves, on 6-cylinders through the exhaust valves. For this purpose the camshaft has been manufactured with an additional cam for short-…p. 683
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013p. 683
+14.10 Check the engine oil levelp. 684
14.8 Wastegate – charge pressure controller on TCD-enginesp. 684
+The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 684
The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbochargerp. 684
The Wastegate (exhaust gas bypass valve) is used to control the charge pressurep. 684
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust gas turbine into the exhaust withou…p. 684
The bypass valve is normally closedp. 684
Fig. 1 Exhaust gas turbocharger with Wastegatep. 684
Wastegate active, charge pressure control, i.e. bypass valve openp. 684
Fig. 1 Exhaust gas turbocharger with Wastegatep. 684
Wastegate on TCD 2013p. 685
Fig. 2 Exhaust gas turbocharger with Wastegatep. 685
+14.10 Check the engine oil levelp. 686
14.9 Engine problemsp. 686
+Faultp. 686
Faultp. 686
+Possible causep. 686
Possible causep. 686
+Remedyp. 686
Remedyp. 686
+Engine does not start or starts poorlyp. 686
Engine does not start or starts poorlyp. 686
+Temperature below starting limitp. 686
Temperature below starting limitp. 686
Oil level too lowp. 686
Lubrication oil level too highp. 686
Lubrication oil cooler defectivep. 686
+Checkp. 686
Checkp. 686
Fill up lubrication oilp. 686
Check the lubrication oil level, drain off if necessaryp. 686
Checkp. 686
+Exhaust gas counter pressure too highp. 686
Exhaust gas counter pressure too highp. 686
+Checkp. 686
Checkp. 686
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 686
V-belt/ribbed V-belt (fuel pump in belt drive)p. 686
+check, whether torn or loosep. 686
check, whether torn or loosep. 686
+Engine oil with wrong SAE viscosity classp. 686
Engine oil with wrong SAE viscosity classp. 686
+Change the lubrication oilp. 686
Change the lubrication oilp. 686
+Fuel quality not as specified in the operating instructionsp. 686
Fuel quality not as specified in the operating instructionsp. 686
+Change the fuelp. 686
Change the fuelp. 686
+Air in the fuel systemp. 686
Air in the fuel systemp. 686
+Bleed the fuel systemp. 686
Bleed the fuel systemp. 686
+Battery defective or not chargedp. 686
Battery defective or not chargedp. 686
+Check the batteryp. 686
Check the batteryp. 686
+Cable to starter loose or oxidizedp. 686
Cable to starter loose or oxidizedp. 686
+Check cable connectionp. 686
Check cable connectionp. 686
+Starter defective or pinion does not engagep. 686
Starter defective or pinion does not engagep. 686
+Check starterp. 686
Check starterp. 686
+Engine does not start and diagnostic lamp flashingp. 686
Engine does not start and diagnostic lamp flashingp. 686
+Engine electronics prevent startingp. 686
Engine electronics prevent startingp. 686
+Check fault by fault code, repair as necessaryp. 686
Check fault by fault code, repair as necessaryp. 686
+Engine starts, but runs irregularly or misfiresp. 686
Engine starts, but runs irregularly or misfiresp. 686
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 686
V-belt/ribbed V-belt (fuel pump in belt drive)p. 686
+check, whether torn or loosep. 686
check, whether torn or loosep. 686
+Incorrect valve clearancep. 686
Incorrect valve clearancep. 686
+Adjustp. 686
Adjustp. 686
+Injector defectivep. 686
Injector defectivep. 686
+Replacep. 686
Replacep. 686
+Injection valve defectivep. 686
Injection valve defectivep. 686
+Check / replace the injection valvep. 686
Check / replace the injection valvep. 686
+Glow plug defectivep. 686
Glow plug defectivep. 686
+Replacep. 686
Replacep. 686
+Air in the fuel systemp. 686
Air in the fuel systemp. 686
+Bleed the fuel systemp. 686
Bleed the fuel systemp. 686
+Fuel pre-cleaner soiledp. 686
Fuel pre-cleaner soiledp. 686
+Clean/replacep. 686
Clean/replacep. 686
+Fuel quality not as specified in the operating instructionsp. 686
Fuel quality not as specified in the operating instructionsp. 686
+Change the fuelp. 686
Change the fuelp. 686
+Injection line leakingp. 686
Injection line leakingp. 686
+Check the injection linep. 686
Check the injection linep. 686
+Speed changes are possible and diagnostic lamp lightsp. 686
Speed changes are possible and diagnostic lamp lightsp. 686
+Engine electronics detected a system fault and activates a substitute speedp. 686
Engine electronics detected a system fault and activates a substitute speedp. 686
+Check fault by fault code, repair as necessaryp. 686
Check fault by fault code, repair as necessaryp. 686
+Engine overheating, temperature warning system respondsp. 687
Engine overheating, temperature warning system respondsp. 687
+Bleeding line cloggedp. 687
Bleeding line cloggedp. 687
+Clean ventilation linep. 687
Clean ventilation linep. 687
+Injector defectivep. 687
Injector defectivep. 687
+Replacep. 687
Replacep. 687
+Coolant heat exchanger soiledp. 687
Coolant heat exchanger soiledp. 687
+Cleanp. 687
Cleanp. 687
+Coolant pump defective (V-belt torn or loose)p. 687
Coolant pump defective (V-belt torn or loose)p. 687
+check, whether torn or loosep. 687
check, whether torn or loosep. 687
+Lack of coolantp. 687
Lack of coolantp. 687
+Fill upp. 687
Fill upp. 687
+Charge air pipe leakingp. 687
Charge air pipe leakingp. 687
+Check the charge air pipep. 687
Check the charge air pipep. 687
+V-belt/ribbed V-belt (fuel pump in belt drive)p. 687
V-belt/ribbed V-belt (fuel pump in belt drive)p. 687
+check, whether torn or loosep. 687
check, whether torn or loosep. 687
+Lubrication oil filter soiledp. 687
Lubrication oil filter soiledp. 687
+Replacep. 687
Replacep. 687
+Lubrication oil level too lowp. 687
Lubrication oil level too lowp. 687
+Fill up lubrication oilp. 687
Fill up lubrication oilp. 687
+Lubrication oil level too highp. 687
Lubrication oil level too highp. 687
+Check the lubrication oil level, drain off if necessaryp. 687
Check the lubrication oil level, drain off if necessaryp. 687
Air filter clogged / exhaust turbocharger defectivep. 688
+Check/replacep. 688
Check/replacep. 688
+Charge air pipe leakingp. 688
Charge air pipe leakingp. 688
+Check charge air linep. 688
Check charge air linep. 688
+Injection valve defectivep. 688
Injection valve defectivep. 688
+Check / replace the injection valvep. 688
Check / replace the injection valvep. 688
+Injector defectivep. 688
Injector defectivep. 688
+Replacep. 688
Replacep. 688
14.10 Check the engine oil levelp. 689
+14.10 Check the engine oil levelp. 689
14.10 Check the engine oil levelp. 689
+Danger of injury!p. 689
+Danger of injury!p. 689
Danger of injury!p. 689
Support the engine hood for all maintenance and repair work.p. 689
+The machine must be parked horizontally with the engine shut down.p. 689
The machine must be parked horizontally with the engine shut down.p. 689
Fig. 3p. 689
+l Pull the dipstickp. 689
+l Pull the dipstickp. 689
(Fig. 3)p. 689
l Pull the dipstick back out again.p. 689
l If the oil level is below the "MAX" mark fill in oil.p. 689
l If the oil level is above the “Max” mark determine the cause and drain the oil off.p. 689
+Before longer work periods you should always top the oil up to the "MAX"-mark.p. 689
Before longer work periods you should always top the oil up to the "MAX"-mark.p. 689
For quality and quantity of oil refer to the table of fuels and lubricants.p. 689
+14.11 Changing engine oil and oil filter cartridgesp. 690
14.11 Changing engine oil and oil filter cartridgesp. 690
+The oil change at 500 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 690
+The oil change at 500 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 690
The oil change at 500 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.p. 690
Refer also to the chapter 5.2, fuels and lubricants.p. 690
Drain the engine oil only when the engine is warm.p. 690
+Danger of scalding!p. 690
Danger of scalding!p. 690
When draining off hot oil.p. 690
By hot oil when unscrewing the engine oil filter.p. 690
+Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.p. 690
Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.p. 690
Fig. 4p. 690
+l Unscrew the drain plugp. 690
+l Unscrew the drain plugp. 690
(Fig. 4)p. 690
l Turn the drain plug tightly back in.p. 690
Fig. 5p. 690
+l Thoroughly clean the outside of the filter cartridgep. 690
+l Thoroughly clean the outside of the filter cartridgep. 690
(Fig. 5)p. 690
l Unscrew the filter cartridge using an appropriate filter wrench.p. 690
+l Clean the sealing face on the filter carrier from any dirt.p. 690
l Clean the sealing face on the filter carrier from any dirt.p. 690
l Slightly oil the rubber seal on the new filter cartridge.p. 690
Fig. 6p. 690
+l Turn the new filter cartridgep. 690
+l Turn the new filter cartridgep. 690
(Fig. 6)p. 690
l Tighten the filter element for another half turn.p. 690
Fig. 7p. 690
+l Fill in new engine oilp. 690
+l Fill in new engine oilp. 690
(Fig. 7)p. 690
For quality and quantity of oil refer to the table of fuels and lubricants.p. 691
+l Tighten the oil filler cap properly.p. 691
l Tighten the oil filler cap properly.p. 691
+Before starting crank the engine with the starter motor until the oil pressure warning light goes out.p. 691
Before starting crank the engine with the starter motor until the oil pressure warning light goes out.p. 691
+l After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 691
l After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.p. 691
l Check filter cartridge and drain plug for leaks after a short test run.p. 691
l Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump.p. 691
l Check the oil level again , if necessary fill up to the Max.-mark.p. 691
+14.12 Change the fuel pre-filter cartridgep. 691
14.12 Change the fuel pre-filter cartridgep. 691
+Fire hazard!p. 691
+Fire hazard!p. 691
Fire hazard!p. 691
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 691
Catch running out fuel, do not let it seep into the ground.p. 691
Do not inhale any fuel fumes.p. 691
Fig. 8p. 691
+l Slacken the bleeding screwp. 691
+l Slacken the bleeding screwp. 691
(Fig. 8)p. 691
Fig. 9p. 691
+l Pull the cable off the water separator and unscrew the fuel filter cartridgep. 691
+l Pull the cable off the water separator and unscrew the fuel filter cartridgep. 691
(Fig. 9)p. 691
l Clean the sealing face on the filter carrier from any dirt.p. 691
Fig. 10p. 692
+l Unscrew the water separator from the filter cartridgep. 692
+l Unscrew the water separator from the filter cartridgep. 692
(Fig. 10)p. 692
Fig. 11p. 692
+l Apply a thin coat of oil to the rubber seal of the water separator 1p. 692
+l Apply a thin coat of oil to the rubber seal of the water separator 1p. 692
(Fig. 11)p. 692
l Screw the water separator on by hand (2), until the seal contacts.p. 692
l Tighten the water separator for another half turn (3).p. 692
l Fill the filter cartridge with clean diesel fuel (4).p. 692
l Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.p. 692
l Tighten the filter element for another half turn (6).p. 692
l Plug the water sensor cable back on.p. 692
l Check the filter cartridge for leaks after a short test run.p. 692
+Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 692
Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 692
Therefore bleed the fuel system after changing the fuel pre-filter.p. 692
+Catch running out fuel and dispose of environmentally.p. 692
Catch running out fuel and dispose of environmentally.p. 692
Fig. 12p. 692
+l With the bleeding pump loosened operate the hand pump manually, until fuel flows out of the slackened bleeding screwp. 692
+l With the bleeding pump loosened operate the hand pump manually, until fuel flows out of the slackened bleeding screwp. 692
(Fig. 12)p. 692
l Then tighten the bleeding screw while pumping.p. 692
+14.13 Replace the fuel filter cartridgep. 693
14.13 Replace the fuel filter cartridgep. 693
+Fire hazard!p. 693
+Fire hazard!p. 693
Fire hazard!p. 693
When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.p. 693
Catch running out fuel, do not let it seep into the ground.p. 693
Do not inhale any fuel fumes.p. 693
Fig. 13p. 693
+l Loosen and unscrew the fuel filter cartridgep. 693
+l Loosen and unscrew the fuel filter cartridgep. 693
(Fig. 13)p. 693
l Clean the sealing face on the filter carrier from any dirt.p. 693
Fig. 14p. 693
+l Slightly oil the rubber sealp. 693
+l Slightly oil the rubber sealp. 693
(Fig. 14)p. 693
+The filter cartridge must not be pre-filled. Danger of contamination!p. 693
The filter cartridge must not be pre-filled. Danger of contamination!p. 693
+l Turn the new filter cartridge on by hand, until the seal contacts.p. 693
l Turn the new filter cartridge on by hand, until the seal contacts.p. 693
l Tighten the filter element for another half turn.p. 693
l Check the filter cartridge for leaks after a short test run.p. 693
+Bleed the fuel systemp. 693
Bleed the fuel systemp. 693
+Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 693
Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.p. 693
Therefore bleed the fuel system after changing the fuel pre-filter or working on the fuel system.p. 693
Fig. 15p. 693
+l Slacken the bleeding screw (1)p. 693
+l Slacken the bleeding screw (1)p. 693
(Fig. 12)p. 693
l Unlock the bayonet lock of the fuel hand pump by pressing it down and turning it anti-clockwise.p. 693
+l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles.p. 693
l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles.p. 693
l Then tighten the bleeding screw while pumping.p. 693
l Lock the bayonet lock of the fuel hand pump by pressing it down and turning it clockwise.p. 693
l Start the engine and run it 5 minutes with idle speed.p. 693
+14.14 Check, clean the water separatorp. 694
14.14 Check, clean the water separatorp. 694
+Danger of injury!p. 694
+Danger of injury!p. 694
Danger of injury!p. 694
Support the engine hood for all maintenance and repair work.p. 694
+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. 694
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. 694
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. 694
+Catch running out fuel and dispose of environmentally.p. 694
Catch running out fuel and dispose of environmentally.p. 694
Fig. 16p. 694
+l Slacken the drain plugp. 694
+l Slacken the drain plugp. 694
(Fig. 16)p. 694
l Tighten the drain plug again and check for leaks, if necessary replace the seal ring.p. 694
+14.15 Check the coolant levelp. 694
14.15 Check the coolant levelp. 694
+Danger of scalding!p. 694
+Danger of scalding!p. 694
Danger of scalding!p. 694
Fill up coolant only when the engine is cold.p. 694
+If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 694
If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.p. 694
Do not use radiator sealant to seal leaks.p. 694
For quality and quantity of coolant refer to the "table of fuels and lubricants".p. 694
Fig. 17p. 694
+l Check the coolant levelp. 694
+l Check the coolant levelp. 694
(Fig. 17)p. 694
l To top up unscrew the filler cap and fill in coolant up to the MAX-mark.p. 694
+14.16 Change the coolantp. 695
14.16 Change the coolantp. 695
+Danger of scalding!p. 695
+Danger of scalding!p. 695
Danger of scalding!p. 695
Change the coolant only when the engine is cold.p. 695
+Catch running out coolant and dispose of environmentally.p. 695
Catch running out coolant and dispose of environmentally.p. 695
Fig. 18p. 695
+l Set the cock valve for the cabin heaterp. 695
+l Set the cock valve for the cabin heaterp. 695
(Fig. 18)p. 695
Fig. 19p. 695
+l Unscrew the plugp. 695
+l Unscrew the plugp. 695
(Fig. 19)p. 695
l Screw the plug back in once all coolant has run out.p. 695
Fig. 20p. 695
+l Unscrew the cap and fill in coolant up to the MAX- markp. 695
+l Unscrew the cap and fill in coolant up to the MAX- markp. 695
(Fig. 20)p. 695
For quality of coolant refer to the chapter 5.2, fuels and lubricants.p. 695
+l Start the diesel engine and run it warm to operating temperature.p. 695
l Start the diesel engine and run it warm to operating temperature.p. 695
l Let the engine cool down and check the coolant level again, top up if necessary.p. 695
+14.18 Service the combustion air filterp. 696
14.17 Checking the thermostat in disassembled statep. 696
+The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 83°C the thermostat is closed. Once…p. 696
The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 83°C the thermostat is closed. Once…p. 696
Fig. 1p. 696
+l Measure and write down the measurement "a" on the thermostatp. 696
+l Measure and write down the measurement "a" on the thermostatp. 696
(Fig. 1)p. 696
+"a" = beginning of stroke at approx. 83 ± 2°C (T1)p. 696
"a" = beginning of stroke at approx. 83 ± 2°C (T1)p. 696
"b" = end of stroke at approx. 95 °C (T2)p. 696
Fig. 2p. 696
+l Warm up the thermostat in a water bathp. 696
+l Warm up the thermostat in a water bathp. 696
(Fig. 2)p. 696
+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. 696
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. 696
The water must thereby be stirred continuously, to ensure even temperature distribution.p. 696
The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.p. 696
Fig. 3p. 696
+l Measure and write down the measurement "b" on the thermostat .p. 696
+l Measure and write down the measurement "b" on the thermostat .p. 696
(Fig. 3)p. 696
l Calculate the stroke.p. 696
Stroke = b – ap. 696
+The stroke at the given temperature (T2) should be min. 8 mm.p. 696
The stroke at the given temperature (T2) should be min. 8 mm.p. 696
+14.18 Service the combustion air filterp. 697
14.18 Service the combustion air filterp. 697
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 697
+Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 697
Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.p. 697
Fig. 4p. 697
+Maintenance of the dry air filter is due when control light 1p. 697
(Fig. 4)p. 697
+Once the air filter service indicator lights up, work may be continued until the end of the day.p. 697
Once the air filter service indicator lights up, work may be continued until the end of the day.p. 697
Fig. 5p. 697
+l Open the engine hoodp. 697
+l Open the engine hoodp. 697
(Fig. 5)p. 697
+Removing the main filter elementp. 697
Removing the main filter elementp. 697
Fig. 6p. 697
+l Loosen both locking hooksp. 697
+l Loosen both locking hooksp. 697
(Fig. 6)p. 697
Fig. 7p. 697
+l Pull out the main filter elementp. 697
+l Pull out the main filter elementp. 697
(Fig. 7)p. 697
+Cleaning the main filter elementp. 697
Cleaning the main filter elementp. 697
+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. 697
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. 697
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. 697
Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new filter cartridge.p. 697
Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine.p. 697
Replace the safety cartridge if the main filter element is defective!p. 697
Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.p. 698
Fig. 8p. 698
+l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar)p. 698
+l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar)p. 698
(Fig. 8)p. 698
Fig. 9p. 698
+l Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 698
+l Examine the filter cartridge with a torch for cracks and holes in the paper bellowsp. 698
(Fig. 9)p. 698
+Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 698
Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.p. 698
+Cleaning the dust bowlp. 698
Cleaning the dust bowlp. 698
Fig. 10p. 698
+l Pull the internal partp. 698
+l Pull the internal partp. 698
(Fig. 10)p. 698
l Reinsert the inner part.p. 698
+When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part.p. 698
When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part.p. 698
+Installing the main filter elementp. 698
Installing the main filter elementp. 698
+l Slide the main filter element carefully into the housing.p. 698
l Slide the main filter element carefully into the housing.p. 698
When closing the housing cover the main filter element is automatically forced in the correct position.p. 698
+Changing the safety filter elementp. 698
Changing the safety filter elementp. 698
+The safety filter element must not be cleaned and should not be used again after it has been removed.p. 698
The safety filter element must not be cleaned and should not be used again after it has been removed.p. 698
Break the seal only to replace the safety filter element.p. 698
The safety filter element must be replaced:p. 698
If the main filter element is defective.p. 698
after five service intervals of the filter cartridge,p. 698
at the latest after 2 years,p. 698
if the warning light comes on again after servicing the main filter cartridge.p. 698
+l Remove the housing cover and pull the main filter element off.p. 698
l Remove the housing cover and pull the main filter element off.p. 698
Fig. 11p. 699
+l Pull the safety elementp. 699
+l Pull the safety elementp. 699
(Fig. 11)p. 699
l Push in a new safety filter element.p. 699
l Reassemble main filter element and cover.p. 699
+Make sure that the cover locks engage correctly.p. 699
Make sure that the cover locks engage correctly.p. 699
+14.19 Check the dust separatorp. 699
14.19 Check the dust separatorp. 699
Fig. 12p. 699
+l Unscrew wing nut 1p. 699
+l Unscrew wing nut 1p. 699
(Fig. 12)p. 699
l Clean housing (2).p. 699
l Reassemble the dust separator.p. 699
+14.20 Cleaning the oil bath air filterp. 700
+14.20 Cleaning the oil bath air filterp. 700
Optionp. 700
Fig. 13p. 700
+l Loosen the quick locksp. 700
+l Loosen the quick locksp. 700
(Fig. 13)p. 700
l Clean the filter mesh by repetitive dipping into diesel fuel.p. 700
l Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark.p. 700
l reinstall the filter bowl.p. 700
+14.21 Adjusting the valve clearancep. 700
14.21 Adjusting the valve clearancep. 700
+We recommend to have this work carried out by trained personnel or our after sales service.p. 700
+We recommend to have this work carried out by trained personnel or our after sales service.p. 700
We recommend to have this work carried out by trained personnel or our after sales service.p. 700
Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 °C.p. 700
After a short test run check the engine for leaks.p. 700
+l Attach the cranking device over the V-belt pulley fastening screws.p. 700
l Attach the cranking device over the V-belt pulley fastening screws.p. 700
+l Remove the valve cover (2).p. 700
l Remove the valve cover (2).p. 700
l Crank the engine, until the valves on cylinder 1 overlap.p. 700
l The individual cylinder positions can be taken from the section "valve adjustment schematic".p. 700
+Adjusting the valve clearancep. 700
Adjusting the valve clearancep. 700
Fig. 14p. 700
+l Loosen counter nut 1p. 700
+l Loosen counter nut 1p. 700
(Fig. 14)p. 700
Fig. 15p. 701
Fig. 16p. 701
+l Attach the rotation angle disc 3p. 701
+l Attach the rotation angle disc 3p. 701
(Fig. 16)p. 701
(Fig. 15)p. 701
+l Fix the magnet (5) of the rotation angle disc.p. 701
l Fix the magnet (5) of the rotation angle disc.p. 701
+l Turn the rotation angle disc counter-clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 701
l Turn the rotation angle disc counter-clockwise against the stop (rocker arm no clearance) and set the scale to zero.p. 701
+l Turn the rotation angle disc clockwise, until the specified angle is reached.p. 701
l Turn the rotation angle disc clockwise, until the specified angle is reached.p. 701
+Intake valve INp. 701
Intake valve INp. 701
75° (0,3 mm)p. 701
Exhaust valves EXp. 701
120° (0,5 mm)p. 701
+l Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 701
+l Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1p. 701
(Fig. 14)p. 701
l Repeat this adjustment procedure an all other cylinders, after cranking the crankshaft accordingly.p. 701
+l Assemble the cylinder head cover with a new gasket.p. 701
l Assemble the cylinder head cover with a new gasket.p. 701
+Valve adjustment schematicp. 701
Valve adjustment schematicp. 701
+l Firing sequence 1-5-3-6-2-4p. 701
l Firing sequence 1-5-3-6-2-4p. 701
+Valvesp. 701
Valvesp. 701
+Cylinderp. 701
Cylinderp. 701
+overlappingp. 701
overlappingp. 701
+1p. 701
1p. 701
+5p. 701
5p. 701
+3p. 701
3p. 701
+6p. 701
6p. 701
+2p. 701
2p. 701
+4p. 701
4p. 701
+adjustmentp. 701
adjustmentp. 701
+6p. 701
6p. 701
+2p. 701
2p. 701
+4p. 701
4p. 701
+1p. 701
1p. 701
+5p. 701
5p. 701
+3p. 701
3p. 701
Overlapping of valves:p. 701
Exhaust valve not yet closed,p. 701
intake valve starts to open.p. 701
+With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 701
With the intake valve opened, the exhaust valve will temporarily open for about 2 mm.p. 701
This is no valve overlap condition!p. 701
+14.22 Checking / replacing the ribbed V-beltp. 702
14.22 Checking / replacing the ribbed V-beltp. 702
+Danger of injury!p. 702
+Danger of injury!p. 702
Danger of injury!p. 702
Work on the V-belt must only be performed with the engine shut down.p. 702
+Checking the wear limit of the ribbed V- beltp. 702
Checking the wear limit of the ribbed V- beltp. 702
Fig. 17p. 702
+l Check the distance between the tongue of the moveable tensioner arm and the fixed tensioner housingp. 702
+l Check the distance between the tongue of the moveable tensioner arm and the fixed tensioner housingp. 702
(Fig. 17)p. 702
+l If measurement "a" is smaller than 3 mm, replace the ribbed V-belt.p. 702
l If measurement "a" is smaller than 3 mm, replace the ribbed V-belt.p. 702
+Changing the ribbed V-beltp. 702
Changing the ribbed V-beltp. 702
Fig. 18p. 702
+l Unscrew the fastening screwsp. 702
+l Unscrew the fastening screwsp. 702
(Fig. 18)p. 702
Fig. 19p. 702
+l Press idling pulley 1p. 702
+l Press idling pulley 1p. 702
(Fig. 19)p. 702
The ribbed V-belt (2) is thus relieved from tension.p. 702
+l Remove the ribbed V-belt first from the smallest roller or from the idling pulley.p. 702
l Remove the ribbed V-belt first from the smallest roller or from the idling pulley.p. 702
+l Check the condition of the idling pulley, replace if necessary.p. 702
l Check the condition of the idling pulley, replace if necessary.p. 702
+l Install the new ribbed V-belt.p. 702
l Install the new ribbed V-belt.p. 702
+l Counter the idling pulley with the socket wrench and remove the locking pin.p. 702
l Counter the idling pulley with the socket wrench and remove the locking pin.p. 702
l Relieve the idling pulley and tension the ribbed V- belt.p. 702
+14.23 Check the engine mountsp. 703
14.23 Check the engine mountsp. 703
Fig. 20p. 703
+l Tighten fastenings of intake and exhaust manifoldsp. 703
+l Tighten fastenings of intake and exhaust manifoldsp. 703
(Fig. 20)p. 703
l Check sockets and clamps between air filter, exhaust turbocharger and charge air line as well as the lubrication air line for tight fit and leaks.p. 703
l Retighten the fastening screws for oil sump and engine mounts.p. 703
+14.24 Replacing the crank case pressure ventilation valvep. 703
14.24 Replacing the crank case pressure ventilation valvep. 703
Fig. 21p. 703
+l Replace the crank case ventilation valvep. 703
+l Replace the crank case ventilation valvep. 703
(Fig. 20)p. 703
+14.25 Engine conservationp. 704
14.25 Engine conservationp. 704
+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. 704
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. 704
14.26 Special tools, Deutz engine (TCD 2012 2V)p. 705
+15 Air conditioning systemp. 721
15 Air conditioning systemp. 721
+15.10 Checking, replacing the refrigerant compressor V-beltp. 722
15.1 Physical basicsp. 722
+In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system.p. 722
In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system.p. 722
The four well known physical conditions of water apply also for the refrigerant in the air conditioning system.p. 722
1. gaseous (invisible)p. 722
2. vaporousp. 722
3. liquidp. 722
4. solidp. 722
Fig. 1p. 722
If the water in a container is heated up (absorption of heat), the rising steam is visible. If the steam is heated up further, due to the absorption of heat, the visible steam will turn into invisible gas. This process is reversible. When withdrawing…p. 722
+A – heat absorptionp. 722
A – heat absorptionp. 722
B- Heat dissipationp. 722
Fig. 2p. 722
+Heat always flows from the warmer to the colder matter. Any matter consists of a mass of moving molecules. The rapidly moving molecules or a warmer matter dissipate part of their energy to the slower moving molecules with less heat. The movement of t…p. 722
Pressure and boiling pointp. 723
The boiling point is the temperature at which fluid changes to gaseous state.p. 723
Changing the pressure above a fluid also changes the boiling point. It is a well known fact, that e.g. the lower the pressure applied to water, the lower the boiling point.p. 723
When looking at water, the following values do apply:p. 723
+l Atmospheric pressure, boiling point 100°Cp. 723
l Atmospheric pressure, boiling point 100°Cp. 723
l Overpressure 0.4 bar, boiling point 126°Cp. 723
l Vacuum -0.6 bar, boiling point 71°Cp. 723
For an optimal exchange of heat, liquid refrigerants must have a low boiling point, so that they can absorb and dissipate heat quickly.p. 723
Fig. 3 Steam pressure curvep. 723
Steam pressure curve for refrigerant R134ap. 723
The steam pressure curve is a means for explaining the operation principle of an air conditioning system.p. 723
A- liquidp. 723
B- gaseousp. 723
The diagram shows the evaporation curve of R134a. The diagram for example shows, that R134a is liquid at 0°C and a pressure of 5 bar, but becomes gaseous at 40°C and 5 bar.p. 723
For better understanding one must also be aware of the following:p. 723
1. A gas heats up when being compressed (e.g. air pump, turbo charger, …).p. 723
2. When relieving gas it will cool down (e.g. white frost forms on the valve when relieving air pressure from a car tire).p. 723
3. Condensing gas dissipates a lot of heat energy.p. 723
4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby cools down the surrounding environment (e.g. alcohol on skin)p. 723
+At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated …p. 723
At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated …p. 723
Fig. 4 Pressure – Temperature Diagramp. 723
In the pressure – temperature diagram for the refrigerant the drawn in closed curve shows the cycle of the refrigerant. This cycle permanently continues in direction of the arrow.p. 723
The characters A, B, C, D stand for:p. 723
A – compressionp. 723
B- condensationp. 723
C- relaxationp. 723
D- evaporation.p. 723
+Excerpt from the wet steam tablep. 723
+Excerpt from the wet steam tablep. 723
This table is used for the determination of evaporation and condensation temperature.p. 723
+Saturation temperaturep. 724
Saturation temperaturep. 724
+Overpressure (pressure gauge reading Pe in bar)p. 724
Overpressure (pressure gauge reading Pe in bar)p. 724
+Absolute pressure (pamb = 1 bar P in bar)p. 724
Absolute pressure (pamb = 1 bar P in bar)p. 724
+-20p. 724
-20p. 724
+0,33p. 724
0,33p. 724
+1,33p. 724
1,33p. 724
+-10p. 724
-10p. 724
+1,01p. 724
1,01p. 724
+2,01p. 724
2,01p. 724
+0p. 724
0p. 724
+1,93p. 724
1,93p. 724
+2,93p. 724
2,93p. 724
+10p. 724
10p. 724
+3,15p. 724
3,15p. 724
+4,15p. 724
4,15p. 724
+20p. 724
20p. 724
+4,72p. 724
4,72p. 724
+5,72p. 724
5,72p. 724
+15.10 Checking, replacing the refrigerant compressor V-beltp. 725
15.2 Refrigerant R134ap. 725
+Generalp. 725
Generalp. 725
The evaporation and condensation process is the method commonly used in mobile air conditioning systems. The system in this case works with a substance that boils at low temperature, a substance referred to a refrigerant. The refrigerant used is tetr…p. 725
Although the refrigerant circuit is a hermetically closed loop, the system loses approx. 100g of refrigerant over the course of 1 year by diffusion through hoses, pipes and seals, even though the system is free of leaks. If too much refrigerant is lo…p. 725
Physical data of the refrigerant R134ap. 725
Chemical formula:p. 725
CH2F-CF3 or CF3-CH2Fp. 725
Chemical designation:p. 725
Tetrafluoroethanep. 725
Boiling point at 1 bar:p. 725
– 26.5 °Cp. 725
Solidification point:p. 725
-101.6 °Cp. 725
Critical temperature:p. 725
100,6 °Cp. 725
Critical pressure:p. 725
40.56 bar (absolute)p. 725
Critical point:p. 725
Critical point (critical temperature and critical pressure) means that above this point there is no separating interface between liquid and gas. Above its critical point any substance is gaseous. At temperatures below the critical point all refrigera…p. 725
Characteristics of the refrigerant R134a:p. 725
Refrigerant R134a is currently available under the following trade marks. H-FKW 134a SUVA 134a KLEA 134ap. 725
Colour:p. 725
Refrigerant in form of vapour or liquid is colourless as water. The gas is invisible. Only the bordering layer between gas and liquid is visible. (Fluid level in rising pipe of filling cylinder or bubbles in inspection glass). In the inspection glass…p. 725
Steam pressure:p. 725
In an incompletely filled, closed container, vaporous refrigerant will volatilize from the surface in the same quantity that will turn liquid in combination with steam particles. This state of equilibrium occurs under pressure and is frequently refer…p. 725
Physical properties of R134a:p. 725
The steam pressure curves of R134a and other refrigerants are partly very similar, making a clear differentiation solely by pressure impossible. With R 134a the compressor is lubricated by special synthetic refrigeration oils, e.g. PAG-oils (polyalky…p. 725
Behaviour with metals:p. 725
In pure condition refrigerant R134a is chemically stable and does not attack iron and aluminium. However, contamination of the refrigerant, e.g. with chlorine compounds, leads to aggressiveness against certain metals and plastics. This can cause clog…p. 725
Critical temperature / critical pressure:p. 725
Up to a gas pressure of 39.5 bar overpressure (this corresponds with a temperature of 101 °C) the refrigerant R134a remains chemically stable, above this temperature the refrigerant decomposes (see combustibility).p. 725
Water content:p. 725
In liquid refrigerant water can only be dissolved in very low quantities. In contrast to this refrigerant steam mixes with water steam at any ratio. If the dryer in the liquid container has absorbed approx. 8 gr. of water, the refrigerant circuit tra…p. 725
Inflammability:p. 726
Refrigerant is not inflammable. On the contrary, it has fire inhibiting or fire extinguishing properties. Refrigerant is decomposed by flames or glowing surfaces. Ultraviolet light also cracks refrigerant (caused by electric welding). This results in…p. 726
Filling factor:p. 726
In a container there must be a steam space above the liquid space. The liquid expands with increasing temperature. The steam filled space becomes smaller. From a certain time on the container will be filled with just liquid. After this only a minor t…p. 726
+Environmental aspectsp. 726
Environmental aspectsp. 726
The contribution of R134a to the greenhouse effect is by factor 10 smaller than the contribution of R12.p. 726
Since approx. 1992 the air conditioning systems for newly produced construction equipment were successively converted to refrigerant R134a. This refrigerant does not contain any chlorine and is thus harmless for the ozone layer. Until approx. 1992 ai…p. 726
+15.10 Checking, replacing the refrigerant compressor V-beltp. 726
15.3 Compressor oil / refrigeration oilp. 726
+The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up.p. 726
The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up.p. 726
Part of the compressor oil dissolves in the refrigerant until saturation is reached, so that a gas mixture of refrigerant, water steam, compressor oil and contrast agent circulates through the system.p. 726
Compressor oil (the oil quantity should be 10 % of the refrigerant weight) mixes with the refrigerant and circulates permanently through the system.p. 726
In connection with R134a- air conditioning systems special synthetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are used. This is necessary, because e.g. mineral oil does not mix with R134a. Apart from this, the materials in the R134a air …p. 726
Properties of compressor oil / refrigeration oil:p. 726
The most important properties are high solvency in connection with refrigerants, good lubrication characteristics, that they are free of acids and their low water content. For this purpose only certain oils can be used. PAG-oils suitable for use with…p. 726
+15.10 Checking, replacing the refrigerant compressor V-beltp. 727
15.4 Working principle of the air conditioning systemp. 727
+All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri…p. 727
All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri…p. 727
Fig. 1 Principle sketch of an air conditioning systemp. 727
An engine driven compressor (1) draws in gaseous refrigerant from the evaporator (5) and compresses it. During this process the temperature of the refrigerant increases tremendously.p. 727
The refrigerant vapour is then pumped to the condenser (2). This condenser is arranged directly in front of the vehicle radiator, so that a sufficient air flow is assured. In the condenser (2) the gas is cooled down and consequently liquefied.p. 727
In the dryer / liquid container (3) the refrigerant is then collected and freed of moisture and contaminants.p. 727
The expansion valve (4) regulates the flow rate from the dryer / liquid container (3) back to the evaporator (5) and the circuit starts again.p. 727
+15.10 Checking, replacing the refrigerant compressor V-beltp. 727
+15.5 Monitoring devicesp. 727
+Pressure switchp. 727
Pressure switchp. 727
The pressure switch (8) is used as monitoring feature for too high and too low pressures. The switching contacts (4 and 5) effect the magnetic clutch of the compressor via a relay (6).p. 727
If the system pressure increases excessively, e.g. because of a excessively soiled condenser, a failed fan or a defective expansion valve, the high pressure contact (5) will cut off the electric power supply to the magnetic clutch when the set pressu…p. 727
The low pressure contact (4) interrupts the electric power supply to the magnetic clutch when the set pressure is fallen short of (possible causes: lack of refrigerant, defective expansion valve, too low heat load, defective evaporator fan, …). Sin…p. 727
+Thermostatp. 727
Thermostatp. 727
A frost protection thermostat (3) protects the evaporator against icing. Similar to the pressure switch, the thermostat activates or deactivates the magnetic clutch for the compressor. Depending on the design, the feeler of the temperature control is…p. 727
With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature.p. 727
+Monitoring chainp. 728
Monitoring chainp. 728
Fig. 2 Monitoring chain consisting of:p. 728
+l 1 Switchp. 728
l 1 Switchp. 728
l 2 Fusep. 728
l 3 Thermostatp. 728
l 4 Low pressure switch contactp. 728
l 5 High pressure switch contactp. 728
l 6 Relayp. 728
l 7 Connection for magnetic clutchp. 728
l 8 Pressure switchp. 728
+15.10 Checking, replacing the refrigerant compressor V-beltp. 728
15.6 Description of componentsp. 728
+Compressorp. 728
Compressorp. 728
Fig. 1p. 728
The compressor is mounted to the engine and has the duty to build up the refrigerant pressure required for the function of the system. Coupling and decoupling is accomplished by an electromagnetically controlled mechanical clutch, which is integrated…p. 728
Compressor datap. 728
Displacement: 155 cm²p. 728
Weight: 6.9 kgp. 728
max. rpm: 6000p. 728
Sense of rotation: clockwisep. 728
Refrigerant: R134ap. 728
Oil quantity (scope of delivery): 207 grp. 728
Oil: PAG SP-20 (H14-003-404)p. 728
+The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only refrigeration oil PAG SP-20 (H14-003-404).p. 728
The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only refrigeration oil PAG SP-20 (H14-003-404).p. 728
When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil / refrigeration oil lost by exchanging the components, must be replaced with fresh oil.p. 728
The actual quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 728
+Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 728
Used compressor oil / refrigeration oil must be disposed of as hazardous waste.p. 728
The following table shows how much compressor oil / refrigeration oil will be lost in connection with various types of work on the air conditioning system.p. 728
+Reason of oil lossp. 729
Reason of oil lossp. 729
+Amount of oil lostp. 729
Amount of oil lostp. 729
+Loss when emptyingp. 729
Loss when emptyingp. 729
+approx. 15 grp. 729
approx. 15 grp. 729
+Defective A/C hosep. 729
Defective A/C hosep. 729
+approx. 30 grp. 729
approx. 30 grp. 729
+Hose changep. 729
Hose changep. 729
+approx. 15 grp. 729
approx. 15 grp. 729
+Replacement of condenserp. 729
Replacement of condenserp. 729
+approx. 30 grp. 729
approx. 30 grp. 729
+Replacement of evaporatorp. 729
Replacement of evaporatorp. 729
+approx. 30 grp. 729
approx. 30 grp. 729
+Replacement of liquid containerp. 729
Replacement of liquid containerp. 729
+approx. 30 grp. 729
approx. 30 grp. 729
+Replacement of expansion valvep. 729
Replacement of expansion valvep. 729
+approx. 15 grp. 729
approx. 15 grp. 729
+Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A/C-system and thus a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly.p. 729
Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A/C-system and thus a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly.p. 729
The quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components.p. 729
The compressor oil quantity must be 10% of the refrigerant quantity in the complete system.p. 729
With a refrigerant filling of 1100 gr. the system requires a compressor oil / refrigerant oil filling of 100 gr.p. 729
Procedure:p. 729
Drain and measure the compressor oil from the old compressor.p. 729
Drain the compressor oil from the new compressor and only fill in the exact quantity that had been drained out of the old compressor. The compressor oil from the new compressor can be used for this purpose.p. 729
+Topping up compressor oil / refrigeration oil is possible on a pressureless compressor directly into the oil pan, in a pressureless refrigeration system directly into the pressure side, but it is also possible to draw it into the pressure side of the…p. 729
Topping up compressor oil / refrigeration oil is possible on a pressureless compressor directly into the oil pan, in a pressureless refrigeration system directly into the pressure side, but it is also possible to draw it into the pressure side of the…p. 729
Condenserp. 729
Fig. 1p. 729
The condenser is located in front of the the radiator for the machine. It emits heat energy from the system into the surrounding air and liquefies the gaseous refrigerant.p. 729
+The fins must be free of dirt and damage.p. 729
The fins must be free of dirt and damage.p. 729
+When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 729
When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 729
The fluid container collects the fluid drops and passes these then as a constant flow to the expansion valve. Moisture that has entered during assembly of the refrigerant circuit is absorbed by a dryer in the fluid container.p. 730
At evaporation temperatures below zero the refrigerant will deposit previously absorbed moisture on the expansion valve, where this water turns into ice and thus adversely affects the controllability of the expansion valve. Moreover, moisture in the …p. 730
Inside the refrigerant container the heavy liquid refrigerant collects in the lower part of the container, flows through a rising pipe to the outlet marked "A" and thus ensures bubble free operation of the expansion valve.p. 730
+Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years, before the start of the season.p. 730
Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years, before the start of the season.p. 730
+The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 730
The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case.p. 730
This requires emptying the air conditioning system!p. 730
Installation position:p. 730
The arrow marks on the filter/dryer must point in flow direction, i.e. towards the expansion valve.p. 730
Filter/dryer cannot be treated for further use!p. 730
+Pressure relief valvep. 730
Pressure relief valvep. 730
Fig. 2p. 730
The fluid container is equipped with a safety valve.p. 730
Response pressure 32 +/- 4 barp. 730
Tightening torque 10 – 15 Nmp. 730
+Inspection glassp. 730
Inspection glassp. 730
Fig. 3p. 730
During operation the refrigerant must flow through the inspection glass without air bubbles. In most cases the presence of air bubbles is a sign for a too low refrigerant level in the system. Apart from this, the refrigerant may not sufficiently cond…p. 730
However, incorrect evacuation or filling may also be the reason for air entering into the system and since air cannot be condensed, one will not be able to get rid of these bubbles by topping up refrigerant. In this case the air conditioning system n…p. 730
+Air in the system is characterized by high pressures and temperatures.p. 731
Air in the system is characterized by high pressures and temperatures.p. 731
On R134a refrigeration systems from KONVEKTA the inspection glasses are equipped with moisture indicators. In addition to the float, the dryer/collector/inspection glass combination has an indicator pearl integrated in the inspection glass, which cha…p. 731
The refrigerant level should be inside the inspection glass and should only be checked after approx. 5 minutes continuous operation, because the refrigerant must first evenly distribute all over the system.p. 731
+In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 731
In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.p. 731
Expansion valvep. 731
Fig. 1p. 731
The expansion valve is mounted inside the HKL-module in the cabin. The expansion valve always allows a small amount of the high pressure liquefied refrigerant to flow into the evaporator, which has a much lower pressure. This lower pressure causes th…p. 731
The thermostatic expansion valve operates with an external pressure compensation. This type of expansion valve works with high accuracy, because it uses pressure and temperature at the evaporator outlet and adjusts and overheating of approx. 7 K. The…p. 731
+In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 731
In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+p. 731
Evaporatorp. 732
Fig. 1p. 732
The evaporator is mounted inside the HKL-module in the cabin. It consists of a heat exchanger (inside air – refrigerant), with refrigerant flowing to a pipe system with cooling flanges.p. 732
As with the condenser, correct operation of all fans and cleanliness of the fins must be assured.p. 732
Air conditioning systems have a circulation air filter mounted in the air flow in front of the evaporator, which should be cleaned or changed by the operator after each third trip, depending on the amount of dirt.p. 732
A condensation water filter is mounted in the air flow after the evaporator. This filter has the function to collect the water that has condensed from the air in the evaporator block and to discharge this water into the water pan With a defective con…p. 732
+When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 732
When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil.p. 732
Thermostatp. 732
+Thermostat with fixed settingp. 732
Thermostat with fixed settingp. 732
Fig. 1p. 732
The feeler of a defroster thermostat to switch off the magnetic clutch in case of icing up or to switch the clutch back on after defrosting, is mounted on the evaporator.p. 732
With fixed temperature controls the control switches the compressor off at about +1 °C and back on again at about +2.5°C to +5.5 °C.p. 732
+Adjustable thermostatp. 732
Adjustable thermostatp. 732
With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature.p. 732
Fig. 2 adjustable temperature controllerp. 732
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 732
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 732
Pressure switchp. 733
Fig. 1p. 733
After a minimum pressure is reached in the low pressure side or a maximum pressure in the high pressure side, the pressure switch will switch of the magnetic clutch of the compressor, thus to avoid destruction of system components by excessive pressu…p. 733
Working pressure:p. 733
Low pressure off: 1,5 ±0,5 barp. 733
Low pressure on: 3.5 barp. 733
Overpressure off: 25,0 ±1,5 barp. 733
Overpressure on: 18,0 ±1,5 barp. 733
Pipes and hosesp. 733
+Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug…p. 733
Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug…p. 733
O-rings are made of a special type of chloroprene rubber (neoprene). Before assembly of the air conditioning system these O-rings must be lubricated with compressor oil / refrigeration oil. The O-rings must always be replaced when assembling A/C-comp…p. 733
Recommended tightening torques for O-ring sealed fittingsp. 733
+Threadp. 733
+Threadp. 733
Threadp. 733
+Spanner widthp. 733
Spanner widthp. 733
+Torquep. 733
Torquep. 733
+5/8“p. 733
5/8“p. 733
+17 or 19p. 733
17 or 19p. 733
+13,6 – 20,3 Nmp. 733
13,6 – 20,3 Nmp. 733
+3/4“p. 733
3/4“p. 733
+32,5 – 39,3 Nmp. 733
32,5 – 39,3 Nmp. 733
+7/8“p. 733
7/8“p. 733
+27p. 733
27p. 733
+35,3 – 42,0 Nmp. 733
35,3 – 42,0 Nmp. 733
+1 1/16“p. 733
1 1/16“p. 733
+32p. 733
32p. 733
+40,7 – 47,5 Nmp. 733
40,7 – 47,5 Nmp. 733
+M30X2p. 733
M30X2p. 733
+36p. 733
36p. 733
+105,0 – 115,0 Nmp. 733
105,0 – 115,0 Nmp. 733
+M36X2p. 733
M36X2p. 733
+41p. 733
41p. 733
+165,0 – 175,0 Nmp. 733
165,0 – 175,0 Nmp. 733
Bending radii for air conditioning hosesp. 733
+Hose typep. 733
Hose typep. 733
+Nominal widthp. 733
Nominal widthp. 733
+Bending radiusp. 733
Bending radiusp. 733
+GH 134p. 733
GH 134p. 733
+NW8p. 733
NW8p. 733
+min. 50 mmp. 733
min. 50 mmp. 733
+GH 134p. 733
GH 134p. 733
+NW10p. 733
NW10p. 733
+min. 65 mmp. 733
min. 65 mmp. 733
+GH 134p. 733
GH 134p. 733
+NW12p. 733
NW12p. 733
+min. 75 mmp. 733
min. 75 mmp. 733
+GH 134p. 733
GH 134p. 733
+NW16p. 733
NW16p. 733
+min. 100 mmp. 733
min. 100 mmp. 733
+GH 494p. 733
GH 494p. 733
+NW20p. 733
NW20p. 733
+min. 160 mmp. 733
min. 160 mmp. 733
+GH 494p. 733
GH 494p. 733
+NW25p. 733
NW25p. 733
+min. 194 mmp. 733
min. 194 mmp. 733
+GH 494p. 733
GH 494p. 733
+NW32p. 733
NW32p. 733
+min. 225 mmp. 733
min. 225 mmp. 733
+15.10 Checking, replacing the refrigerant compressor V-beltp. 734
15.7 Measuring the compressor oil levelp. 734
+The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil / refrigeration oil PAG SP-20 (H14-003-404).p. 734
+The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil / refrigeration oil PAG SP-20 (H14-003-404).p. 734
The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil / refrigeration oil PAG SP-20 (H14-003-404).p. 734
+l Run the compressor for 10 minutes at engine idle speed.p. 734
l Run the compressor for 10 minutes at engine idle speed.p. 734
l remove the refrigerant from the air conditioning system.p. 734
Fig. 1p. 734
+l Turn the compressor, as shown inp. 734
+l Turn the compressor, as shown inp. 734
(Fig. 1)p. 734
l Remove the oil plug.p. 734
+The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 734
The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary.p. 734
+l Close the oil plug again.p. 734
l Close the oil plug again.p. 734
+The contact area must be clean and should be free of damage.p. 734
The contact area must be clean and should be free of damage.p. 734
Tightening torque 15 to 25 Nmp. 734
+l Refill the air conditioning system.p. 734
l Refill the air conditioning system.p. 734
+15.10 Checking, replacing the refrigerant compressor V-beltp. 734
15.8 Checking the magnetic clutchp. 734
+l Measure the voltage.p. 734
+l Measure the voltage.p. 734
l Measure the voltage.p. 734
+Nominal value = vehicle voltagep. 734
Nominal value = vehicle voltagep. 734
+l Check the magnetic coil locking ring for secure fit.p. 734
l Check the magnetic coil locking ring for secure fit.p. 734
l Check the current consumption.p. 734
Fig. 1p. 734
+at 12 Volt vehicle voltage approx. 3.5 Amp.p. 734
at 12 Volt vehicle voltage approx. 3.5 Amp.p. 734
at 24 Volt vehicle voltage approx. 1.75 Amp.p. 734
Overcurrent indicates a short circuit inside the magnetic coil.p. 734
No current indicates an interrupted electric circuit.p. 734
Fig. 2 Measuring the air gapp. 734
+l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 734
l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).p. 734
+The gap should be 0.4 to 0.8 mm.p. 735
The gap should be 0.4 to 0.8 mm.p. 735
+l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 735
l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.p. 735
+In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 735
In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.p. 735
+Cross-section of magnetic clutchp. 735
Cross-section of magnetic clutchp. 735
Fig. 3 shows a cross-section of the magnetic clutch. If the coil (7) is not supplied with operating voltage, there is no contact between the front plate of the clutch (1) and the V-belt pulley (2). A spring presses the front plate away from the belt …p. 735
Fig. 3 Cross-section of magnetic clutchp. 735
+15.10 Checking, replacing the refrigerant compressor V-beltp. 735
15.9 Inspection and maintenance workp. 735
+l Visual inspection of the complete system for damage.p. 735
+l Visual inspection of the complete system for damage.p. 735
l Visual inspection of the complete system for damage.p. 735
l Check the compressor mounting bracket on the vehicle engine for tight fit and damage.p. 735
l Check the condition, alignment and tightness of the V-belt.p. 735
l Check the routing of refrigerant hoses and cables in the area of the vehicle engine and transmission, as well as on the chassis for chafing and rectify any detected faults. Ensure sufficient clearance to hot parts, such as the exhaust; install a pr…p. 735
l Check the routing of hoses and hoses on the attachment box or in the cabin.p. 735
l Check all hose and screw fittings for leaks.p. 735
l Check the fastening of the condenser unit.p. 735
l Clean the condenser fins, replace the condenser block if damaged fins are found.p. 735
l Check the fastening of the evaporator unit.p. 735
l Check the function of evaporator and condenser fans.p. 735
l Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays.p. 735
l Switch on the cooling system and check the refrigerant level.p. 735
l Filter/dryer and filter/dryer/fluid container combinations must always be replaced after opening the refrigerant circuit. If these are in service for more than 1 year, there is a risk that they may be clogged by excessive absorption of moisture! Th…p. 735
l Measure the temperature on the evaporator: Measure the intake air temperature – Measure the blow out air temperature – The temperature difference should be at least 8-10 K.p. 735
+l Measuring the pressure in the refrigerant circuitp. 735
l Measuring the pressure in the refrigerant circuitp. 735
+15.10 Checking, replacing the refrigerant compressor V-beltp. 736
+15.10 Checking, replacing the refrigerant compressor V-beltp. 736
Optional equipmentp. 736
+Danger of injury!p. 736
+Danger of injury!p. 736
Danger of injury!p. 736
Work on the V-belt must only be performed with the engine shut down.p. 736
Wear safety goggles.p. 736
+Check the V-beltp. 736
Check the V-beltp. 736
Fig. 4p. 736
+l Inspect the entire circumference of the V-beltp. 736
+l Inspect the entire circumference of the V-beltp. 736
(Fig. 4)p. 736
l Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary.p. 736
+Tighten the V-belt.p. 736
Tighten the V-belt.p. 736
Fig. 5p. 736
+l Slightly slacken fastening screws 1, 2 and 3p. 736
+l Slightly slacken fastening screws 1, 2 and 3p. 736
(Fig. 5)p. 736
l Press the compressor in direction of arrow, until the correct V-belt tension is reached.p. 736
l Retighten all fastening screws.p. 736
+Changing the V-beltp. 736
Changing the V-beltp. 736
+l Slightly slacken the fastening screws 1, 2 and 3.p. 736
l Slightly slacken the fastening screws 1, 2 and 3.p. 736
l Press the compressor against the direction of arrow completely against the engine.p. 736
l Take the old V-belt off.p. 736
l Fit the new V-belt to the V-belt pulleys.p. 736
l Tension the V-belt as previously described.p. 736
+Check the V-belt tension after a running time of 30 minutes.p. 736
Check the V-belt tension after a running time of 30 minutes.p. 736
+15.11 Air conditioningp. 737
+15.11 Air conditioningp. 737
Optional equipmentp. 737
+Clean the condenserp. 737
Clean the condenserp. 737
+A soiled condenser results in a considerable reduction of air conditioning power.p. 737
A soiled condenser results in a considerable reduction of air conditioning power.p. 737
Under extremely dusty conditions it may be necessary to clean the condenser several times per day.p. 737
If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser.p. 737
In case of formation of foam have the air conditioning system inspected by the service department.p. 737
+Danger of accident!p. 737
Danger of accident!p. 737
Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.p. 737
Use access steps and grips to mount and dismount the machine.p. 737
Fig. 6p. 737
+l Unscrew the condenser fastening screwsp. 737
+l Unscrew the condenser fastening screwsp. 737
(Fig. 6)p. 737
+l Clean the condenser fins on front and back with compressed air or cold water .p. 737
l Clean the condenser fins on front and back with compressed air or cold water .p. 737
+Checking the refrigerant levelp. 737
Checking the refrigerant levelp. 737
+l Start the engine.p. 737
l Start the engine.p. 737
Fig. 7p. 737
+l Switch the air conditioningp. 737
+l Switch the air conditioningp. 737
(Fig. 7)p. 737
Fig. 8p. 737
+l Choose a cooling temperature with the rotary switch for cabin heaterp. 737
+l Choose a cooling temperature with the rotary switch for cabin heaterp. 737
(Fig. 8)p. 737
+l Open the air outlet nozzles.p. 737
l Open the air outlet nozzles.p. 737
l Check, whether the out flowing air is noticeably cooler.p. 737
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 737
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 737
+l Open the hood.p. 737
l Open the hood.p. 737
Fig. 9p. 738
+l Check whether the white floatp. 738
+l Check whether the white floatp. 738
(Fig. 9)p. 738
+The refrigerant level is correct.p. 738
The refrigerant level is correct.p. 738
Fig. 10p. 738
+l If the white floatp. 738
+l If the white floatp. 738
(Fig. 10)p. 738
+The refrigerant level is not correct.p. 738
The refrigerant level is not correct.p. 738
+l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 738
l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 738
+Checking the moisture level of the drying agentp. 738
Checking the moisture level of the drying agentp. 738
Fig. 11p. 738
+l Check the moisture indication pearlp. 738
+l Check the moisture indication pearlp. 738
(Fig. 11)p. 738
+orangep. 738
orangep. 738
drying agent o.k.p. 738
colourlessp. 738
moisture level of drying agent too high.p. 738
+l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 738
l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 738
+Have the drier/collector unit replaced by the service department every year before the operating season.p. 738
Have the drier/collector unit replaced by the service department every year before the operating season.p. 738
+Checking the condition of the drier/collector unitp. 738
Checking the condition of the drier/collector unitp. 738
+According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t…p. 738
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t…p. 738
+Danger of injury!p. 738
Danger of injury!p. 738
In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.p. 738
Fig. 12p. 739
+l Check the drier/collector unitp. 739
+l Check the drier/collector unitp. 739
(Fig. 12)p. 739
+15.12 Service the air conditioningp. 739
+15.12 Service the air conditioningp. 739
Optional equipmentp. 739
+Clean the condenserp. 739
Clean the condenserp. 739
+Danger of accident!p. 739
Danger of accident!p. 739
Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.p. 739
Use access steps and grips to mount and dismount the machine.p. 739
+A soiled condenser results in a considerable reduction of air conditioning power.p. 739
A soiled condenser results in a considerable reduction of air conditioning power.p. 739
Under extremely dusty conditions it may be necessary to clean the condenser several times per day.p. 739
If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser.p. 739
In case of formation of foam have the air conditioning system inspected by the service department.p. 739
Fig. 13p. 739
+l Unscrew the condenser fastening screwsp. 739
+l Unscrew the condenser fastening screwsp. 739
(Fig. 6)p. 739
+l Clean the condenser fins on front and back with compressed air or cold water .p. 739
l Clean the condenser fins on front and back with compressed air or cold water .p. 739
+Checking the refrigerant levelp. 739
Checking the refrigerant levelp. 739
+l Start the engine.p. 739
l Start the engine.p. 739
Fig. 14p. 740
+l Turn the rotary switch for the cab ventilatorp. 740
+l Turn the rotary switch for the cab ventilatorp. 740
(Fig. 14)p. 740
Fig. 15p. 740
+l Choose a cooling temperature with the rotary switch for the air conditioning systemp. 740
+l Choose a cooling temperature with the rotary switch for the air conditioning systemp. 740
(Fig. 15)p. 740
+l Open the air outlet nozzles.p. 740
l Open the air outlet nozzles.p. 740
l Check, whether the out flowing air is noticeably cooler.p. 740
+The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 740
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.p. 740
Fig. 16p. 740
+l Check whether the white floatp. 740
+l Check whether the white floatp. 740
(Fig. 16)p. 740
+The refrigerant level is correct.p. 740
The refrigerant level is correct.p. 740
Fig. 17p. 740
+l If the white floatp. 740
+l If the white floatp. 740
(Fig. 17)p. 740
+The refrigerant level is not correct.p. 740
The refrigerant level is not correct.p. 740
+l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 740
l Refrigerant must be filled up, if necessary check the air conditioning system for leaks.p. 740
+Checking the moisture level of the drying agentp. 741
Checking the moisture level of the drying agentp. 741
Fig. 18p. 741
+l Check the moisture indication pearlp. 741
+l Check the moisture indication pearlp. 741
(Fig. 18)p. 741
+orangep. 741
orangep. 741
Drying agent o.k.p. 741
colourlessp. 741
moisture level of drying agent too high.p. 741
+l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 741
l Inform the service department. Replace drier/collector unit, check air conditioning system.p. 741
+Have the drier/collector unit replaced by the service department every year before the operating season.p. 741
Have the drier/collector unit replaced by the service department every year before the operating season.p. 741
+Checking the condition of the drier/collector unitp. 741
Checking the condition of the drier/collector unitp. 741
+According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t…p. 741
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t…p. 741
+Danger of injury!p. 741
Danger of injury!p. 741
In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.p. 741
Fig. 19p. 741
+l Check the drier/collector unitp. 741
+l Check the drier/collector unitp. 741
(Fig. 19)p. 741
15.13 Drying and evacuationp. 742
+Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t…p. 742
Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t…p. 742
Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage.p. 742
Vacuum pumps with a capacity of more than 100 l/min and a final pressure of less than 30 micron, i.e. 0.039 mbar should be used to evacuate the refrigeration system.p. 742
The refrigerant compressor is not suitable for the purpose of evacuation, because it is not able to achieve a sufficient final vacuum and, apart from this, may be mechanically damaged because of a lack of lubrication when running empty during evacuationp. 742
It is common practice to evacuate the refrigeration system to a final vacuum of 1 Torr, i.e. 1.33 mbar.p. 742
Function drying:p. 742
Under normal ambient pressure (1.013 mbar) evaporates absolute at 100° C. If the pressure is reduced, water will already evaporate, e.g. under a pressure of 10 mbar, at an ambient temperature of almost 7°C, but the water will not evaporate all at o…p. 742
15.14 Emptying in case of repairp. 742
+For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 742
For repair work the air conditioning systems must very often be emptied of all refrigerant.p. 742
Especially with expensive refrigerants and larger amounts of oil it may be necessary to keep the refrigerant for later use.p. 742
For later use these refrigerants must be drawn out with suitable equipment and intermediately stored in collecting containers.p. 742
+Contaminated refrigerant must be disposed of environmentallyp. 742
Contaminated refrigerant must be disposed of environmentallyp. 742
Releasing refrigerant into the atmosphere is prohibited (see restrictive injunction concerning CFC, day of enforcement 01. 08. 1991, § 8)p. 742
+For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive.p. 742
For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive.p. 742
When transferring refrigerant you must make sure that the bottle does not contain more than the permitted amount of refrigerant in litres and has sufficient gas space for expansion (filling factor: 0,7).p. 742
In order to reduce the evacuation period in case of short repairs, you may fill the refrigerant circuit with approx. 0.5 bar nitrogen when opening. This ensures that nitrogen will flow out of the refrigerant circuit while it is open and no air or moi…p. 742
15.15 Leak testp. 743
+The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 743
+The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 743
The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul…p. 743
Before starting the evacuation process, the refrigerant circuit is filled with nitrogen through a pressure reducer valve (approx. 22 bar). After this all connections in the air conditioning system are checked with the help of a suitable leak detectio…p. 743
A leak test is required if a pressure drop is noticed.p. 743
The leak test must be repeated after filling the air conditioning system with refrigerant.p. 743
Leak test with electronic leak testerp. 743
Fig. 1 Electronic leak testerp. 743
Small leaks with only very low amounts of refrigerant escaping can be detected, e.g. with an electronic leak tester. Such equipment is able to detect leaks of less than 5 gr. per year.p. 743
The leak tester used must be specially designed for the refrigerant composition in the air conditioning system. For example, leak detectors for refrigerant R12 are not suitable for R134a, because the refrigerant R134a is free of chlorine atoms, meani…p. 743
+Leak test with soap bubblesp. 743
Leak test with soap bubblesp. 743
Fig. 2 Soap bubble testp. 743
Points susceptible for leakage are sprayed with a soapy solution. Bubbles indicate the leak. The detection limit for R 134a is 250 g/year.p. 743
15.16 Filling instructionsp. 744
+Filling instructionsp. 744
+Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 744
Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions.p. 744
In most large series production facilities highly complicated equipment is available for this purpose, whereas individual machines at the place of installation must be filled directly from the refrigerant container.p. 744
Liquid refrigerant is only used to pre-fill the pressure side of the evacuated refrigeration system (protective filling).p. 744
After switching the refrigeration system on and watching the inspection glass, gaseous refrigerant can be filled into the system while the engine is running, if the refrigerant level is found to be too low (gas bubbles in the inspection glass).p. 744
+Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor..p. 744
Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor..p. 744
When filling the air conditioning system directly from the refrigerant bottle care must be taken not to overfill the system. As an additional control and for statistical purposes, e.g. for refilling, it is important to write down the weight of the fi…p. 744
With correct operation of the air conditioning the refrigerant container should be about 1/3 filled with liquid refrigerant, the evaporator should be maximally filled at the calculated evaporation temperature, i.e. the suction line should only be a f…p. 744
+White frost on the suction line is no measure for assessing the filling.p. 744
White frost on the suction line is no measure for assessing the filling.p. 744
Fig. 1p. 745
+1 High pressure – gaseousp. 745
+1 High pressure – gaseousp. 745
1 High pressure – gaseousp. 745
2 High pressure – liquidp. 745
3 Low pressure – gaseousp. 745
4 Compressorp. 745
5 Compressor pressure switch (not used)p. 745
6 not usedp. 745
7 Evaporatorp. 745
8 Expansion valvep. 745
9 Inspection glassp. 745
10 Filter dryerp. 745
11 Fluid containerp. 745
12 Condenserp. 745
13 Manual shut-off valve (not used)p. 745
14 Pressure switch with high and low pressure contactsp. 745
15 Defroster thermostatp. 745
16 Vacuum meterp. 745
17 Low pressure gaugep. 745
18 High pressure gaugep. 745
19 Pressure reducing valvep. 746
20 Vacuum pumpp. 746
21 Nitrogen bottlep. 746
22 Refrigerant bottlep. 746
23 Pressure gauge barp. 746
+Filling instructionsp. 746
Filling instructionsp. 746
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 746
+1 Connect the service adapter with the blue hand wheel in the suction side.p. 746
1 Connect the service adapter with the blue hand wheel in the suction side.p. 746
2 Connect the service adapter with the red hand wheel in the pressure side (the hand wheels on the service adapters must be fully backed out – left hand stop)p. 746
3 Connect the blue suction hose below the blue hand wheel on the pressure gauge bar to the blue service adapter.p. 746
4 Connect the red pressure hose below the red hand wheel on the pressure gauge bar to the red service adapter.p. 746
5 Connect the yellow hose below the yellow hand wheel on the manometer bar to the 2-stage vacuum pump.p. 746
6 Connect the last hose below the black hand wheel on the nitrogen bottle via the pressure reducing valve.p. 746
7 Check on the pressure gauge bar that all hand wheels are closed.p. 746
8 Turn the hand wheels on both service adapter clockwise. This opens the valves (right hand stop).p. 746
9 Open the valve on the nitrogen bottle (only via pressure reducer); pressure approx. 20 bar.p. 746
10 Open the black and red hand wheels on the pressure gauge bar and fill nitrogen into the system, until a pressure of approx. 3.5 to 5.0 bar is indicated on the suction side.p. 746
11 Then open the blue hand wheel and raise the pressure in the suction side (max. 10 bar). Check for leaks with a leak detection fluid or soapsuds.p. 746
12 If the system is leak tight, release the nitrogen from the system. For this purpose disconnect the hose from the nitrogen bottle and open the red, blue and black hand wheels on the pressure gauge bar.p. 746
13 Then connect the hose to the refrigerant bottle.p. 746
14 Switch on the vacuum pump and open all hand wheels on the pressure gauge bar. In case of a leak no or only an insufficient vacuum will be reached. In this case proceed as described under point 9-12. Once the leak is sealed continue with point 14.p. 746
15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the pressure gauge bar.p. 746
16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained.p. 746
17 Open the valve on the refrigerant bottle and open the black and red hand wheels on the pressure gauge bar. Fill refrigerant into the system, until a pressure equilibrium between suction and pressure side is reached (reading of pressure gauges).p. 746
18 Close the red hand wheel.p. 746
19 Perform a leak test with the electronic leak detector.p. 746
20 Start the engine and switch on the system.p. 746
21 Open the blue hand wheel and continue filling in refrigerant until the inspection glass is free or air bubbles (in fluid container/dryer combinations the white pearl should float in the upper third of the inspection glass). Then close the refriger…p. 746
22 Close the blue hand wheel on the pressure gauge bar.p. 746
23 Preparing the test run: -Close windows and doors -Fan on full speed stage -Mount measuring feelers to air discharge and air intake.p. 746
24 Run the system for approx. 20 minutes with medium engine speed.p. 746
25 The temperature difference between air discharge and air intake should be (depending on type of air condition) 8-10°C. The ambient temperature thereby is approx. 20°C. (These data are only reference values, which may be influenced by possible in…p. 746
26 Switch off system and engine and check for leaks again.p. 746
27 Turn out (left hand stop) and remove the hand wheels on both service adapters.p. 746
28 Fit all valves with dust caps.p. 746
29 Perform a leak test.p. 746
30 Mark the system with the corresponding type plates and information decals, such as type of oil and refrigerant.p. 746
15.17 Trouble shooting in refrigerant circuit, basic principlesp. 747
+Basic principlesp. 747
Basic principlesp. 747
+Requirementsp. 747
Requirementsp. 747
For trouble shooting two requirements must be fulfilled:p. 747
+l Expert knowledgep. 747
l Expert knowledgep. 747
l technical equipmentp. 747
+Technical equipmentp. 747
Technical equipmentp. 747
The most important aids for trouble shooting are pressure gauges and thermometer. The refrigerant conditions, like overheating and excessive cooling provide important Information when searching for faults. Even your own senses are important aids for …p. 747
The following tools and auxiliary materials should be available for trouble shooting:p. 747
+l Service stationp. 747
l Service stationp. 747
l Pressure gaugep. 747
l Thermometerp. 747
l dry nitrogenp. 747
l Refrigerant bottle for new refrigerantp. 747
l Container for old oilp. 747
l Vacuum pumpp. 747
l Hosesp. 747
l Scalesp. 747
l Suction stationp. 747
l Leak detectorp. 747
The measuring equipment must be checked at regular intervals. Calibration can only be made by an approved testing authority.p. 747
+Pressure gaugep. 747
Pressure gaugep. 747
Most pressure gauges used in practice are (for cost reasons) excess pressure gauges. These pressure gauges measure the excess pressure in relation to the ambient pressure (air pressure). In order to achieve the absolute (actual) pressure the ambient …p. 747
+Pp. 747
absp. 747
ambp. 747
ep. 747
+Pp. 747
absp. 747
+Pp. 747
ambp. 747
+Pp. 747
ep. 747
Fig. 2 Pressure gaugep. 747
Example:p. 747
+A totally empty air conditioning system holds an atmospheric pressure of approx. Pp. 747
ampp. 747
+Filling the system with refrigerant causes an excess pressure of Pp. 747
ep. 747
+Pp. 747
absp. 747
ambp. 747
ep. 747
+Evacuating the system down to Pp. 747
ep. 747
+Pp. 747
absp. 747
ambp. 747
ep. 747
+Pressure gauge with saturation temperature scalep. 748
Pressure gauge with saturation temperature scalep. 748
Fig. 3 Absolute pressure gaugep. 748
Temperature scales on the pressure gauges always refer to the absolute pressures Pabs. Please note that it is not possible to measure a temperature directly with a pressure gauge. The indicated temperatures are just reference values. Only the saturat…p. 748
If the refrigerant is fluid, the temperature is below the saturation temperature.p. 748
If the refrigerant is gaseous, the temperature is above the saturation temperature.p. 748
Pressure gauges must indicate 0 bar when not connected to the system.p. 748
Low pressure gauges have a blue, high pressure gauges a red border.p. 748
+Thermometerp. 748
Thermometerp. 748
Normally digital thermometers with surface or contact feelers are used. Especially for high temperature differences excellent heat insulation of the measuring location is of utmost importance. The sparing use of a heat conducting paste is highly reco…p. 748
+Overheatingp. 748
Overheatingp. 748
+Common overheating valuesp. 748
Due to its design a refrigerant compressor can only deliver gaseous or vaporous substances. Fluids are not compressible and must therefore not enter into the compression chamber of the compressor.p. 748
If the suction condition of the compressor is directly on the dew line, an e.g. incorrect evaporator load can cause "wet suction". This can lead to two processes, which are destructive for the compressor. The liquid refrigerant washes off the lubrica…p. 748
Apart from protecting the compressor against fluid, overheating has further advantages. Since the fluid proportions in the drawn in steam reduces the flow rate of the compressor, it may be increased by a overheating. Overheating also improves the oil…p. 748
+Common overheating valuesp. 748
Common overheating valuesp. 748
The optimal overheating value is approx. 5 – 8 Kelvin. With this overheating the maximum system power is reached. However, the thermostatic expansion valve is unable to regulate this value exactly. Depending on design and operating conditions overhea…p. 748
+Overheating is calculated as follows:p. 748
Overheating is calculated as follows:p. 748
+D tp. 748
Dp. 748
o2hp. 748
o2hp. 748
op. 748
+D tp. 748
Dp. 748
o2hp. 748
+tp. 748
o2hp. 748
+tp. 748
op. 748
+„p. 748
hp. 748
+Supercoolingp. 748
Supercoolingp. 748
+Common supercooling valuesp. 748
It is the function of the expansion valve to reduce the refrigerant to a lower pressure level (evaporation pressure) after it has been liquefied. For an optimal function of the valve pure fluid must be applied to its inlet port.p. 748
The refrigerant must "squeeze" (literally speaking) through a throttle gap inside the expansion valve. When comparing a certain mass of refrigerant in fluid and in vaporous state (with constant pressure), the vaporous refrigerant requires a much high…p. 748
Vaporous refrigerant in front of the expansion valve reduces the flow rate and results in an undersupply of the evaporator with refrigerant. Evaporation pressure and evaporator power will drop.p. 748
If the refrigeration system is operated with the "expansion valve inlet" condition directly on the boiling curve, slightest fluctuations in operating condition may cause a formation of bubbles in front of the expansion element.p. 748
For this reason one shifts the condition "Expansion Valve Inlet" away from the boiling curve into the fluid area and refers to this condition as Supercooling. This supercooling ensures a fluid supply in front of the expansion valve.p. 749
+Common supercooling valuesp. 749
Common supercooling valuesp. 749
In systems with fluid container the supercooling at the fluid container outlet is approx. Zero "0" Kelvin (assumed that the system is filled with the correct refrigerant quantity). In this case the fluid container provides the required fluid supply.p. 749
+Supercooling is calculated as follows:p. 749
Supercooling is calculated as follows:p. 749
+D tp. 749
Dp. 749
c2up. 749
cp. 749
c2up. 749
+D tp. 749
Dp. 749
c2up. 749
+tp. 749
c2up. 749
+tp. 749
cp. 749
+„p. 749
up. 749
Fig. 1 Refrigerant circuit with t, h- diagramp. 750
9 Pressure switch with high and low pressure contactsp. 751
10 Dryerp. 751
11 Fluid containerp. 751
12 Hot airp. 751
13 Compressorp. 751
14 Condenserp. 751
15 Cooling airp. 751
16 Pressure gauge, low pressurep. 751
15.19 Trouble shooting procedurep. 752
+Procedurep. 752
Procedurep. 752
+Knowledgep. 752
Knowledgep. 752
Trouble shooting is not possible with exact knowledge about the system design, the installed components and their function in the system trouble shooting is not possible:p. 752
+Visual inspectionp. 752
Visual inspectionp. 752
With the appropriate experience some faults can be visually detected or felt. Frequently occurring condenser soiling or formation of steam bubbles in the inspection glass can be quickly detected.p. 752
In case of unusual formation of hoarfrost on the evaporator the hoarfrost pattern provides useful information. Hoarfrost only occurring at the inlet side is a clear indication of insufficient refrigerant feed, which in turn indicates an incorrectly w…p. 752
Even overheating can sometimes be detected with the naked eye. At the end of the evaporator there should be an area which is dry or at least drier at evaporator temperatures above -2 °C.p. 752
The fluid line in the refrigeration system is warm. If a local cooling can be felt or if condensation develops, this is a clear indicator for an extreme pressure drop in the line. Similar phenomena can be noticed in case of blocked filters.p. 752
Unusually cold pressure lines indicate "wet" intake of the compressor.p. 752
The oil level in the compressor sight glass provides information about the oil quantity and the oil recirculation in the system. However, the oil level may also be considerably influenced by condensing refrigerant. Discoloration informs about the sta…p. 752
Water in the system can simply be detected through the inspection glass with moisture indicator.p. 752
+The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states in the individual piping sections or components must therefore be exactly determined by means of pressure and temperature measurements.p. 752
The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states in the individual piping sections or components must therefore be exactly determined by means of pressure and temperature measurements.p. 752
+Test prerequisitesp. 752
Test prerequisitesp. 752
+l Cooler and condenser are clean, clean if necessary.p. 752
l Cooler and condenser are clean, clean if necessary.p. 752
l The ribbed belt for compressor and generator is correctly tightened.p. 752
l All air ducts, covers and seals are OK and correctly fitted. Flaps reach their end positions.p. 752
l The engine has operating temperature.p. 752
l Evaporator and heating (with highest fresh air fan speed) do not draw leak air.p. 752
l The fresh air fan runs when the engine is running and the air conditioning system is set to max. cooling power.p. 752
l Ambient temperature above 15 °C.p. 752
l The thermostat is correctly installed and the switching temperatures are correct.p. 752
+Example: Measurement of overheatingp. 753
Measuring points and measurementsp. 753
Fig. 2 Flow diagram with measuring pointsp. 753
+l C, condenser measuring pointsp. 753
l C, condenser measuring pointsp. 753
l E, expansion valve measuring pointsp. 753
l O, evaporator measuring pointsp. 753
l V, compressor measuring pointsp. 753
The flow diagram contains "Minimum Requirements" which must be fulfilled to be able to check the system or perform trouble shooting.p. 753
+Example: Measurement of overheatingp. 753
Example: Measurement of overheatingp. 753
+l a) Which measuring equipment is required?p. 753
l a) Which measuring equipment is required?p. 753
l b) Where to measure with which size?p. 753
+l c) A pressure gauge connected to the evaporator indicates "Pp. 753
eo2p. 753
op. 753
+l d) How high is the evaporator temperature "tp. 753
op. 753
+l e) A thermal sensor attached to the evaporator outlet measures the temperature "tp. 753
o2hp. 753
Dp. 753
o2hp. 753
l f) Evaluation of the measured overheating.p. 753
+Solution:p. 754
Solution:p. 754
+l a) Pressure gauge, thermometer, steam tablep. 754
l a) Pressure gauge, thermometer, steam tablep. 754
+l b) Evaporation pressure "Pp. 754
eo2p. 754
o2hp. 754
+l c) Pp. 754
op. 754
eo2p. 754
ambp. 754
+l d) "Pp. 754
cp. 754
op. 754
+l e)p. 754
Dp. 754
o2hp. 754
o2hp. 754
op. 754
l f) The determined overheating is within the usual range of 4 – 12 Kelvin.p. 754
+Example: Measuring supercoolingp. 754
Example: Measuring supercoolingp. 754
+l a) Which measuring equipment is required?p. 754
l a) Which measuring equipment is required?p. 754
l b) Where to measure with which size?p. 754
+l c) A pressure gauge connected to the condenser indicates "Pp. 754
ec2p. 754
cp. 754
+l d) How high is the condensing temperature "tp. 754
cp. 754
+l e) A thermal sensor attached to the condenser outlet measures the temperature "tp. 754
c2up. 754
Dp. 754
c2up. 754
l f) Evaluation of the measured supercooling.p. 754
+Solution:p. 754
Solution:p. 754
+l a) Pressure gauge, thermometer, steam tablep. 754
l a) Pressure gauge, thermometer, steam tablep. 754
+l b) Condensing pressure "Pp. 754
ec2p. 754
c2up. 754
+l c) Pp. 754
cp. 754
ec2p. 754
ambp. 754
+l d) "Pp. 754
cp. 754
cp. 754
+l e)p. 754
Dp. 754
c2up. 754
cp. 754
c2up. 754
l f) The determined overheating is within the usual range of approx. "0" Zero Kelvin.p. 754
+Typical faults and possible causesp. 754
Typical faults and possible causesp. 754
Most faults in the refrigerant side of the system can be clearly assigned with the help a checklist. r Occurring faults frequently have a similar appearance, but different causes. An evaporator showing hoarfrost may be quite normal. However, there ma…p. 754
The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds).p. 754
Suction pressure (low pressure gauge)p. 754
+Ambient temperature in °Cp. 754
Ambient temperature in °Cp. 754
+Excess pressure in barp. 754
Excess pressure in barp. 754
+25p. 754
25p. 754
+approx. 2,0p. 754
approx. 2,0p. 754
+30p. 754
30p. 754
+approx. 2,5p. 754
approx. 2,5p. 754
+35p. 754
35p. 754
+approx. 3p. 754
approx. 3p. 754
High pressure (high pressure gauge)p. 754
+Ambient temperature in °Cp. 754
Ambient temperature in °Cp. 754
+Excess pressure in barp. 754
Excess pressure in barp. 754
+25p. 754
25p. 754
+approx. 8,0p. 754
approx. 8,0p. 754
+35p. 754
35p. 754
+approx. 13p. 754
approx. 13p. 754
+40p. 754
40p. 754
+approx. 16p. 754
approx. 16p. 754
+45p. 754
45p. 754
+approx. 18p. 754
approx. 18p. 754
+Noise in systemp. 755
Values effecting the operating pressuresp. 755
Since the pressures occurring in a refrigeration system are highly dependent on environmental conditions, it is mandatory to know these dependencies. The following table contains some of these dependencies.p. 755
+Measuring valuep. 755
Measuring valuep. 755
+Suction pressurep. 755
Suction pressurep. 755
+High pressurep. 755
High pressurep. 755
+increasesp. 755
increasesp. 755
+dropsp. 755
dropsp. 755
+increasesp. 755
increasesp. 755
+dropsp. 755
dropsp. 755
+Compressor speedp. 755
Compressor speedp. 755
+increasesp. 755
increasesp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+dropsp. 755
dropsp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+Vehicle interior temperaturep. 755
Vehicle interior temperaturep. 755
+increasesp. 755
increasesp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+dropsp. 755
dropsp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+Ambient temperaturep. 755
Ambient temperaturep. 755
+increasesp. 755
increasesp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+dropsp. 755
dropsp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+Humidityp. 755
Humidityp. 755
+increasesp. 755
increasesp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+dropsp. 755
dropsp. 755
+Xp. 755
Xp. 755
+Xp. 755
Xp. 755
+Noise in systemp. 756
Suction pressure too low (1), high pressure too low to normal (2)p. 756
Fig. 3p. 756
+Causep. 756
Causep. 756
+Possible effectp. 756
Possible effectp. 756
+Remedyp. 756
Remedyp. 756
+Lack of refrigerantp. 756
Lack of refrigerantp. 756
+no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 756
no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporatorp. 756
+Check for leaks, refillp. 756
Check for leaks, refillp. 756
+Evaporator fins or air filter soiledp. 756
Evaporator fins or air filter soiledp. 756
+Cooling power too lowp. 756
Cooling power too lowp. 756
+cleanp. 756
cleanp. 756
+Evaporator fan failedp. 756
Evaporator fan failedp. 756
+Low pressure shut offp. 756
Low pressure shut offp. 756
+Repair the fanp. 756
Repair the fanp. 756
+Expansion valve defectivep. 756
Expansion valve defectivep. 756
+Suction pressure gauge shows vacuum, because the valve has closedp. 756
Suction pressure gauge shows vacuum, because the valve has closedp. 756
+Replace the valvep. 756
Replace the valvep. 756
+Screen or nozzle in expansion valve cloggedp. 756
Screen or nozzle in expansion valve cloggedp. 756
+high overheatingp. 756
high overheatingp. 756
+cleanp. 756
cleanp. 756
+Filter dryer cloggedp. 756
Filter dryer cloggedp. 756
+Bubbles in inspection glass, high overheating, filter dryer coldp. 756
Bubbles in inspection glass, high overheating, filter dryer coldp. 756
Suction pressure normal (1), high pressure too high (2)p. 757
Fig. 4p. 757
+Causep. 757
Causep. 757
+Possible effectp. 757
Possible effectp. 757
+Remedyp. 757
Remedyp. 757
+Condenser dirtyp. 757
Condenser dirtyp. 757
+high hot gas temperature, low cooling powerp. 757
high hot gas temperature, low cooling powerp. 757
+cleanp. 757
cleanp. 757
+Condenser fan failedp. 757
Condenser fan failedp. 757
+high hot gas temperature, high pressure shut downp. 757
high hot gas temperature, high pressure shut downp. 757
+repairp. 757
repairp. 757
+overfilledp. 757
overfilledp. 757
+high hot gas temperature, low supercooling, low cooling powerp. 757
high hot gas temperature, low supercooling, low cooling powerp. 757
+Correct the filling capacityp. 757
Correct the filling capacityp. 757
+Leak gas (air)p. 757
Leak gas (air)p. 757
+high hot gas temperature, low measured supercooling, low cooling powerp. 757
high hot gas temperature, low measured supercooling, low cooling powerp. 757
+renew fillingp. 757
renew fillingp. 757
+Restriction between compressor and condenserp. 757
Restriction between compressor and condenserp. 757
+high hot gas temperature, low cooling powerp. 757
high hot gas temperature, low cooling powerp. 757
+Check lines and valvesp. 757
Check lines and valvesp. 757
+Noise in systemp. 758
Suction pressure too high (1), high pressure too low to normal (2)p. 758
Fig. 5p. 758
+Causep. 758
Causep. 758
+Possible effectp. 758
Possible effectp. 758
+Remedyp. 758
Remedyp. 758
+Compressor defectivep. 758
Compressor defectivep. 758
+Cooling power too lowp. 758
Cooling power too lowp. 758
+Replace the compressorp. 758
Replace the compressorp. 758
+Noise in systemp. 759
Suction pressure too high (1), high pressure too high (2)p. 759
Fig. 6p. 759
+Causep. 759
Causep. 759
+Possible effectp. 759
Possible effectp. 759
+Remedyp. 759
Remedyp. 759
+Expansion valve defectivep. 759
Expansion valve defectivep. 759
+overheating too low, wet operation of compressorp. 759
overheating too low, wet operation of compressorp. 759
+Replace the valvep. 759
Replace the valvep. 759
+Noise in systemp. 760
Other faultsp. 760
+Symptomp. 760
Symptomp. 760
+Causep. 760
Causep. 760
+Possible effectp. 760
Possible effectp. 760
+Remedyp. 760
Remedyp. 760
+Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 760
Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a handp. 760
+Lack of refrigeration oilp. 760
Lack of refrigeration oilp. 760
+increased compressor wearp. 760
increased compressor wearp. 760
+Refill refrigeration oilp. 760
Refill refrigeration oilp. 760
+Compressor does not startp. 760
Compressor does not startp. 760
+Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 760
Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerantp. 760
+System stoppedp. 760
System stoppedp. 760
+Check the control units, check cause for switching and rectifyp. 760
Check the control units, check cause for switching and rectifyp. 760
+Compressor switches continuouslyp. 760
Compressor switches continuouslyp. 760
+Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 760
Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilledp. 760
+Cycling of compressor, increased wear, too low cooling powerp. 760
Cycling of compressor, increased wear, too low cooling powerp. 760
+Check the control units, check cause for switching and rectifyp. 760
Check the control units, check cause for switching and rectifyp. 760
+Excessive overheatingp. 760
Excessive overheatingp. 760
+Expansion valve deadjusted or screen blocked, lack of refrigerantp. 760
Expansion valve deadjusted or screen blocked, lack of refrigerantp. 760
+low cooling power, hot gas temperatures too highp. 760
low cooling power, hot gas temperatures too highp. 760
+Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 760
Replace the expansion valve, clean the screen, fill in refrigerant, leak testp. 760
+Hoarfrost on inlet side of evaporatorp. 760
Hoarfrost on inlet side of evaporatorp. 760
+incorrectly working expansion valve, lack of refrigerantp. 760
incorrectly working expansion valve, lack of refrigerantp. 760
+too low infeed of refrigerant into the evaporatorp. 760
too low infeed of refrigerant into the evaporatorp. 760
+Check the expansion valve, check the refrigerant fillingp. 760
Check the expansion valve, check the refrigerant fillingp. 760
+Evaporator fully covered with hoarfrostp. 760
Evaporator fully covered with hoarfrostp. 760
+Load problem, too low air flow volumep. 760
Load problem, too low air flow volumep. 760
+low cooling power of systemp. 760
low cooling power of systemp. 760
+Clean the evaporator, check the evaporator fanp. 760
Clean the evaporator, check the evaporator fanp. 760
+Fluid line is warm and shows condensationp. 760
Fluid line is warm and shows condensationp. 760
+Pressure drop in fluid line, filter dryer cloggedp. 760
Pressure drop in fluid line, filter dryer cloggedp. 760
+low cooling powerp. 760
low cooling powerp. 760
+Eliminate the pressure drop, replace the filter dryerp. 760
Eliminate the pressure drop, replace the filter dryerp. 760
+Exceptionally cold pressure linesp. 760
Exceptionally cold pressure linesp. 760
+"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 760
"Wet intake" of the compressor due to insufficient overheating of evaporatorp. 760
+low cooling power, excessive wear of compressorp. 760
low cooling power, excessive wear of compressorp. 760
+Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 760
Clean the compressor, replace if necessary, replace the expansion valve if necessaryp. 760
+Noise in systemp. 760
Noise in systemp. 760
+Faultsp. 760
Faultsp. 760
+Possible causep. 760
Possible causep. 760
+Remedyp. 760
Remedyp. 760
+V-belt loose or excessively wornp. 760
V-belt loose or excessively wornp. 760
+V-belt slips and generates noisep. 760
V-belt slips and generates noisep. 760
+Retention or renew the V-beltp. 760
Retention or renew the V-beltp. 760
+Magnetic clutch loudp. 760
Magnetic clutch loudp. 760
+Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 760
Magnetic clutch runs until high pressure builds up, then the clutch starts to slipp. 760
+Repair or replace the magnetic clutchp. 760
Repair or replace the magnetic clutchp. 760
+Refrigerant compressor is loudp. 760
Refrigerant compressor is loudp. 760
+Mounting bracket is loose, internal parts worn, low oil level in compressorp. 760
Mounting bracket is loose, internal parts worn, low oil level in compressorp. 760
+Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 760
Repair the mounting bracket, replace the compressor, renew the refrigeration oilp. 760
+Fan is loud, fan motor excessively wornp. 760
Fan is loud, fan motor excessively wornp. 760
+Replace the fan motorp. 760
Replace the fan motorp. 760
+Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 760
Whistling and rattling noise in operation, noticeable unevenness when turning by handp. 760
+V-belt pulley and bearing wornp. 760
V-belt pulley and bearing wornp. 760
+Replace the bearing, check V-belt pulley for wearp. 760
Replace the bearing, check V-belt pulley for wearp. 760
+Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 760
Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the topp. 760
+System overfilledp. 760
System overfilledp. 760
+Draw out refrigerantp. 760
Draw out refrigerantp. 760
+Expansion valve loudp. 760
Expansion valve loudp. 760
+excessive moisture in systemp. 760
excessive moisture in systemp. 760
+Replace the dryerp. 760
Replace the dryerp. 760
+Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 760
Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not floatp. 760
+refrigerant level in system too lowp. 760
refrigerant level in system too lowp. 760
+Perform a leak test, fill up the systemp. 760
Perform a leak test, fill up the systemp. 760
+Inspection glassp. 761
Inspection glassp. 761
+Faultsp. 761
Faultsp. 761
+Possible causep. 761
Possible causep. 761
+Remedyp. 761
Remedyp. 761
+Steam bubbles in inspection glassp. 761
Steam bubbles in inspection glassp. 761
+No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 761
No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryerp. 761
+Fill up the system, replace the filter dryer, perform a leak testp. 761
Fill up the system, replace the filter dryer, perform a leak testp. 761
+Discolouration of inspection glass (black from inside)p. 761
Discolouration of inspection glass (black from inside)p. 761
+Lubricant destroyed by excessive operating temperaturesp. 761
Lubricant destroyed by excessive operating temperaturesp. 761
+Replace the refrigeration oil, examine the temperature increasep. 761
Replace the refrigeration oil, examine the temperature increasep. 761
+Moisture indicator changes to pinkp. 761
Moisture indicator changes to pinkp. 761
+Moisture level of drying agent too highp. 761
Moisture level of drying agent too highp. 761
+Replace the filter dryerp. 761
Replace the filter dryerp. 761
+Ball floats at bottomp. 761
Ball floats at bottomp. 761
+lack of refrigerantp. 761
lack of refrigerantp. 761
+Fill the systemp. 761
Fill the systemp. 761
+Monitoring devicesp. 761
Monitoring devicesp. 761
+Faultsp. 761
Faultsp. 761
+Possible causep. 761
Possible causep. 761
+Remedyp. 761
Remedyp. 761
+The high pressure contact has switched off the magnetic clutchp. 761
The high pressure contact has switched off the magnetic clutchp. 761
System pressure exceeded, condenser excessively soiled, condenser fan defective, expansion valve defectivep. 761
+Clean the condenser, replace the expansion valve, check the condenser fanp. 761
Clean the condenser, replace the expansion valve, check the condenser fanp. 761
+The low pressure contact has switched off the magnetic clutchp. 761
The low pressure contact has switched off the magnetic clutchp. 761
+System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 °Cp. 761
System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 °Cp. 761
+Clean the evaporator, replace the expansion valve, check the evaporator fanp. 761
Clean the evaporator, replace the expansion valve, check the evaporator fanp. 761
+The thermostat has switched off the magnetic clutchp. 761
The thermostat has switched off the magnetic clutchp. 761
+Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 761
Ambient temperature below 1°C, expansion valve defective, thermostat defective, air flow volume too lowp. 761
+Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 761
Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fanp. 761
Steam table for R134a
+Temperaturep. 762
Temperaturep. 762
+Pressurep. 762
Pressurep. 762
+Densityp. 762
Densityp. 762
+spec. volumep. 762
spec. volumep. 762
+spec. enthalpyp. 762
spec. enthalpyp. 762
+Evaporation heatp. 762
Evaporation heatp. 762
+of the fluidp. 762
of the fluidp. 762
+of the steamp. 762
of the steamp. 762
+of the fluidp. 762
of the fluidp. 762
+of the steamp. 762
of the steamp. 762
+of the fluidp. 762
of the fluidp. 762
+of the steamp. 762
of the steamp. 762
+16 Cabin assemblyp. 767
16 Cabin assemblyp. 767
+General safety regulations for assemblyp. 768
General safety regulations for assemblyp. 768
When installing the cabin to your machine you must strictly comply with the valid accident prevention instructions or the country specific regulations. However, dangers for persons and property may still arise, if:p. 768
+l the lifting gear used has a too low bearing capacityp. 768
l the lifting gear used has a too low bearing capacityp. 768
l damaged or worn lifting tackle is usedp. 768
l unqualified personnel is entrusted with the installationp. 768
l the safety instructions are not observedp. 768
Each person involved in the installation of the cabin must therefore read and comply with these safety regulations. If necessary, the customer must demand a written confirmation with signature.p. 768
Moreover, the following instructions and regulations must obviously also be complied with:p. 768
l applicable accident prevention instructionsp. 768
l generally accepted safety and road traffic regulationsp. 768
l country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accordingly. This applies also for local regulations concerning different types of handling work. Should the recommendat…p. 768
+Changes and conversions to the cabin/ machinep. 768
Changes and conversions to the cabin/ machinep. 768
Unauthorized changes to the cabin are prohibited for safety reasons.p. 768
Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/ or use of such products may have an …p. 768
The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.p. 768
+Notes on safety in the assembly instructionsp. 768
Notes on safety in the assembly instructionsp. 768
+Paragraphs marked like this highlight possible dangers for persons.p. 768
Paragraphs marked like this highlight possible dangers for persons.p. 768
+Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 768
Paragraphs marked like this highlight possible dangers for machines or parts of the machine.p. 768
+Paragraphs marked like this contains technical information and hints for optimal assembly.p. 768
Paragraphs marked like this contains technical information and hints for optimal assembly.p. 768
+Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 768
Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.p. 768
Strictly observe the national regulations for the protection of the environment.p. 768
+Information and safety stickers/decals on the cabinp. 768
Information and safety stickers/decals on the cabinp. 768
Keep stickers/decals in good and legible condition (see spare parts catalogue) and comply with their meaning.p. 768
Replace damaged stickers/decalsp. 768
+Work on heating linesp. 768
Work on heating linesp. 768
Before starting work on heating pipes relieve any pressure and let them cool down – danger of scalding!p. 768
After completing work on the heating system of the machine check all connections and fittings for leaks.p. 768
+Working on electric parts of the machinep. 768
Working on electric parts of the machinep. 768
Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.p. 768
Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard.p. 768
+16.1 Preparationsp. 769
16.1 Preparationsp. 769
+Danger of accident!p. 769
+Danger of accident!p. 769
Danger of accident!p. 769
For transport purposes the driver's seat must be tied down with cable straps thus to operate the seat contact switch. Before resuming operation of the machine these cable straps must strictly be removed to ensure safe and reliable function of the sea…p. 769
Check the 4 lifting eyes on the cabin roof for tight fit.p. 769
Fasten the lifting gear to all four lifting eyes.p. 769
Use lifting gear (chains or ropes) of sufficient load bearing capacity. The minimum load bearing capacity of the crane must be 1000 kg.p. 769
Do not stand or step under loads being lifted.p. 769
Fig. 7p. 769
+l Make sure that all fastening screws, washers, spacers and nuts to fasten the cabin are availablep. 769
+l Make sure that all fastening screws, washers, spacers and nuts to fasten the cabin are availablep. 769
(Fig. 7)p. 769
+l Check whether rear rack, foot mat, step plate and fastening kit are available.p. 769
l Check whether rear rack, foot mat, step plate and fastening kit are available.p. 769
Fig. 8p. 769
+l Fasten the lifting gear to the four lifting eyes 1p. 769
+l Fasten the lifting gear to the four lifting eyes 1p. 769
(Fig. 8)p. 769
l Loosen possible fastening on the transport pallet.p. 769
+l Slowly list the crane with a crane.p. 769
l Slowly list the crane with a crane.p. 769
+Danger of accident!p. 769
Danger of accident!p. 769
Do not stand or step under loads being lifted.p. 769
+16.2 Cabin assemblyp. 770
16.2 Cabin assemblyp. 770
+Danger of accident!p. 770
+Danger of accident!p. 770
Danger of accident!p. 770
Use lifting gear (chains or ropes) of sufficient load bearing capacity. The minimum load bearing capacity of the crane must be 1000 kg.p. 770
Do not stand or step under loads being lifted.p. 770
+l Clean the operator's stand of dirt, oil and moisture.p. 770
l Clean the operator's stand of dirt, oil and moisture.p. 770
Fig. 9p. 770
+l Stick the supplied sealing tape 1p. 770
+l Stick the supplied sealing tape 1p. 770
(Fig. 9)p. 770
+Only unroll and stick the sealing tape on just before mounting the cab to the operator's stand. The sealing tape will swell a few minutes after being unrolled. In this case the cabin can no longer be mounted!p. 770
Only unroll and stick the sealing tape on just before mounting the cab to the operator's stand. The sealing tape will swell a few minutes after being unrolled. In this case the cabin can no longer be mounted!p. 770
Fig. 10p. 770
+l Stick the sealing tape 1p. 770
+l Stick the sealing tape 1p. 770
(Fig. 10)p. 770
l Do not run the sealing tape across the front recess in the operator's stand (2), since this is the air inlet for the cabin ventilation.p. 770
+Mount the cabin immediately after sticking on the sealing tape, because the sealing tape will swell.p. 770
Mount the cabin immediately after sticking on the sealing tape, because the sealing tape will swell.p. 770
Fig. 11p. 770
+l Spray the sealing tape with soapsudsp. 770
+l Spray the sealing tape with soapsudsp. 770
(Fig. 11)p. 770
Fig. 12p. 770
+l Slowly lower the cabin vertically to the operator's standp. 770
+l Slowly lower the cabin vertically to the operator's standp. 770
(Fig. 12)p. 770
+The cabine must be lowered vertically onto the operator's stand.p. 770
The cabine must be lowered vertically onto the operator's stand.p. 770
Fig. 13p. 771
+Take care that none of the hoses and electric cables become squashedp. 771
+Take care that none of the hoses and electric cables become squashedp. 771
(Fig. 13)p. 771
+l Run cables and hoses from inside the cabin through the operator's stand to the outside.p. 771
l Run cables and hoses from inside the cabin through the operator's stand to the outside.p. 771
Fig. 14p. 771
+l Turn both fastening screwsp. 771
+l Turn both fastening screwsp. 771
(Fig. 14)p. 771
Fig. 15p. 771
+If the bores do not match the cabin can be moved into position by means of a crow barp. 771
+If the bores do not match the cabin can be moved into position by means of a crow barp. 771
(Fig. 15)p. 771
Fig. 16p. 771
+l Tighten the bottom fastening screw on the access sidep. 771
+l Tighten the bottom fastening screw on the access sidep. 771
(Fig. 16)p. 771
Fig. 17p. 771
+l Loosen both fastening screwsp. 771
+l Loosen both fastening screwsp. 771
(Fig. 17)p. 771
+The cabin will now slide into final assembly position.p. 771
The cabin will now slide into final assembly position.p. 771
+l Tighten both fastening screwsp. 771
+l Tighten both fastening screwsp. 771
(Fig. 17)p. 771
Fig. 18p. 771
+l Tighten the rear lateral fastening screw on the left hand side with 578 Nmp. 771
+l Tighten the rear lateral fastening screw on the left hand side with 578 Nmp. 771
(Fig. 18)p. 771
Fig. 19p. 772
+l Tighten the rear lateral fastening screw on the right hand side with 578 Nmp. 772
+l Tighten the rear lateral fastening screw on the right hand side with 578 Nmp. 772
(Fig. 19)p. 772
Fig. 20p. 772
+l Tighten the rear inside fastening screw on the right hand side with 578 Nmp. 772
+l Tighten the rear inside fastening screw on the right hand side with 578 Nmp. 772
(Fig. 20)p. 772
Fig. 21p. 772
+l Turn nuts with washers onto both studs and tighten with 200 Nmp. 772
+l Turn nuts with washers onto both studs and tighten with 200 Nmp. 772
(Fig. 21)p. 772
Fig. 22p. 772
+l Tighten the front lateral fastening screw on the right hand side with 578 Nmp. 772
+l Tighten the front lateral fastening screw on the right hand side with 578 Nmp. 772
(Fig. 22)p. 772
Fig. 23p. 772
+l Tighten the front lateral fastening screw on the left hand side with 578 Nmp. 772
+l Tighten the front lateral fastening screw on the left hand side with 578 Nmp. 772
(Fig. 23)p. 772
Fig. 24p. 772
+l Cover all lateral fastening screws with plastic capsp. 772
+l Cover all lateral fastening screws with plastic capsp. 772
(Fig. 24)p. 772
Fig. 25p. 773
+l Insert the foot mat 1p. 773
+l Insert the foot mat 1p. 773
+l Insert the foot mat 1p. 773
(Fig. 25)p. 773
Fig. 26p. 773
+l Attach the step plate 1p. 773
+l Attach the step plate 1p. 773
(Fig. 26)p. 773
Fig. 27p. 773
+l Insert the dashboard and fasten it with four fastening screwsp. 773
+l Insert the dashboard and fasten it with four fastening screwsp. 773
(Fig. 27)p. 773
Fig. 28p. 773
+l Insert the rear rack and knock both plastic fasteners carefully into the bores with a hammerp. 773
+l Insert the rear rack and knock both plastic fasteners carefully into the bores with a hammerp. 773
(Fig. 28)p. 773
Fig. 29p. 773
+l Connect the feed 1p. 773
+l Connect the feed 1p. 773
(Fig. 29)p. 773
l Connect the feed (4) and the return flow (3) of the heating. (Observe the marks on the hoses).p. 773
+Run the connecting lines for the heating parallel to each other (do not cross).p. 773
Run the connecting lines for the heating parallel to each other (do not cross).p. 773
+Check the function of air conditioning and heating within the scope of the function test.p. 773
Check the function of air conditioning and heating within the scope of the function test.p. 773
Observe identical hose diameters when connecting.p. 773
Fig. 30p. 774
+l Plug on both connecting plugs for the washing water pumpsp. 774
+l Plug on both connecting plugs for the washing water pumpsp. 774
(Fig. 30)p. 774
Fig. 31p. 774
+l Plug on the hoses for the washing water supply to front and rear windscreens 1p. 774
+l Plug on the hoses for the washing water supply to front and rear windscreens 1p. 774
(Fig. 31)p. 774
+Check the function of the washing water system within the scope of the function test.p. 774
Check the function of the washing water system within the scope of the function test.p. 774
Fig. 32p. 774
+l Insert the plug 1p. 774
+l Insert the plug 1p. 774
(Fig. 32)p. 774
l Close the bayonet catch by turning the corrugated cap nut in clockwise direction against the stop.p. 774
+Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.p. 774
Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.p. 774
Fig. 33p. 774
+l Connect the plug connection of the air conditioning systemp. 774
+l Connect the plug connection of the air conditioning systemp. 774
(Fig. 33)p. 774
+16.3 Final function tests and checksp. 775
16.3 Final function tests and checksp. 775
+Make sure that all screws have been tightened with the specified torque.p. 775
+Make sure that all screws have been tightened with the specified torque.p. 775
Make sure that all screws have been tightened with the specified torque.p. 775
+After the cabin assembly the following tests must be performed to assure that all cables and lines are correctly connected.p. 775
After the cabin assembly the following tests must be performed to assure that all cables and lines are correctly connected.p. 775
+l Insert the ignition key and turn clockwise to position "1".p. 775
l Insert the ignition key and turn clockwise to position "1".p. 775
l Operate the switches for headlights, direction indicators and interior light to check their function.p. 775
l Operate the switches for front and rear windscreen washer system and check their correct function.p. 775
+If the function of the windscreen washer system is reversed, the two washing water hoses must be interchanged.p. 775
If the function of the windscreen washer system is reversed, the two washing water hoses must be interchanged.p. 775
+l Start the engine.p. 775
l Start the engine.p. 775
+l Switch the air conditioning on by the switch. After a five minute operation the cabin must become noticeably cooler.p. 775
l Switch the air conditioning on by the switch. After a five minute operation the cabin must become noticeably cooler.p. 775
l Switch the air heater on by the switch. After a five minute operation the cabin must become noticeably warmer.p. 775
+l Function of the seat contact switch.p. 775
l Function of the seat contact switch.p. 775
+The machine must not be operated if the seat contact switch is not functioning correctly.p. 775
The machine must not be operated if the seat contact switch is not functioning correctly.p. 775
+17 Replacing the cab window panesp. 777
+17 Replacing the cab window panesp. 777
Assembly of window panes
Fig. 1p. 778
+1 Glass panesp. 778
1 Glass panesp. 778
2 Fastening elementp. 778
3 Fixing washer and spacerp. 778
4 Washerp. 778
5 Hexagon nut, self lockingp. 778
6 Protective capp. 778
17.2 Special tools, cabin windowsp. 779
+Fig. 1p. 779
Fig. 1p. 779
+1. Locking handle for fastening elementp. 779
1. Locking handle for fastening elementp. 779
BOMAG part-no.: 055 705 84p. 779
+Fig. 2p. 779
Fig. 2p. 779
+2. Suction lifterp. 779
2. Suction lifterp. 779
commercialp. 779
+Fig. 3p. 779
Fig. 3p. 779
+3. Cutterp. 779
3. Cutterp. 779
Commercialp. 779
17.3 Auxiliary materialsp. 780
+Safety glovesp. 780
Safety glovesp. 780
+Fig. 1p. 780
Fig. 1p. 780
+4. Cutterp. 780
4. Cutterp. 780
Commercialp. 780
+Fig. 2p. 780
Fig. 2p. 780
+5. Window glass bonding agentp. 780
5. Window glass bonding agentp. 780
BOMAG part-no.: 009 780 32p. 780
+Fig. 3p. 780
Fig. 3p. 780
+6. Activatorp. 780
6. Activatorp. 780
BOMAG part-no.: 009 780 33p. 780
+Fig. 4p. 781
Fig. 4p. 781
+7. Silicone sealantp. 781
7. Silicone sealantp. 781
BOMAG part-no.: 009 700 36p. 781
17.4 Removing and installing the window panep. 782
+Fig. 1p. 782
Fig. 1p. 782
+Environmental damagep. 782
Environmental damagep. 782
Dispose of glass splinters fro0m machine and cabin or inside cabin in an environmentally friendly way.p. 782
+Danger of cuttingp. 782
Danger of cuttingp. 782
Wear safety gloves.p. 782
+1. Pull large glass rests off the bonding stripp. 782
+1. Pull large glass rests off the bonding stripp. 782
(Fig. 1)p. 782
+Fig. 2p. 782
Fig. 2p. 782
+2. Clean the sealing surfaces from any adhesive materialp. 782
+2. Clean the sealing surfaces from any adhesive materialp. 782
(Fig. 2)p. 782
+3. Use a cutter to remove adhesive residues with glass rests.p. 782
3. Use a cutter to remove adhesive residues with glass rests.p. 782
+4. Cover places without adhesive residues with an activator.p. 782
4. Cover places without adhesive residues with an activator.p. 782
+Fig. 3p. 782
Fig. 3p. 782
+5. Insert the fastening element with washer into the bore in the glass panep. 782
+5. Insert the fastening element with washer into the bore in the glass panep. 782
(Fig. 3)p. 782
+Fig. 4p. 783
Fig. 4p. 783
+6. Turn the fixing and spacer washer hand-tight onto the thread of the fastening elementp. 783
+6. Turn the fixing and spacer washer hand-tight onto the thread of the fastening elementp. 783
(Fig. 4)p. 783
+Do not overtighten the thread.p. 783
Do not overtighten the thread.p. 783
+Fig. 5p. 783
Fig. 5p. 783
+7. Lay an approx. 1 cm high triangular bead of glass pane bonding agent on the inside of the pane, approx. 1.5 cm away from the edgep. 783
+7. Lay an approx. 1 cm high triangular bead of glass pane bonding agent on the inside of the pane, approx. 1.5 cm away from the edgep. 783
(Fig. 5)p. 783
+Apply window pane bonding agent only to the sides (sealing areas) which have contact with the cabin.p. 783
Apply window pane bonding agent only to the sides (sealing areas) which have contact with the cabin.p. 783
+Fig. 6p. 783
Fig. 6p. 783
+8. Attach the suction lifter to the outside of the panep. 783
+8. Attach the suction lifter to the outside of the panep. 783
(Fig. 6)p. 783
+9. Install the window pane so that the fastening elements fit into the bores of the fastening bars.p. 783
9. Install the window pane so that the fastening elements fit into the bores of the fastening bars.p. 783
+10. Press the glass pane against the sealing surface.p. 783
10. Press the glass pane against the sealing surface.p. 783
+Fig. 7p. 783
Fig. 7p. 783
+11. Assemble the washer and the self-locking hexagon nut.p. 783
11. Assemble the washer and the self-locking hexagon nut.p. 783
+12. Fasten the window pane to the fastening bar using a locking handle and a ring spannerp. 783
+12. Fasten the window pane to the fastening bar using a locking handle and a ring spannerp. 783
(Fig. 7)p. 783
+Only use the locking handle to counter.p. 783
Only use the locking handle to counter.p. 783
+13. Press the protective cap onto the hexagon nut.p. 783
13. Press the protective cap onto the hexagon nut.p. 783
+Fig. 8p. 784
Fig. 8p. 784
+14. Remove the suction lifterp. 784
+14. Remove the suction lifterp. 784
(Fig. 8)p. 784
+Fig. 9p. 784
Fig. 9p. 784
+15. Clean the joining edges on the window panep. 784
+15. Clean the joining edges on the window panep. 784
(Fig. 9)p. 784
+The joint flanks must be solid, dry and free of dirt, dust, grease, oil and other foreign substances.p. 784
The joint flanks must be solid, dry and free of dirt, dust, grease, oil and other foreign substances.p. 784
+16. Mask the upper and lower contact areas to the cabin.p. 784
16. Mask the upper and lower contact areas to the cabin.p. 784
+Fig. 10p. 784
Fig. 10p. 784
+17. Apply silicone sealant evenly and under pressure first to the inside joint edgep. 784
+17. Apply silicone sealant evenly and under pressure first to the inside joint edgep. 784
(Fig. 10)p. 784
+Fig. 11p. 784
Fig. 11p. 784
+18. Then apply silicone sealant evenly and under pressure to the outside joint edgep. 784
+18. Then apply silicone sealant evenly and under pressure to the outside joint edgep. 784
(Fig. 11)p. 784
+Fig. 12p. 785
Fig. 12p. 785
+19. Then spray the joints from inside and outside with water containing washing up liquidp. 785
+19. Then spray the joints from inside and outside with water containing washing up liquidp. 785
(Fig. 12)p. 785
+Fig. 13p. 785
Fig. 13p. 785
+20. Treat the inside jointp. 785
+20. Treat the inside jointp. 785
(Fig. 13)p. 785
+Fig. 14p. 785
Fig. 14p. 785
+21. and the outside jointp. 785
+21. and the outside jointp. 785
(Fig. 14)p. 785
+Once the silicone sealing agent has cured it can only be removed mechanically.p. 785
Once the silicone sealing agent has cured it can only be removed mechanically.p. 785
+18 Drump. 787
18 Drump. 787
+5p. 788
Repair overview for drump. 788
Fig. 1 Drum + drum drivep. 788
+1 Vibration motorp. 789
+1 Vibration motorp. 789
1 Vibration motorp. 789
2 Swivel motorp. 789
3 Travel motorp. 789
4 Travel gearp. 789
+5 Exciter unitp. 789
+5 Exciter unitp. 789
5 Exciter unitp. 789
6 Drum shellp. 789
7 Rubber bufferp. 789
Fig. 2 Exciter shafts and eccentric weightsp. 789
+1 Eccentric weights, outerp. 789
+1 Eccentric weights, outerp. 789
1 Eccentric weights, outerp. 789
2 Eccentric weight, middlep. 789
3 Exciter shaft, leftp. 789
4 Exciter shaft, rightp. 789
+5 Exciter shaft, middlep. 789
+5 Exciter shaft, middlep. 789
5 Exciter shaft, middlep. 789
6 Coupling shaftp. 789
7 Additional weight only BW226p. 789
Fig. 3 Exciter unitp. 790
+1 Exciter housing leftp. 791
+1 Exciter housing leftp. 791
1 Exciter housing leftp. 791
2 Eccentric weightsp. 791
3 Coupling shaftp. 791
4 Exciter housing rightp. 791
+5 Exciter housing middlep. 791
+5 Exciter housing middlep. 791
5 Exciter housing middlep. 791
6 Drive shaftp. 791
7 Vibrator shaftp. 791
Fig. 4 Pinionp. 791
+1 Inner bearing racep. 791
+1 Inner bearing racep. 791
1 Inner bearing racep. 791
2 Pinionp. 791
3 Circlip (outer)p. 791
4 Feather keyp. 791
5 Gearp. 791
6 Circlip (outer)p. 791
7 Inner bearing race, bearing flangep. 791
+8 Circlip (outer)p. 791
+8 Circlip (outer)p. 791
8 Circlip (outer)p. 791
9 Outer bearing race with rolls, bearing flangep. 791
Coat gear box from inside with grease (AUTOL TOP 2000).p. 796
+1 Drive shaftp. 796
+1 Drive shaftp. 796
1 Drive shaftp. 796
2 Acceleration transducer, B62p. 796
3 Speed sensor, B59p. 796
+4 Vibration motorp. 796
+4 Vibration motorp. 796
4 Vibration motorp. 796
5 Potentiometer, B97p. 796
6 Swivel motorp. 796
Fig. 10p. 797
+5p. 798
5p. 798
18.2 Removing and installing the drump. 798
+Removing the drump. 798
+Fig. 1p. 798
Fig. 1p. 798
+After disassembling the side plate (vibration motor side) the drum can be lifted sideways out of the framep. 798
+After disassembling the side plate (vibration motor side) the drum can be lifted sideways out of the framep. 798
(Fig. 1)p. 798
+Fig. 2p. 798
Fig. 2p. 798
+However, the drum can also be removed without having to disassemble the side plate, if it is lifted up and out of the framep. 798
+However, the drum can also be removed without having to disassemble the side plate, if it is lifted up and out of the framep. 798
(Fig. 2)p. 798
+Removing the drump. 798
Removing the drump. 798
+The following section describes the procedure for lifting the frame sideways out of the drum.p. 798
The following section describes the procedure for lifting the frame sideways out of the drum.p. 798
+Fig. 3p. 798
Fig. 3p. 798
+1. Unscrew the fastening screws and remove the protection hoodp. 798
+1. Unscrew the fastening screws and remove the protection hoodp. 798
(Fig. 3)p. 798
+Fig. 4p. 799
Fig. 4p. 799
+2. Open the hose bracketsp. 799
+2. Open the hose bracketsp. 799
(Fig. 4)p. 799
+Fig. 5p. 799
Fig. 5p. 799
+Environmental damagep. 799
Environmental damagep. 799
Catch running out hydraulic oil and dispose of environmentally.p. 799
+3. Mark the hydraulic hoses on the vibration motorp. 799
+3. Mark the hydraulic hoses on the vibration motorp. 799
(Fig. 5)p. 799
+4. Close all hydraulic hoses and vibration motor ports with suitable plugs.p. 799
4. Close all hydraulic hoses and vibration motor ports with suitable plugs.p. 799
+Fig. 6p. 799
Fig. 6p. 799
+5. Mark the hydraulic hoses on the slewing motorp. 799
+5. Mark the hydraulic hoses on the slewing motorp. 799
(Fig. 6)p. 799
+6. Close all hydraulic hoses and slewing motor ports with suitable plugs.p. 799
6. Close all hydraulic hoses and slewing motor ports with suitable plugs.p. 799
+Fig. 7p. 799
Fig. 7p. 799
+7. Mark the hydraulic hoses on the control valve blockp. 799
+7. Mark the hydraulic hoses on the control valve blockp. 799
(Fig. 7)p. 799
+8. Close all hydraulic hoses and control valve ports with suitable plugs.p. 799
8. Close all hydraulic hoses and control valve ports with suitable plugs.p. 799
+9. Pull off both plugs (2) from the solenoid valve.p. 799
9. Pull off both plugs (2) from the solenoid valve.p. 799
+10. Disassemble the protection hood (1) for the plug of the wiring loom.p. 799
10. Disassemble the protection hood (1) for the plug of the wiring loom.p. 799
+Fig. 8p. 800
Fig. 8p. 800
+11. Disconnect all plugsp. 800
+11. Disconnect all plugsp. 800
(Fig. 8)p. 800
+Fig. 9p. 800
Fig. 9p. 800
+12. Mark the hydraulic hosesp. 800
+12. Mark the hydraulic hosesp. 800
(Fig. 9)p. 800
+13. Close all hydraulic hoses and travel motor ports with suitable plugs.p. 800
13. Close all hydraulic hoses and travel motor ports with suitable plugs.p. 800
+14. Disassemble the guard plates for speed range selection solenoid valve (1) and speed sensor (2).p. 800
14. Disassemble the guard plates for speed range selection solenoid valve (1) and speed sensor (2).p. 800
+Fig. 10p. 800
Fig. 10p. 800
+15. Disconnect the plug from the speed sensor solenoid valvep. 800
+15. Disconnect the plug from the speed sensor solenoid valvep. 800
(Fig. 10)p. 800
+16. Close the connections with plugs.p. 800
16. Close the connections with plugs.p. 800
+Fig. 11p. 800
Fig. 11p. 800
+17. Disassemble the front scraper 1p. 800
+17. Disassemble the front scraper 1p. 800
(Fig. 11)p. 800
+18. Disassemble the rear scraper (2).p. 800
+18. Disassemble the rear scraper (2).p. 800
+18. Disassemble the rear scraper (2).p. 800
18. Disassemble the rear scraper (2).p. 800
+Fig. 12p. 801
Fig. 12p. 801
+Danger of accident!p. 801
Danger of accident!p. 801
Do not start or run the engine during repair work.p. 801
+19. Support the front cross-member safelyp. 801
+19. Support the front cross-member safelyp. 801
(Fig. 12)p. 801
+Fig. 13p. 801
Fig. 13p. 801
+20. Properly support the rear cross-member on both sidesp. 801
+20. Properly support the rear cross-member on both sidesp. 801
(Fig. 13)p. 801
+Fig. 14p. 801
Fig. 14p. 801
+21. Attach the lifting tackle to the side platep. 801
+21. Attach the lifting tackle to the side platep. 801
(Fig. 14)p. 801
+22. Unscrew the front and rear fastening screws from the side plate.p. 801
22. Unscrew the front and rear fastening screws from the side plate.p. 801
+Fig. 15p. 801
Fig. 15p. 801
+23. Unscrew the fastening screwsp. 801
+23. Unscrew the fastening screwsp. 801
(Fig. 15)p. 801
+Danger of accident! Do not stand or step under loads being loaded.p. 801
Danger of accident! Do not stand or step under loads being loaded.p. 801
+24. Take off the side plate and lay it down.p. 801
24. Take off the side plate and lay it down.p. 801
+Fig. 16p. 802
Fig. 16p. 802
+25. Unscrew the fastening screws on the travel motor sidep. 802
+25. Unscrew the fastening screws on the travel motor sidep. 802
(Fig. 16)p. 802
+Fig. 17p. 802
Fig. 17p. 802
+26. Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front framep. 802
+26. Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front framep. 802
(Fig. 17)p. 802
+Danger of squashing! Do not stand or step under loads being loaded.p. 802
Danger of squashing! Do not stand or step under loads being loaded.p. 802
+Fig. 18p. 802
Fig. 18p. 802
+27. Examine all rubber buffers on the travel motor sidep. 802
+27. Examine all rubber buffers on the travel motor sidep. 802
(Fig. 18)p. 802
+28. Check the rectangular rubber buffers on the vibration motor side, replace if necessary.p. 802
28. Check the rectangular rubber buffers on the vibration motor side, replace if necessary.p. 802
Installing the drump. 803
+Fig. 1p. 803
Fig. 1p. 803
+Danger of squashing!p. 803
Danger of squashing!p. 803
Do not stand or step under loads being loaded.p. 803
+1. Place the drum into the frame and align it parallel to the framep. 803
+1. Place the drum into the frame and align it parallel to the framep. 803
(Fig. 1)p. 803
+Fig. 2p. 803
Fig. 2p. 803
+Assemble the side platep. 803
Assemble the side platep. 803
+2. Attach the lifting tackle and assemble the side platep. 803
+2. Attach the lifting tackle and assemble the side platep. 803
(Fig. 2)p. 803
+Apply sliding lacquer OKS 240 to threads and screw head contact face to ease assembly.p. 803
Apply sliding lacquer OKS 240 to threads and screw head contact face to ease assembly.p. 803
+3. Turn in the front and rear fastening screws and tighten with 463 Nm.p. 803
3. Turn in the front and rear fastening screws and tighten with 463 Nm.p. 803
+Fig. 3p. 803
Fig. 3p. 803
+4. Turn in and tighten the fastening screws on the travel motor sidep. 803
+4. Turn in and tighten the fastening screws on the travel motor sidep. 803
(Fig. 3)p. 803
+Fig. 4p. 803
Fig. 4p. 803
+Adjust the pretension of the rubber buffers.p. 803
Adjust the pretension of the rubber buffers.p. 803
+5. On the vibration motor side measure the distance „X“ between spacer block 1p. 803
+5. On the vibration motor side measure the distance „X“ between spacer block 1p. 803
(Fig. 4)p. 803
+6. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mmp. 803
6. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mmp. 803
+7. Turn in one screw (3) into each welded nut (2) on the spacer blocks and provide sufficient space to insert the compensation plates.p. 803
7. Turn in one screw (3) into each welded nut (2) on the spacer blocks and provide sufficient space to insert the compensation plates.p. 803
+Fig. 5p. 804
Fig. 5p. 804
+8. Insert the compensation platesp. 804
+8. Insert the compensation platesp. 804
(Fig. 5)p. 804
+9. Turn in the fastening screws.p. 804
9. Turn in the fastening screws.p. 804
+10. Unscrew the screws from the welded nuts.p. 804
10. Unscrew the screws from the welded nuts.p. 804
+11. Tighten the fastening screws.p. 804
11. Tighten the fastening screws.p. 804
+Fig. 6p. 804
Fig. 6p. 804
+Connecting the travel motor sidep. 804
Connecting the travel motor sidep. 804
+12. Connect hydraulic hoses to the travel motor ports according to the marks made during disassemblyp. 804
+12. Connect hydraulic hoses to the travel motor ports according to the marks made during disassemblyp. 804
(Fig. 6)p. 804
+13. Connect the plugs (Solenoid valve for travel speed range selection and speed sensor) and reassemble the guard plates (1) and (2).p. 804
13. Connect the plugs (Solenoid valve for travel speed range selection and speed sensor) and reassemble the guard plates (1) and (2).p. 804
+Fig. 7p. 804
Fig. 7p. 804
+Connecting the vibration motor sidep. 804
Connecting the vibration motor sidep. 804
+14. Connect the hydraulic hoses to the ports on the vibration motor according to the markingp. 804
+14. Connect the hydraulic hoses to the ports on the vibration motor according to the markingp. 804
(Fig. 7)p. 804
+Fig. 8p. 804
Fig. 8p. 804
+15. Connect hydraulic hoses to the slewing motor ports according to the marks made during disassemblyp. 804
+15. Connect hydraulic hoses to the slewing motor ports according to the marks made during disassemblyp. 804
(Fig. 8)p. 804
+Fig. 9p. 805
Fig. 9p. 805
+16. Connect all cable plugs and reassemble the protection hood 1p. 805
+16. Connect all cable plugs and reassemble the protection hood 1p. 805
(Fig. 9)p. 805
+Ensure correct routing of the wiring harnesses!p. 805
Ensure correct routing of the wiring harnesses!p. 805
+17. Connect the hydraulic hoses to the ports on the control valve block according to the marking.p. 805
17. Connect the hydraulic hoses to the ports on the control valve block according to the marking.p. 805
+18. Plug in both plugs (2) on the solenoid valve.p. 805
18. Plug in both plugs (2) on the solenoid valve.p. 805
+Fig. 10p. 805
Fig. 10p. 805
+19. Fasten the bracketsp. 805
+19. Fasten the bracketsp. 805
(Fig. 10)p. 805
+Fig. 11p. 805
Fig. 11p. 805
+Adjusting the scrapersp. 805
Adjusting the scrapersp. 805
+20. Assemble the front scraper 1p. 805
+20. Assemble the front scraper 1p. 805
(Fig. 11)p. 805
+21. Assemble the rear scraper (2).p. 805
+21. Assemble the rear scraper (2).p. 805
+21. Assemble the rear scraper (2).p. 805
21. Assemble the rear scraper (2).p. 805
+Observe the adjustment measurement 30-35 mm.p. 805
Observe the adjustment measurement 30-35 mm.p. 805
+Fig. 12p. 805
Fig. 12p. 805
+22. Assemble the protection hoodp. 805
+22. Assemble the protection hoodp. 805
(Fig. 12)p. 805
+Check the hydraulic system for function and leak tightness before putting the machine back into service.p. 805
Check the hydraulic system for function and leak tightness before putting the machine back into service.p. 805
Adjust the potentiometer (see Technical Manual VC).p. 805
Adjust the slewing motor (see Technical Manual VC).p. 805
18.3 Dismantling the drump. 806
+Fig. 1p. 806
Fig. 1p. 806
+The oil drain plug must be positioned vertically below the drum center, if necessary move the drum as required.p. 806
The oil drain plug must be positioned vertically below the drum center, if necessary move the drum as required.p. 806
+1. Unscrew the oil drain plug with the seal ring (1p. 806
+1. Unscrew the oil drain plug with the seal ring (1p. 806
(Fig. 1)p. 806
+2. Drain the oil off into a suitable container.p. 806
2. Drain the oil off into a suitable container.p. 806
+Dispose of oil according to applicable environmental regulations.p. 806
Dispose of oil according to applicable environmental regulations.p. 806
+3. Screw the oil plug with seal ring back in.p. 806
3. Screw the oil plug with seal ring back in.p. 806
+Left drum sidep. 806
Left drum sidep. 806
+Fig. 2p. 806
Fig. 2p. 806
+4. Attach the lifting tackle to the spacer blockp. 806
+4. Attach the lifting tackle to the spacer blockp. 806
(Fig. 2)p. 806
+BW213 = 4 Rectangular rubber buffers.p. 806
BW213 = 4 Rectangular rubber buffers.p. 806
BW226 = 8 Rectangular rubber buffers.p. 806
+Fig. 3p. 806
Fig. 3p. 806
+Attach a support on the opposite side of the side platep. 806
+Attach a support on the opposite side of the side platep. 806
(Fig. 3)p. 806
+Fig. 4p. 807
Fig. 4p. 807
+5. Loosen the screw connections 1p. 807
+5. Loosen the screw connections 1p. 807
(Fig. 4)p. 807
+6. Lift the longitudinal rubber element with spacer block off the side plate and lay it down safely.p. 807
6. Lift the longitudinal rubber element with spacer block off the side plate and lay it down safely.p. 807
+Fig. 5p. 807
Fig. 5p. 807
+7. Attach the lifting tackle to the second spacer block .p. 807
7. Attach the lifting tackle to the second spacer block .p. 807
+8. Loosen the screw connections 1p. 807
+8. Loosen the screw connections 1p. 807
(Fig. 5)p. 807
+9. Lift the longitudinal rubber element with spacer block off the side plate and lay it down safely.p. 807
9. Lift the longitudinal rubber element with spacer block off the side plate and lay it down safely.p. 807
+Fig. 6p. 807
Fig. 6p. 807
+10. Attach the lifting tackle to the exciter unitp. 807
+10. Attach the lifting tackle to the exciter unitp. 807
(Fig. 6)p. 807
+Fig. 7p. 807
Fig. 7p. 807
+11. Unscrew the fastening screws for the flanged hubp. 807
+11. Unscrew the fastening screws for the flanged hubp. 807
(Fig. 7)p. 807
+12. Unscrew the dummy plug (1) from the flanged hub and screw in fastening screws (forcing screws).p. 807
12. Unscrew the dummy plug (1) from the flanged hub and screw in fastening screws (forcing screws).p. 807
+13. Press the exciter unit out of the drum with forcing screws.p. 807
13. Press the exciter unit out of the drum with forcing screws.p. 807
+Fig. 8p. 808
Fig. 8p. 808
+14. Lift the exciter unit carefully out of the drump. 808
+14. Lift the exciter unit carefully out of the drump. 808
(Fig. 8)p. 808
Right drum sidep. 808
+Fig. 9p. 808
Fig. 9p. 808
+15. Attach lifting tackle to the drive disc with gearbox, travel motor and gearbox holderp. 808
+15. Attach lifting tackle to the drive disc with gearbox, travel motor and gearbox holderp. 808
(Fig. 9)p. 808
+Fig. 10p. 808
Fig. 10p. 808
+16. Disassemble nuts and washersp. 808
+16. Disassemble nuts and washersp. 808
(Fig. 10)p. 808
+Fig. 11p. 808
Fig. 11p. 808
+17. Pull the drive unit out of the drump. 808
+17. Pull the drive unit out of the drump. 808
(Fig. 11)p. 808
+Fig. 12p. 809
Fig. 12p. 809
+18. Check the rubber buffers, replace if necessaryp. 809
+18. Check the rubber buffers, replace if necessaryp. 809
(Fig. 12)p. 809
+Fig. 13p. 809
Fig. 13p. 809
+19. Unscrew the fastening screws from the bearing flangep. 809
+19. Unscrew the fastening screws from the bearing flangep. 809
(Fig. 13)p. 809
+20. Turn in two guide bolts (2) (M20).p. 809
20. Turn in two guide bolts (2) (M20).p. 809
+21. Unscrew the dummy plug (1) from the bearing flange and screw in fastening screws (forcing screws).p. 809
21. Unscrew the dummy plug (1) from the bearing flange and screw in fastening screws (forcing screws).p. 809
+22. Force the bearing flange off the drum using two forcing screws.p. 809
22. Force the bearing flange off the drum using two forcing screws.p. 809
+Fig. 14p. 809
Fig. 14p. 809
+23. Attach the lifting tackle to the bearing flange and lift it off the drump. 809
+23. Attach the lifting tackle to the bearing flange and lift it off the drump. 809
(Fig. 14)p. 809
+Fig. 15p. 809
Fig. 15p. 809
+24. Check cylinder roller bearing 1p. 809
+24. Check cylinder roller bearing 1p. 809
(Fig. 15)p. 809
18.4 Assembling the vibrator unitp. 810
+Fig. 1p. 810
Fig. 1p. 810
+Explorer bearings represent an entirely new performance class in the range of cylinder roller bearings with considerably improved performance parameters with respect to endurance, rotating characteristics and dynamic loading capacity.p. 810
Explorer bearings represent an entirely new performance class in the range of cylinder roller bearings with considerably improved performance parameters with respect to endurance, rotating characteristics and dynamic loading capacity.p. 810
+Inner and outer bearing races are matched to each other and must not be mixed up by mistake.p. 810
Inner and outer bearing races are matched to each other and must not be mixed up by mistake.p. 810
+Mark inner (A)p. 810
(Fig. 1)p. 810
Ensure strict cleanliness.p. 810
+Assembling the exciter shaft (middle)p. 810
Assembling the exciter shaft (middle)p. 810
+Fig. 2 Sectional drawingp. 810
Fig. 2 Sectional drawingp. 810
+1 Outer bearing race with rolls, travel motor sidep. 810
1 Outer bearing race with rolls, travel motor sidep. 810
2 Circlip (inner)p. 810
3 Exciter shaft (middle)p. 810
4 Inner bearing race, travel motor sidep. 810
5 Inner bearing race, vibration motor sidep. 810
6 Circlips (outer)p. 810
7 Outer bearing race with rolls, vibration motor sidep. 810
8 Circlip (inner)p. 810
+Fig. 3p. 810
Fig. 3p. 810
+1. Clean the exciter housing and blow it out with compressed airp. 810
+1. Clean the exciter housing and blow it out with compressed airp. 810
(Fig. 3)p. 810
+Lubricate the bearing seat area.p. 810
Lubricate the bearing seat area.p. 810
+Inner and outer bearing races must not be mixed up by mistake.p. 810
Inner and outer bearing races must not be mixed up by mistake.p. 810
+2. Cool down the outer bearing race (1) to -25°C.p. 810
2. Cool down the outer bearing race (1) to -25°C.p. 810
+3. Press the outer bearing race (1)p. 810
+3. Press the outer bearing race (1)p. 810
(Fig. 2)p. 810
(Fig. 3)p. 810
+Wipe off any ice!p. 810
Wipe off any ice!p. 810
+4. Insert the circlip (2) into the groove (arrow) in the exciter housing.p. 810
4. Insert the circlip (2) into the groove (arrow) in the exciter housing.p. 810
+Fig. 4p. 811
Fig. 4p. 811
+Lubricate the bearing seat areas.p. 811
Lubricate the bearing seat areas.p. 811
+Inner and outer bearing races must not be mixed up by mistake.p. 811
Inner and outer bearing races must not be mixed up by mistake.p. 811
+Danger of burning!p. 811
Danger of burning!p. 811
Wear safety gloves.p. 811
+5. Heat both inner bearing races (4) and (5)p. 811
+5. Heat both inner bearing races (4) and (5)p. 811
(Fig. 4)p. 811
+6. Insert the circlips (6) into the grooves (arrow) in the exciter shaft.p. 811
6. Insert the circlips (6) into the grooves (arrow) in the exciter shaft.p. 811
+Oil the inner bearing races.p. 811
Oil the inner bearing races.p. 811
+Fig. 5p. 811
Fig. 5p. 811
+7. Turn the exciter housing by 180°.p. 811
7. Turn the exciter housing by 180°.p. 811
+8. Attach suitable lifting tackle to the pre-assembled exciter shaft and move it carefully into the exciter housingp. 811
+8. Attach suitable lifting tackle to the pre-assembled exciter shaft and move it carefully into the exciter housingp. 811
(Fig. 5)p. 811
+Fig. 6p. 811
Fig. 6p. 811
+9. Remove the lifting gearp. 811
+9. Remove the lifting gearp. 811
(Fig. 6)p. 811
+Check the bearings.p. 811
Check the bearings.p. 811
+Fig. 7p. 812
Fig. 7p. 812
+Lubricate the bearing seat area.p. 812
Lubricate the bearing seat area.p. 812
+Inner and outer bearing races must not be mixed up by mistake.p. 812
Inner and outer bearing races must not be mixed up by mistake.p. 812
+10. Cool down the outer bearing race (7) to -25°C.p. 812
10. Cool down the outer bearing race (7) to -25°C.p. 812
+11. Press the outer bearing race (7)p. 812
+11. Press the outer bearing race (7)p. 812
(Fig. 7)p. 812
(Fig. 2)p. 812
+12. Insert the circlip (8) into the groove (arrow) in the exciter housing.p. 812
12. Insert the circlip (8) into the groove (arrow) in the exciter housing.p. 812
+Fig. 8p. 812
Fig. 8p. 812
+Wipe off ice and check the bearingsp. 812
+Wipe off ice and check the bearingsp. 812
(Fig. 8)p. 812
Assembling the wheel setp. 813
+Fig. 9p. 813
Fig. 9p. 813
+Lubricate the bearing seat area.p. 813
Lubricate the bearing seat area.p. 813
+13. Cool down the outer bearing race 13p. 813
+13. Cool down the outer bearing race 13p. 813
(Fig. 9)p. 813
(Fig. 16)p. 813
+14. Press the outer bearing race (13) into the exciter housing against the end stop.p. 813
14. Press the outer bearing race (13) into the exciter housing against the end stop.p. 813
+Wipe off any ice!p. 813
Wipe off any ice!p. 813
+15. Insert circlip (14)p. 813
+15. Insert circlip (14)p. 813
(Fig. 9)p. 813
(Fig. 16)p. 813
+Fig. 10 Sectional drawingp. 813
Fig. 10 Sectional drawingp. 813
+Assemble the intermediate gearp. 813
+Assemble the intermediate gearp. 813
(Fig. 10)p. 813
+1 Stub axlep. 813
1 Stub axlep. 813
2 Circlip (inner)p. 813
3 Intermediate gearp. 813
4 Inner bearing racep. 813
5 Spacer ringp. 813
6 Bearing racep. 813
7 Outer bearing race with rollsp. 813
+Fig. 11p. 813
Fig. 11p. 813
+16. Insert the spacer ring (5)p. 813
+16. Insert the spacer ring (5)p. 813
(Fig. 11)p. 813
+17. Assemble the bearing race (6).p. 813
17. Assemble the bearing race (6).p. 813
+Fig. 12p. 813
Fig. 12p. 813
+Oil the intermediate gear.p. 813
Oil the intermediate gear.p. 813
+18. Cool down the outer bearing race 7p. 813
+18. Cool down the outer bearing race 7p. 813
(Fig. 12)p. 813
+19. Press the outer bearing race (7) into the intermediate gear (3) against the end stop.p. 813
19. Press the outer bearing race (7) into the intermediate gear (3) against the end stop.p. 813
+Wipe off any ice!p. 813
Wipe off any ice!p. 813
+20. Insert the circlip (2) into the groove in the intermediate gear (3).p. 813
20. Insert the circlip (2) into the groove in the intermediate gear (3).p. 813
+Fig. 13p. 814
Fig. 13p. 814
+21. Push in the pre-assembled intermediate gear (3)p. 814
+21. Push in the pre-assembled intermediate gear (3)p. 814
(Fig. 13)p. 814
+Fig. 14p. 814
Fig. 14p. 814
+Oil the stub axle.p. 814
Oil the stub axle.p. 814
+Danger of burning!p. 814
Danger of burning!p. 814
Wear safety gloves.p. 814
+22. Heat the inner bearing race 4p. 814
+22. Heat the inner bearing race 4p. 814
(Fig. 14)p. 814
+Oil the inner bearing race.p. 814
Oil the inner bearing race.p. 814
+Fig. 15p. 814
Fig. 15p. 814
+23. Assemble the pre-assembled stub axlep. 814
+23. Assemble the pre-assembled stub axlep. 814
(Fig. 15)p. 814
+24. Turn in the socket head cap screws (8).p. 814
24. Turn in the socket head cap screws (8).p. 814
+Do not yet tighten the socket head cap screws.p. 814
Do not yet tighten the socket head cap screws.p. 814
+25. Check the bearings.p. 814
25. Check the bearings.p. 814
+The intermediate gear should be light to turn.p. 814
The intermediate gear should be light to turn.p. 814
Assembling the pinionp. 815
+Fig. 16 Sectional drawingp. 815
Fig. 16 Sectional drawingp. 815
+1 Inner bearing racep. 815
1 Inner bearing racep. 815
2 Pinionp. 815
3 Circlip (outer)p. 815
4 Feather keyp. 815
5 Gearp. 815
6 Circlip (outer)p. 815
7 Inner bearing race, bearing flangep. 815
8 Circlip (outer)p. 815
9 Outer bearing race with rolls, bearing flangep. 815
10 Bearing flangep. 815
11 Circlip (inner)p. 815
12 Circlip (inner)p. 815
+13 Outer bearing race with rolls, see alsop. 815
(Fig. 9)p. 815
+14 Circlip (inner), see alsop. 815
(Fig. 9)p. 815
+Fig. 17p. 815
Fig. 17p. 815
+Lubricate the bearing seat area.p. 815
Lubricate the bearing seat area.p. 815
+Danger of burning!p. 815
Danger of burning!p. 815
Wear safety gloves.p. 815
+26. Heat the inner bearing race 1p. 815
+26. Heat the inner bearing race 1p. 815
(Fig. 17)p. 815
+27. Insert the circlip (3) into the groove in the pinion (2).p. 815
27. Insert the circlip (3) into the groove in the pinion (2).p. 815
+Fig. 18p. 815
Fig. 18p. 815
+28. Insert the feather key (4)p. 815
+28. Insert the feather key (4)p. 815
(Fig. 18)p. 815
+29. Push on gear (5).p. 815
29. Push on gear (5).p. 815
+Fig. 19p. 816
Fig. 19p. 816
+30. Insert the circlip (6) into the groove in the pinion (2)p. 816
+30. Insert the circlip (6) into the groove in the pinion (2)p. 816
(Fig. 19)p. 816
+Fig. 20p. 816
Fig. 20p. 816
+Lubricate the bearing seat area.p. 816
Lubricate the bearing seat area.p. 816
+Danger of burning!p. 816
Danger of burning!p. 816
Wear safety gloves.p. 816
+31. Heat the inner bearing race 7p. 816
+31. Heat the inner bearing race 7p. 816
(Fig. 20)p. 816
+32. Insert the circlip (8) into the groove in the pinion (2).p. 816
32. Insert the circlip (8) into the groove in the pinion (2).p. 816
+Fig. 21p. 816
Fig. 21p. 816
+Oil the inner bearing races.p. 816
Oil the inner bearing races.p. 816
+33. Assemble the pre-assembled pinionp. 816
+33. Assemble the pre-assembled pinionp. 816
(Fig. 21)p. 816
+Fig. 22p. 816
Fig. 22p. 816
+34. Insert the circlip (11) into the groove in the bearing flange (10)p. 816
+34. Insert the circlip (11) into the groove in the bearing flange (10)p. 816
(Fig. 22)p. 816
+Lubricate the bearing seat area.p. 816
Lubricate the bearing seat area.p. 816
+35. Cool down the outer bearing race (9) to -25°C.p. 816
35. Cool down the outer bearing race (9) to -25°C.p. 816
+36. Press the outer bearing race (9) into the bearing flange (10) against the end stop.p. 816
36. Press the outer bearing race (9) into the bearing flange (10) against the end stop.p. 816
+Wipe off any ice!p. 816
Wipe off any ice!p. 816
+37. Insert the circlip (12) into the groove in the bearing flange (10).p. 816
37. Insert the circlip (12) into the groove in the bearing flange (10).p. 816
+Fig. 23p. 817
Fig. 23p. 817
+38. Mount the pre-assembled bearing flangep. 817
+38. Mount the pre-assembled bearing flangep. 817
(Fig. 23)p. 817
(Fig. 16)p. 817
+39. Turn in the socket head cap screws (1).p. 817
39. Turn in the socket head cap screws (1).p. 817
+Do not yet tighten the socket head cap screws.p. 817
Do not yet tighten the socket head cap screws.p. 817
+Check the bearings.p. 817
Check the bearings.p. 817
Intermediate gear and pinion should be light to turn.p. 817
+Fig. 24p. 817
Fig. 24p. 817
+40. Assemble the gear (1), turn in the socket head cap screws (2)p. 817
+40. Assemble the gear (1), turn in the socket head cap screws (2)p. 817
(Fig. 24)p. 817
+Do not yet tighten the socket head cap screws.p. 817
Do not yet tighten the socket head cap screws.p. 817
+41. Check the bearings.p. 817
41. Check the bearings.p. 817
+Intermediate gear, pinion and exciter shaft should be light to turn.p. 817
Intermediate gear, pinion and exciter shaft should be light to turn.p. 817
+Fig. 25p. 817
Fig. 25p. 817
+42. Turn the guide bolt M27X500 into the exciter shaftp. 817
+42. Turn the guide bolt M27X500 into the exciter shaftp. 817
(Fig. 25)p. 817
+Fig. 26p. 817
Fig. 26p. 817
+43. Tighten all socket head cap screws (1)p. 817
+43. Tighten all socket head cap screws (1)p. 817
(Fig. 26)p. 817
+Tightening torque 75Nm.p. 817
Tightening torque 75Nm.p. 817
+Fig. 27p. 818
Fig. 27p. 818
+44. Turn in three guide bolts M18X1,5X 300 mmp. 818
+44. Turn in three guide bolts M18X1,5X 300 mmp. 818
(Fig. 27)p. 818
Assembling the (right) exciter housingp. 819
+Fig. 28 Sectional drawingp. 819
Fig. 28 Sectional drawingp. 819
+1 Radial sealp. 819
1 Radial sealp. 819
2 Outer bearing race with rollsp. 819
3 Circlip (inner)p. 819
4 Inner bearing racep. 819
5 Inner bearing racep. 819
6 Exciter shaft (right)p. 819
7 Circlips (outer)p. 819
8 Inner racep. 819
+9 O-ring, assembly seep. 819
(Fig. 129)p. 819
10 Outer bearing race with rollsp. 819
11 Circlips (inner)p. 819
12 Gearp. 819
13 Socket head cap screwsp. 819
+Fig. 29p. 819
Fig. 29p. 819
+45. Clean the exciter housing and blow it out with compressed airp. 819
+45. Clean the exciter housing and blow it out with compressed airp. 819
(Fig. 29)p. 819
+Fig. 30p. 819
Fig. 30p. 819
+46. Drive the radial seal (1)p. 819
+46. Drive the radial seal (1)p. 819
(Fig. 30)p. 819
(Fig. 28)p. 819
+Sealing lips pointing up.p. 819
Sealing lips pointing up.p. 819
+Fig. 31p. 820
Fig. 31p. 820
+Lubricate the bearing seat area.p. 820
Lubricate the bearing seat area.p. 820
+Inner and outer bearing races must not be mixed up by mistake.p. 820
Inner and outer bearing races must not be mixed up by mistake.p. 820
+47. Cool down the outer bearing race (2) to -25°C.p. 820
47. Cool down the outer bearing race (2) to -25°C.p. 820
+48. Press the outer bearing race (2)p. 820
+48. Press the outer bearing race (2)p. 820
(Fig. 31)p. 820
(Fig. 28)p. 820
+Wipe off any ice!p. 820
Wipe off any ice!p. 820
+49. Insert circlip (3) into the groove in the exciter housing.p. 820
49. Insert circlip (3) into the groove in the exciter housing.p. 820
+Fig. 32p. 820
Fig. 32p. 820
+Lubricate the bearing seat areas.p. 820
Lubricate the bearing seat areas.p. 820
+Inner and outer bearing races must not be mixed up by mistake.p. 820
Inner and outer bearing races must not be mixed up by mistake.p. 820
+Danger of burning!p. 820
Danger of burning!p. 820
Wear safety gloves.p. 820
+50. Heat the inner bearing races 4p. 820
+50. Heat the inner bearing races 4p. 820
(Fig. 32)p. 820
+51. Heat the inner bearing race (8) up to 80°C and slide it over the exciter shaft (6) against the shoulder.p. 820
51. Heat the inner bearing race (8) up to 80°C and slide it over the exciter shaft (6) against the shoulder.p. 820
+52. Insert the circlips (7) into the grooves in the exciter shaft.p. 820
52. Insert the circlips (7) into the grooves in the exciter shaft.p. 820
+Fig. 33p. 820
Fig. 33p. 820
+53. Grease the splined shaft and the grease chambers with Optipitp. 820
+53. Grease the splined shaft and the grease chambers with Optipitp. 820
(Fig. 33)p. 820
+Oil the inner bearing races.p. 820
Oil the inner bearing races.p. 820
+Fig. 34p. 821
Fig. 34p. 821
+54. Insert the pre-assembled exciter shaft carefully into the exciter housingp. 821
+54. Insert the pre-assembled exciter shaft carefully into the exciter housingp. 821
(Fig. 34)p. 821
+55. Check the bearings.p. 821
55. Check the bearings.p. 821
+Fig. 35p. 821
Fig. 35p. 821
+Lubricate the bearing seat area.p. 821
Lubricate the bearing seat area.p. 821
+Inner and outer bearing races must not be mixed up by mistake.p. 821
Inner and outer bearing races must not be mixed up by mistake.p. 821
+56. Insert circlip (11.1) into the groove in the exciter housingp. 821
+56. Insert circlip (11.1) into the groove in the exciter housingp. 821
(Fig. 35)p. 821
+57. Cool down the outer bearing race (10) to -25°C.p. 821
57. Cool down the outer bearing race (10) to -25°C.p. 821
+58. Press the outer bearing race (10) (see alsop. 821
+58. Press the outer bearing race (10) (see alsop. 821
(Fig. 28)p. 821
+59. Insert circlip (11.2) into the groove in the exciter housing.p. 821
59. Insert circlip (11.2) into the groove in the exciter housing.p. 821
+Fig. 36p. 821
Fig. 36p. 821
+Wipe off any ice!p. 821
Wipe off any ice!p. 821
+60. Check the bearings.p. 821
60. Check the bearings.p. 821
+Fig. 37p. 821
Fig. 37p. 821
+61. Assemble the gear (12), turn in the socket head cap screws (13)p. 821
+61. Assemble the gear (12), turn in the socket head cap screws (13)p. 821
(Fig. 37)p. 821
+Fig. 38p. 822
Fig. 38p. 822
+62. Turn the guide bolt M27X500 into the exciter shaftp. 822
+62. Turn the guide bolt M27X500 into the exciter shaftp. 822
(Fig. 38)p. 822
+63. Tighten the socket head cap screws (13).p. 822
63. Tighten the socket head cap screws (13).p. 822
+Tightening torque 75Nm.p. 822
Tightening torque 75Nm.p. 822
+64. Turn in eye bolt (A).p. 822
64. Turn in eye bolt (A).p. 822
+Fig. 39p. 822
Fig. 39p. 822
+65. Turn the exciter housing by 180°and attach suitable lifting tacklep. 822
+65. Turn the exciter housing by 180°and attach suitable lifting tacklep. 822
(Fig. 39)p. 822
+Fig. 40p. 822
Fig. 40p. 822
+66. Carefully Join the pre-assembled exciter units togetherp. 822
+66. Carefully Join the pre-assembled exciter units togetherp. 822
(Fig. 40)p. 822
+The guide bolts (1) must be in line.p. 822
The guide bolts (1) must be in line.p. 822
+67. Remove the lifting gear.p. 822
67. Remove the lifting gear.p. 822
+68. Unscrew the guide bolts (2) and turn in the socket head cap screws with washers (3).p. 822
68. Unscrew the guide bolts (2) and turn in the socket head cap screws with washers (3).p. 822
+Tighten the socket head cap screws 2X crosswise.p. 822
Tighten the socket head cap screws 2X crosswise.p. 822
+Tightening torque 466 Nmp. 822
Tightening torque 466 Nmp. 822
+Fig. 41p. 823
Fig. 41p. 823
+69. Insert the feather key (1)p. 823
+69. Insert the feather key (1)p. 823
(Fig. 41)p. 823
Assembling the (left) exciter housingp. 824
+Fig. 42 Sectional drawingp. 824
Fig. 42 Sectional drawingp. 824
+1 not usedp. 824
1 not usedp. 824
2 Outer bearing race with rollsp. 824
3 Circlip (inner)p. 824
4 Inner bearing racep. 824
5 Inner bearing racep. 824
6 Exciter shaft (left)p. 824
7 Circlips (outer)p. 824
8 not usedp. 824
9 not usedp. 824
10 Outer bearing race with rollsp. 824
11 Circlips (inner)p. 824
+Fig. 43p. 824
Fig. 43p. 824
+70. Clean the exciter housing and blow it out with compressed airp. 824
+70. Clean the exciter housing and blow it out with compressed airp. 824
(Fig. 43)p. 824
+Fig. 44p. 824
Fig. 44p. 824
+Lubricate the bearing seat area.p. 824
Lubricate the bearing seat area.p. 824
+Inner and outer bearing races must not be mixed up by mistake.p. 824
Inner and outer bearing races must not be mixed up by mistake.p. 824
+71. Cool down the outer bearing race (2) to -25°C.p. 824
71. Cool down the outer bearing race (2) to -25°C.p. 824
+72. Press the outer bearing race (2)p. 824
+72. Press the outer bearing race (2)p. 824
(Fig. 44)p. 824
(Fig. 42)p. 824
+Wipe off any ice!p. 824
Wipe off any ice!p. 824
+73. Insert circlip (3) into the groove in the exciter housing.p. 824
73. Insert circlip (3) into the groove in the exciter housing.p. 824
+Fig. 45p. 825
Fig. 45p. 825
+Lubricate the bearing seat areas.p. 825
Lubricate the bearing seat areas.p. 825
+Inner and outer bearing races must not be mixed up by mistake.p. 825
Inner and outer bearing races must not be mixed up by mistake.p. 825
+Danger of burning!p. 825
Danger of burning!p. 825
Wear safety gloves.p. 825
+74. Heat the inner bearing races (4) and (5)p. 825
+74. Heat the inner bearing races (4) and (5)p. 825
(Fig. 45)p. 825
+75. Insert the circlips (7) into the grooves in the exciter shaft.p. 825
75. Insert the circlips (7) into the grooves in the exciter shaft.p. 825
+Fig. 46p. 825
Fig. 46p. 825
+76. Grease the splined shaft and the grease chambers with Optipitp. 825
+76. Grease the splined shaft and the grease chambers with Optipitp. 825
(Fig. 46)p. 825
+Oil the inner bearing races.p. 825
Oil the inner bearing races.p. 825
+Fig. 47p. 825
Fig. 47p. 825
+77. Insert the pre-assembled exciter shaft carefully into the exciter housingp. 825
+77. Insert the pre-assembled exciter shaft carefully into the exciter housingp. 825
(Fig. 47)p. 825
+78. Check the bearings.p. 825
78. Check the bearings.p. 825
+Fig. 48p. 826
Fig. 48p. 826
+Lubricate the bearing seat area.p. 826
Lubricate the bearing seat area.p. 826
+Inner and outer bearing races must not be mixed up by mistake.p. 826
Inner and outer bearing races must not be mixed up by mistake.p. 826
+79. Insert circlip (11.2) into the groove in the exciter housingp. 826
+79. Insert circlip (11.2) into the groove in the exciter housingp. 826
(Fig. 48)p. 826
+80. Cool down the outer bearing race (10) to -25°C.p. 826
80. Cool down the outer bearing race (10) to -25°C.p. 826
+81. Press the outer bearing race (10) (see alsop. 826
+81. Press the outer bearing race (10) (see alsop. 826
(Fig. 42)p. 826
+82. Insert circlip (11.1) into the groove in the exciter housing.p. 826
82. Insert circlip (11.1) into the groove in the exciter housing.p. 826
+Fig. 49p. 826
Fig. 49p. 826
+83. Check the bearingsp. 826
+83. Check the bearingsp. 826
(Fig. 49)p. 826
+Wipe off any ice!p. 826
Wipe off any ice!p. 826
+Fig. 50p. 826
Fig. 50p. 826
+84. Turn the guide bolt M27X500 into the exciter shaftp. 826
+84. Turn the guide bolt M27X500 into the exciter shaftp. 826
(Fig. 50)p. 826
+85. Turn in eye bolt (A).p. 826
85. Turn in eye bolt (A).p. 826
+Fig. 51p. 826
Fig. 51p. 826
+86. Turn the exciter housing by 180°and attach suitable lifting tacklep. 826
+86. Turn the exciter housing by 180°and attach suitable lifting tacklep. 826
(Fig. 51)p. 826
+Fig. 52p. 827
Fig. 52p. 827
+87. Oil and insert the coupling shaft (1)p. 827
+87. Oil and insert the coupling shaft (1)p. 827
(Fig. 52)p. 827
+88. Turn in three guide bolts M18X1,5X 300 mm.p. 827
88. Turn in three guide bolts M18X1,5X 300 mm.p. 827
+Fig. 53p. 827
Fig. 53p. 827
+89. Carefully join the pre-assembled exciter units togetherp. 827
+89. Carefully join the pre-assembled exciter units togetherp. 827
(Fig. 53)p. 827
+The guide bolts (1) must be in line.p. 827
The guide bolts (1) must be in line.p. 827
+90. Remove the lifting gear.p. 827
90. Remove the lifting gear.p. 827
+91. Unscrew the guide bolts (2) and turn in the socket head cap screws with washers (3).p. 827
91. Unscrew the guide bolts (2) and turn in the socket head cap screws with washers (3).p. 827
+Tighten the socket head cap screws 2X crosswise.p. 827
Tighten the socket head cap screws 2X crosswise.p. 827
+Tightening torque 466 Nmp. 827
Tightening torque 466 Nmp. 827
Assembling the weightsp. 828
+Fig. 54p. 828
Fig. 54p. 828
+1 Eccentric weights, outerp. 828
1 Eccentric weights, outerp. 828
2 Eccentric weight, middlep. 828
3 Additional weight only BW226p. 828
+Fig. 55p. 828
Fig. 55p. 828
+92. Turn in the eye bolt (A) and attach lifting gear to the eccentric weight (outer)p. 828
+92. Turn in the eye bolt (A) and attach lifting gear to the eccentric weight (outer)p. 828
(Fig. 55)p. 828
+Fig. 56p. 828
Fig. 56p. 828
+Danger of squashing!p. 828
Danger of squashing!p. 828
+93. Insert both eccentric weights (outer) over guide bolts, one after the otherp. 828
+93. Insert both eccentric weights (outer) over guide bolts, one after the otherp. 828
(Fig. 56)p. 828
+Do not yet unscrew the eye bolts (A)!p. 828
Do not yet unscrew the eye bolts (A)!p. 828
The eye bolts prevent the eccentric weights from swinging over.p. 828
+94. Remove the guide bolt (1) and replace it with socket head cap screw and washer.p. 828
94. Remove the guide bolt (1) and replace it with socket head cap screw and washer.p. 828
+95. Remove the guide bolt (2) and replace it with socket head cap screw and washer.p. 828
95. Remove the guide bolt (2) and replace it with socket head cap screw and washer.p. 828
+Fig. 57p. 829
Fig. 57p. 829
+96. Turn in the eye bolt (B) and attach lifting gear to the eccentric weight (inner)p. 829
+96. Turn in the eye bolt (B) and attach lifting gear to the eccentric weight (inner)p. 829
(Fig. 57)p. 829
+Fig. 58p. 829
Fig. 58p. 829
+97. Insert the (inner) eccentric weight over guide bolts (1)p. 829
+97. Insert the (inner) eccentric weight over guide bolts (1)p. 829
(Fig. 58)p. 829
+98. Unscrew the guide bolts (1), turn in two socket head cap screws with washers.p. 829
98. Unscrew the guide bolts (1), turn in two socket head cap screws with washers.p. 829
+Do not yet unscrew the eye bolt (B)p. 829
+Do not yet unscrew the eye bolt (B)p. 829
(Fig. 58)p. 829
(Fig. 59)p. 829
The eye bolt prevents the eccentric weight from swinging over.p. 829
+Fig. 59p. 829
Fig. 59p. 829
+99. Attach a manual screwer (1)p. 829
+99. Attach a manual screwer (1)p. 829
(Fig. 59)p. 829
+The manual screwer is equipped with a ratchet. Short ratchet movements allow very effective working.p. 829
The manual screwer is equipped with a ratchet. Short ratchet movements allow very effective working.p. 829
+Fig. 60p. 829
Fig. 60p. 829
+100. Turn the exciter housing aroundp. 829
+100. Turn the exciter housing aroundp. 829
(Fig. 60)p. 829
+101. Unscrew all eye bolts.p. 829
101. Unscrew all eye bolts.p. 829
+102. Assemble six additional weights with screws and washers.p. 829
102. Assemble six additional weights with screws and washers.p. 829
+Additional weight only BW 226.p. 829
Additional weight only BW 226.p. 829
+Fig. 61p. 830
Fig. 61p. 830
+103. Assemble spacer blocks (1) with socket head cap screws and washers (2)p. 830
+103. Assemble spacer blocks (1) with socket head cap screws and washers (2)p. 830
(Fig. 61)p. 830
+Tightening torque 466Nm.p. 830
Tightening torque 466Nm.p. 830
Bearing flangep. 831
+Fig. 62p. 831
Fig. 62p. 831
+Lubricate the bearing seat areas.p. 831
Lubricate the bearing seat areas.p. 831
+Inner and outer bearing races must not be mixed up by mistake.p. 831
Inner and outer bearing races must not be mixed up by mistake.p. 831
+Danger of burning!p. 831
Danger of burning!p. 831
Wear safety gloves.p. 831
+104. Heat inner bearing racep. 831
+104. Heat inner bearing racep. 831
(Fig. 62)p. 831
+Fig. 63p. 831
Fig. 63p. 831
+105. Insert the circlipp. 831
+105. Insert the circlipp. 831
(Fig. 63)p. 831
+Fig. 64p. 831
Fig. 64p. 831
+Lubricate the bearing seat area.p. 831
Lubricate the bearing seat area.p. 831
+Inner and outer bearing races must not be mixed up by mistake.p. 831
Inner and outer bearing races must not be mixed up by mistake.p. 831
+106. Cool down the outer bearing race to -25°C.p. 831
106. Cool down the outer bearing race to -25°C.p. 831
+107. Press the outer bearing race (3) into the bearing flange against the end stopp. 831
+107. Press the outer bearing race (3) into the bearing flange against the end stopp. 831
(Fig. 64)p. 831
+Fig. 65p. 832
Fig. 65p. 832
+108. Insert the circlip (6)p. 832
+108. Insert the circlip (6)p. 832
(Fig. 65)p. 832
+Wipe off any ice!p. 832
Wipe off any ice!p. 832
+Fig. 66p. 832
Fig. 66p. 832
+109. Attach the radial seal (7)p. 832
+109. Attach the radial seal (7)p. 832
(Fig. 66)p. 832
+Sealing lips pointing up.p. 832
Sealing lips pointing up.p. 832
+Fig. 67p. 832
Fig. 67p. 832
+110. Press the radial seal in until it bottomsp. 832
+110. Press the radial seal in until it bottomsp. 832
+The tapered roller bearing set must only be assembled with the associated intermediate rings (C)p. 834
+The tapered roller bearing set must only be assembled with the associated intermediate rings (C)p. 834
(Fig. 71)p. 834
(Fig. 70)p. 834
Replacement of individual bearings or intermediate rings (C) is not permitted!p. 834
Inner bearing races with rolls (8) and outer bearing races (A) must not be mixed up by mistake.p. 834
+Fig. 72p. 834
Fig. 72p. 834
+Lubricate the bearing seat areas.p. 834
Lubricate the bearing seat areas.p. 834
+Inner and outer bearing races must not be mixed up by mistake.p. 834
Inner and outer bearing races must not be mixed up by mistake.p. 834
+Danger of burning!p. 834
Danger of burning!p. 834
Wear safety gloves.p. 834
+113. Heat inner bearing race (4)p. 834
+113. Heat inner bearing race (4)p. 834
(Fig. 72)p. 834
+Fig. 73p. 835
Fig. 73p. 835
+114. Insert the circlip (5)p. 835
+114. Insert the circlip (5)p. 835
(Fig. 73)p. 835
+Fig. 74p. 835
Fig. 74p. 835
+Lubricate the bearing seat area.p. 835
Lubricate the bearing seat area.p. 835
+Inner and outer bearing races must not be mixed up by mistake.p. 835
Inner and outer bearing races must not be mixed up by mistake.p. 835
+115. Cool down the outer bearing race to -25°C.p. 835
115. Cool down the outer bearing race to -25°C.p. 835
+116. Press the outer bearing race (3) into the bearing flange against the end stopp. 835
+116. Press the outer bearing race (3) into the bearing flange against the end stopp. 835
(Fig. 74)p. 835
+Fig. 75p. 835
Fig. 75p. 835
+117. Insert the circlip (6)p. 835
+117. Insert the circlip (6)p. 835
(Fig. 75)p. 835
+Wipe off any ice!p. 835
Wipe off any ice!p. 835
+Fig. 76p. 835
Fig. 76p. 835
+118. Attach the radial seal (7)p. 835
+118. Attach the radial seal (7)p. 835
(Fig. 76)p. 835
+Sealing lips pointing up.p. 835
Sealing lips pointing up.p. 835
+Fig. 77p. 836
Fig. 77p. 836
+119. Press the radial seal in until it bottomsp. 836
+119. Press the radial seal in until it bottomsp. 836
(Fig. 77)p. 836
+Fig. 78p. 836
Fig. 78p. 836
+Grease the O-ring.p. 836
Grease the O-ring.p. 836
+120. Assemble the O-ring (9)p. 836
+120. Assemble the O-ring (9)p. 836
(Fig. 78)p. 836
+Fig. 79p. 836
Fig. 79p. 836
+121. Fill the bearing with greasep. 836
+121. Fill the bearing with greasep. 836
(Fig. 79)p. 836
+Fig. 80p. 836
Fig. 80p. 836
+122. Turn the flanged hub.p. 836
122. Turn the flanged hub.p. 836
+123. Assemble the magnetic plugs with seal rings (A)p. 836
+123. Assemble the magnetic plugs with seal rings (A)p. 836
(Fig. 80)p. 836
+124. Turn in dummy plugs.p. 836
124. Turn in dummy plugs.p. 836
+Fig. 81p. 837
Fig. 81p. 837
+125. Assemble the assembly ringsp. 837
+125. Assemble the assembly ringsp. 837
(Fig. 81)p. 837
+Fig. 82p. 837
Fig. 82p. 837
+126. Attach the mechanical seal (8.1) to the assembly tool.p. 837
+126. Attach the mechanical seal (8.1) to the assembly tool.p. 837
(Fig. 82)p. 837
+Fig. 83p. 837
Fig. 83p. 837
+127. Insert the mechanical seal (8.1) into the flanged hubp. 837
+127. Insert the mechanical seal (8.1) into the flanged hubp. 837
(Fig. 83)p. 837
+Fig. 84p. 837
Fig. 84p. 837
+128. Remove the assembly tool and check the mechanical seal for correct fitp. 837
+128. Remove the assembly tool and check the mechanical seal for correct fitp. 837
(Fig. 84)p. 837
+Fig. 85p. 838
Fig. 85p. 838
+129. Grease the mechanical seal ring and fill the space between mechanical seal and flanged hub with greasep. 838
+129. Grease the mechanical seal ring and fill the space between mechanical seal and flanged hub with greasep. 838
(Fig. 85)p. 838
+Fig. 86p. 838
Fig. 86p. 838
+Lubricate the bearing seat area.p. 838
Lubricate the bearing seat area.p. 838
+130. Cool down the outer bearing race to -25°C.p. 838
130. Cool down the outer bearing race to -25°C.p. 838
+131. Press the outer bearing race (B) into the bearing platep. 838
+131. Press the outer bearing race (B) into the bearing platep. 838
(Fig. 86)p. 838
+Wipe off any ice!p. 838
Wipe off any ice!p. 838
+132. Assemble plug (A).p. 838
132. Assemble plug (A).p. 838
+Fig. 87p. 838
Fig. 87p. 838
+133. Mark the side plate with a center punch to secure the outer bearing race (B) against moving.p. 838
+133. Mark the side plate with a center punch to secure the outer bearing race (B) against moving.p. 838
(Fig. 87)p. 838
+Fig. 88p. 838
Fig. 88p. 838
+134. Attach the mechanical seal (8.2) to the assembly toolp. 838
+134. Attach the mechanical seal (8.2) to the assembly toolp. 838
(Fig. 88)p. 838
+Fig. 89p. 839
Fig. 89p. 839
+135. Insert the mechanical seal (8.2) into the sdie platep. 839
+135. Insert the mechanical seal (8.2) into the sdie platep. 839
(Fig. 89)p. 839
+136. Remove the assembly tool and check the mechanical seal for correct fit .p. 839
136. Remove the assembly tool and check the mechanical seal for correct fit .p. 839
+Fig. 90p. 839
Fig. 90p. 839
+137. Attach the lifting tackle to the side plate (2)p. 839
+137. Attach the lifting tackle to the side plate (2)p. 839
(Fig. 90)p. 839
+138. Slide the side plate over the flanged hub (1).p. 839
138. Slide the side plate over the flanged hub (1).p. 839
+Fig. 91p. 839
Fig. 91p. 839
+139. Brush some grease on the collar of the side platep. 839
+139. Brush some grease on the collar of the side platep. 839
(Fig. 91)p. 839
+Fig. 92p. 839
Fig. 92p. 839
+Inner and outer bearing races must not be mixed up by mistake.p. 839
Inner and outer bearing races must not be mixed up by mistake.p. 839
+Danger of burning!p. 839
Danger of burning!p. 839
Wear safety gloves.p. 839
+140. Heat the inner bearing race (11) of the tapered roller bearing set up to 80 °C and slide it on against the stopp. 839
+140. Heat the inner bearing race (11) of the tapered roller bearing set up to 80 °C and slide it on against the stopp. 839
(Fig. 92)p. 839
+141. Fill the space between inner race and side plate collar with grease.p. 839
141. Fill the space between inner race and side plate collar with grease.p. 839
+Fig. 93p. 840
Fig. 93p. 840
+Inner and outer bearing races must not be mixed up by mistake.p. 840
Inner and outer bearing races must not be mixed up by mistake.p. 840
+142. Cool down the outer bearing race (10) of the tapered roller bearing set up to -25 °C and press it in against the stop.p. 840
+142. Cool down the outer bearing race (10) of the tapered roller bearing set up to -25 °C and press it in against the stop.p. 840
(Fig. 93)p. 840
+Wipe off any ice!p. 840
Wipe off any ice!p. 840
+Fig. 94p. 840
Fig. 94p. 840
+143. Insert the two matching intermediate rings (12) of the tapered roller bearing setp. 840
+143. Insert the two matching intermediate rings (12) of the tapered roller bearing setp. 840
(Fig. 94)p. 840
+144. Fill the chambers with grease.p. 840
144. Fill the chambers with grease.p. 840
+Fig. 95p. 840
Fig. 95p. 840
+Inner and outer bearing races must not be mixed up by mistake.p. 840
Inner and outer bearing races must not be mixed up by mistake.p. 840
+145. Cool down the outer bearing race (13) of the tapered roller bearing set up to -25 °C and press it in against the stopp. 840
+145. Cool down the outer bearing race (13) of the tapered roller bearing set up to -25 °C and press it in against the stopp. 840
(Fig. 95)p. 840
+Wipe off any ice!p. 840
Wipe off any ice!p. 840
+Fig. 96p. 840
Fig. 96p. 840
+146. Insert the spacer ring (15)p. 840
+146. Insert the spacer ring (15)p. 840
(Fig. 96)p. 840
+Fig. 97p. 841
Fig. 97p. 841
+147. Remove the assembly ringsp. 841
+147. Remove the assembly ringsp. 841
(Fig. 97)p. 841
+During assembly rotate the side plate only to one direction.p. 841
During assembly rotate the side plate only to one direction.p. 841
+Fig. 98p. 841
Fig. 98p. 841
+Inner and outer bearing races must not be mixed up by mistake.p. 841
Inner and outer bearing races must not be mixed up by mistake.p. 841
+Danger of burning!p. 841
Danger of burning!p. 841
Wear safety gloves.p. 841
+148. Heat the inner bearing race (14) of the tapered roller bearing set up to 80 °C and slide it on against the stopp. 841
+148. Heat the inner bearing race (14) of the tapered roller bearing set up to 80 °C and slide it on against the stopp. 841
(Fig. 98)p. 841
+Fig. 99p. 841
Fig. 99p. 841
+149. Insert the circlip (16) into the groovep. 841
+149. Insert the circlip (16) into the groovep. 841
(Fig. 99)p. 841
+Fig. 100p. 841
Fig. 100p. 841
+150. Fasten the clamping ring (17) with socket head cap screws (18)p. 841
+150. Fasten the clamping ring (17) with socket head cap screws (18)p. 841
(Fig. 100)p. 841
+Follow the procedure described next to tighten the screws:p. 841
Follow the procedure described next to tighten the screws:p. 841
During assembly rotate the side plate only to one direction.p. 841
1) Tighten the socket head cap screws (18) crosswise with 80 Nm, then rotate the side plate three times.p. 841
2) Retighten the socket head cap screws (18) crosswise with 100 Nm, rotate the side plate three times.p. 841
3) Retighten the socket head cap screws (18) crosswise with 120 Nm, rotate the side plate three times.p. 842
4) Mark the position of the socket head cap screws (18) to the clamping ring, then loosen one socket head cap screw at a time, screw it back in with Loctite 2701 and tighten it to the mark.p. 842
5) Control: There must be clearance between clamping ring and flanged hub, check with a feeler gauge.p. 842
+Fig. 101p. 842
Fig. 101p. 842
+151. Lubricate with greasep. 842
+151. Lubricate with greasep. 842
(Fig. 101)p. 842
+Fig. 102p. 842
Fig. 102p. 842
+152. Attach the lifting tackle to the pre-assembled unitp. 842
+152. Attach the lifting tackle to the pre-assembled unitp. 842
(Fig. 102)p. 842
+Fig. 103p. 842
Fig. 103p. 842
+153. Lubricate with greasep. 842
+153. Lubricate with greasep. 842
(Fig. 103)p. 842
+Fig. 104p. 843
Fig. 104p. 843
+154. Insert the pre-assembled unit into the exciter housingp. 843
+154. Insert the pre-assembled unit into the exciter housingp. 843
(Fig. 104)p. 843
+Fig. 105p. 843
Fig. 105p. 843
+155. Lubricate the exciter housing with oilp. 843
+155. Lubricate the exciter housing with oilp. 843
(Fig. 105)p. 843
+Fig. 106p. 843
Fig. 106p. 843
+Danger of burning!p. 843
Danger of burning!p. 843
Wear safety gloves.p. 843
+156. Heat the gear up to 80 °C and slide it over the exciter housing.p. 843
+156. Heat the gear up to 80 °C and slide it over the exciter housing.p. 843
(Fig. 106)p. 843
+Mind the feather key (A)p. 843
+Mind the feather key (A)p. 843
(Fig. 105)p. 843
+Fig. 107p. 843
Fig. 107p. 843
+157. Insert the circlipp. 843
+157. Insert the circlipp. 843
(Fig. 107)p. 843
+Fig. 108p. 844
Fig. 108p. 844
+158. Screw in the mechanical lockp. 844
+158. Screw in the mechanical lockp. 844
(Fig. 108)p. 844
+Mechanical lock, vertical amplitude.p. 844
Mechanical lock, vertical amplitude.p. 844
+Fig. 109p. 844
Fig. 109p. 844
+159. Assemble rubber bushing (1) and bolt (2) into gear (3)p. 844
+159. Assemble rubber bushing (1) and bolt (2) into gear (3)p. 844
(Fig. 109)p. 844
+Fig. 110p. 844
Fig. 110p. 844
+Danger of burning!p. 844
Danger of burning!p. 844
Wear safety gloves.p. 844
+160. Heat the inner bearing races up to 80°C and slide over the gear against the shoulder.p. 844
+160. Heat the inner bearing races up to 80°C and slide over the gear against the shoulder.p. 844
(Fig. 110)p. 844
+Fig. 111p. 844
Fig. 111p. 844
+161. Attach the protection ring for assembling the gearp. 844
+161. Attach the protection ring for assembling the gearp. 844
(Fig. 111)p. 844
+Fig. 112p. 845
Fig. 112p. 845
+162. Insert the gear carefully into the bearing in the side platep. 845
+162. Insert the gear carefully into the bearing in the side platep. 845
(Fig. 112)p. 845
+Fig. 113p. 845
Fig. 113p. 845
+Offset the gear by 9 teethp. 845
+Offset the gear by 9 teethp. 845
(Fig. 113)p. 845
+a) Mark on swashing motorp. 845
a) Mark on swashing motorp. 845
b) Middle of tooth on swashing motor = zero positionp. 845
+Fig. 114p. 845
Fig. 114p. 845
+163. Press the gear in until it bottomsp. 845
+163. Press the gear in until it bottomsp. 845
(Fig. 114)p. 845
+Fig. 115p. 845
Fig. 115p. 845
+164. Remove the protection ringp. 845
+164. Remove the protection ringp. 845
(Fig. 115)p. 845
+Fig. 116p. 846
Fig. 116p. 846
+165. Assemble the locking disc (1) with socket head cap screws (2)p. 846
+165. Assemble the locking disc (1) with socket head cap screws (2)p. 846
(Fig. 116)p. 846
+Tightening torque 35Nm.p. 846
Tightening torque 35Nm.p. 846
+Fig. 117p. 846
Fig. 117p. 846
+166. Assemble the cover with a new O-ring (1)p. 846
+166. Assemble the cover with a new O-ring (1)p. 846
(Fig. 117)p. 846
+Assemble the O-ring with some grease.p. 846
Assemble the O-ring with some grease.p. 846
+Fig. 118p. 846
Fig. 118p. 846
+167. Assemble both acceleration transducersp. 846
+167. Assemble both acceleration transducersp. 846
(Fig. 118)p. 846
+Fig. 119p. 846
Fig. 119p. 846
+168. Turn in two guide bolts (1)p. 846
+168. Turn in two guide bolts (1)p. 846
(Fig. 119)p. 846
+169. Assemble the new O-ring (2).p. 846
169. Assemble the new O-ring (2).p. 846
+Assemble the O-ring with some grease.p. 846
Assemble the O-ring with some grease.p. 846
+170. Fill the side plate with grease.p. 846
170. Fill the side plate with grease.p. 846
+Fig. 120p. 847
Fig. 120p. 847
+171. Cool down the outer bearing race (1) to -25°C and press it into the gear cover until it bottomsp. 847
+171. Cool down the outer bearing race (1) to -25°C and press it into the gear cover until it bottomsp. 847
(Fig. 120)p. 847
+172. Assemble circlip (2).p. 847
172. Assemble circlip (2).p. 847
+Wipe off any ice!p. 847
Wipe off any ice!p. 847
+Fig. 121p. 847
Fig. 121p. 847
+173. Use an appropriate assembly mandrel tp knock the seal ring into the gear cover until it bottomsp. 847
+173. Use an appropriate assembly mandrel tp knock the seal ring into the gear cover until it bottomsp. 847
(Fig. 121)p. 847
+Fig. 122p. 847
Fig. 122p. 847
+174. Assemble the gear cover (1) with hexagon screws and washers (2)p. 847
+174. Assemble the gear cover (1) with hexagon screws and washers (2)p. 847
(Fig. 122)p. 847
+175. Remove the guide bolts (2).p. 847
175. Remove the guide bolts (2).p. 847
+Fig. 123p. 847
Fig. 123p. 847
+176. Fill the splined shaft with Optipitp. 847
+176. Fill the splined shaft with Optipitp. 847
(Fig. 123)p. 847
+Fig. 124p. 848
Fig. 124p. 848
+177. Turn the swashing motor againet the left stopp. 848
+177. Turn the swashing motor againet the left stopp. 848
(Fig. 124)p. 848
+178. Unscrew the socket (3).p. 848
178. Unscrew the socket (3).p. 848
+179. Screw in the locking screw (1).p. 848
179. Screw in the locking screw (1).p. 848
+180. Lubricate the splined shaft with Optipit.p. 848
180. Lubricate the splined shaft with Optipit.p. 848
+181. Assemble the new O-ring (2) with grease.p. 848
181. Assemble the new O-ring (2) with grease.p. 848
+Fig. 125p. 848
Fig. 125p. 848
+182. Assemble the swashing motor with radial sealp. 848
+182. Assemble the swashing motor with radial sealp. 848
(Fig. 125)p. 848
+Fig. 126p. 848
Fig. 126p. 848
+183. Fasten the swashing motor with screws and washersp. 848
+183. Fasten the swashing motor with screws and washersp. 848
(Fig. 126)p. 848
+Install the screws with Loctite 243 .p. 848
Install the screws with Loctite 243 .p. 848
+1. Unscrew the locking screw (1) and turn in the hydraulic socket.p. 848
1. Unscrew the locking screw (1) and turn in the hydraulic socket.p. 848
+Fig. 127p. 848
Fig. 127p. 848
+2. Fill the gear with grease, until grease starts to run out from the bore hole (1)p. 848
+2. Fill the gear with grease, until grease starts to run out from the bore hole (1)p. 848
(Fig. 127)p. 848
+3. Turn in the magnetic plugs (2 and 3) with new seal rings.p. 848
3. Turn in the magnetic plugs (2 and 3) with new seal rings.p. 848
+Fig. 128p. 849
Fig. 128p. 849
+4. Unscrew the mechanical lock from the side platesp. 849
+4. Unscrew the mechanical lock from the side platesp. 849
(Fig. 128)p. 849
+5. Screw the magnetic plug back in with a new seal ring.p. 849
5. Screw the magnetic plug back in with a new seal ring.p. 849
+Fig. 129p. 849
Fig. 129p. 849
+6. Insert circlip (1) into the groove in the drive shaftp. 849
+6. Insert circlip (1) into the groove in the drive shaftp. 849
(Fig. 129)p. 849
+7. Fill the drive shaft with Optipit.p. 849
7. Fill the drive shaft with Optipit.p. 849
+8. Lay the new O-ring (9) into the groove in the drive shaft (see alsop. 849
+8. Lay the new O-ring (9) into the groove in the drive shaft (see alsop. 849
(Fig. 28)p. 849
+9. Lubricate the splined shaft with Optipit.p. 849
9. Lubricate the splined shaft with Optipit.p. 849
+Fig. 130p. 849
Fig. 130p. 849
+10. Insert the drive shaftp. 849
+10. Insert the drive shaftp. 849
(Fig. 130)p. 849
+Fig. 131p. 849
Fig. 131p. 849
+11. Cover the motor flange with Hylomarp. 849
+11. Cover the motor flange with Hylomarp. 849
(Fig. 131)p. 849
+1) BW 226p. 849
1) BW 226p. 849
2) BW 213p. 849
+Fig. 132 BW 213p. 850
Fig. 132 BW 213p. 850
+(Fig. 132) BW 213p. 850
+(Fig. 132) BW 213p. 850
(Fig. 132)p. 850
+12. Assemble the motor flange with socket head cap screws and washersp. 850
+12. Assemble the motor flange with socket head cap screws and washersp. 850
(Fig. 132)p. 850
+13. Screw in the bleeding screw (1).p. 850
13. Screw in the bleeding screw (1).p. 850
+14. Turn in twplugs (2).p. 850
14. Turn in twplugs (2).p. 850
+Fig. 133 BW 226p. 850
Fig. 133 BW 226p. 850
+(Fig. 133) BW 226p. 850
+(Fig. 133) BW 226p. 850
(Fig. 133)p. 850
+15. Assemble the motor flange with socket head cap screws and washersp. 850
+15. Assemble the motor flange with socket head cap screws and washersp. 850
(Fig. 132)p. 850
+16. Screw in the bleeding screw (1).p. 850
16. Screw in the bleeding screw (1).p. 850
+Fig. 134p. 850
Fig. 134p. 850
+17. Assemble the seal ring (1)p. 850
+17. Assemble the seal ring (1)p. 850
(Fig. 134)p. 850
+18. Lubricate the splined shaft with Optipit.p. 850
18. Lubricate the splined shaft with Optipit.p. 850
+(Fig. 134) shows vibration motor BW 226p. 850
+(Fig. 134) shows vibration motor BW 226p. 850
(Fig. 134)p. 850
+Fig. 135p. 850
Fig. 135p. 850
+19. Assemble the vibration motor with hexagon screws (1), ball socket (3) and bevelled washers (2)p. 850
+19. Assemble the vibration motor with hexagon screws (1), ball socket (3) and bevelled washers (2)p. 850
(Fig. 135)p. 850
+(Fig. 135) shows vibration motor BW 226p. 850
+(Fig. 135) shows vibration motor BW 226p. 850
(Fig. 135)p. 850
18.5 Installing the exciter unitp. 851
+Fig. 1p. 851
Fig. 1p. 851
+Fitting and contact surfaces of the connection between exciter housing and drum must be absolutely dry and free of grease, oil, paint and conserving agent.p. 851
Fitting and contact surfaces of the connection between exciter housing and drum must be absolutely dry and free of grease, oil, paint and conserving agent.p. 851
+The tapped bores 2p. 851
(Fig. 1)p. 851
+1. Clean the tapped bores (2) on both sides of the drum and blow them out with compressed air.p. 851
1. Clean the tapped bores (2) on both sides of the drum and blow them out with compressed air.p. 851
+2. Clean the contact faces (1) between bearing flange and drum on both sides.p. 851
2. Clean the contact faces (1) between bearing flange and drum on both sides.p. 851
+3. Clean the inner tube in the drum.p. 851
3. Clean the inner tube in the drum.p. 851
Right drum sidep. 851
+Fig. 2p. 851
Fig. 2p. 851
+4. Check cylinder roller bearing 1p. 851
+4. Check cylinder roller bearing 1p. 851
(Fig. 2)p. 851
+5. Fill the bearing with grease "AUTOL TOP 2000 high temp".p. 851
5. Fill the bearing with grease "AUTOL TOP 2000 high temp".p. 851
+6. Grease the new O-ring and insert it into the bearing housing.p. 851
6. Grease the new O-ring and insert it into the bearing housing.p. 851
+7. Clean the contact face (2).p. 851
7. Clean the contact face (2).p. 851
+Fig. 3p. 851
Fig. 3p. 851
+8. Attach the lifting tackle to the bearing flange.p. 851
8. Attach the lifting tackle to the bearing flange.p. 851
+9. Turn in two guide bolts (M20)p. 851
+9. Turn in two guide bolts (M20)p. 851
(Fig. 3)p. 851
+Fig. 4p. 852
Fig. 4p. 852
+Oil drain plug and marking on drump. 852
+Oil drain plug and marking on drump. 852
(Fig. 4)p. 852
+10. Insert the bearing flange into the drum.p. 852
10. Insert the bearing flange into the drum.p. 852
+Fig. 5p. 852
Fig. 5p. 852
+11. Assemble the fastening screwsp. 852
+11. Assemble the fastening screwsp. 852
(Fig. 5)p. 852
+12. Unscrew the guide bolt and replace it with a fastening screw.p. 852
12. Unscrew the guide bolt and replace it with a fastening screw.p. 852
+13. Tighten the screws with washers evenly cross- wise.p. 852
13. Tighten the screws with washers evenly cross- wise.p. 852
+Fig. 6p. 852
Fig. 6p. 852
+14. Check the rubber buffers, replace if necessaryp. 852
+14. Check the rubber buffers, replace if necessaryp. 852
(Fig. 6)p. 852
+Fig. 7p. 852
Fig. 7p. 852
+15. Close free tapped bores (only BW213) with screws and washersp. 852
+15. Close free tapped bores (only BW213) with screws and washersp. 852
(Fig. 7)p. 852
+Fig. 8p. 853
Fig. 8p. 853
+16. Attach lifting tackle to the drive disc with gearbox, travel motor and gearbox holderp. 853
+16. Attach lifting tackle to the drive disc with gearbox, travel motor and gearbox holderp. 853
(Fig. 8)p. 853
+Fig. 9p. 853
Fig. 9p. 853
+17. Attach the drive unit to the rubber buffersp. 853
+17. Attach the drive unit to the rubber buffersp. 853
(Fig. 9)p. 853
+Fig. 10p. 853
Fig. 10p. 853
+18. Fasten the drive unit with nuts and washersp. 853
+18. Fasten the drive unit with nuts and washersp. 853
(Fig. 10)p. 853
+19. Remove the lifting tackle.p. 853
19. Remove the lifting tackle.p. 853
Left drum sidep. 854
+Fig. 11p. 854
Fig. 11p. 854
+20. Attach the lifting tackle to the exciter unitp. 854
+20. Attach the lifting tackle to the exciter unitp. 854
(Fig. 11)p. 854
+Fig. 12p. 854
Fig. 12p. 854
+21. Grease the new O-ring 1p. 854
+21. Grease the new O-ring 1p. 854
(Fig. 12)p. 854
+22. Clean the contact face (2).p. 854
22. Clean the contact face (2).p. 854
+Fig. 13p. 854
Fig. 13p. 854
+23. Fill the inner bearing race with grease "AUTOL TOP 2000 high temp"p. 854
+23. Fill the inner bearing race with grease "AUTOL TOP 2000 high temp"p. 854
(Fig. 13)p. 854
+Fig. 14p. 854
Fig. 14p. 854
+24. Insert the vibrator unit into the drump. 854
+24. Insert the vibrator unit into the drump. 854
(Fig. 14)p. 854
+Fig. 15p. 855
Fig. 15p. 855
+Oil filler opening and marking on drump. 855
+Oil filler opening and marking on drump. 855
(Fig. 15)p. 855
+Fig. 16p. 855
Fig. 16p. 855
+25. Assemble the fastening screwsp. 855
+25. Assemble the fastening screwsp. 855
(Fig. 16)p. 855
+26. Remove the lifting tackle.p. 855
26. Remove the lifting tackle.p. 855
+27. Tighten the screws with washers evenly cross- wise.p. 855
27. Tighten the screws with washers evenly cross- wise.p. 855
+Fig. 17p. 855
Fig. 17p. 855
+28. Keep turning the side plate to both directions and check for resistances while turningp. 855
+28. Keep turning the side plate to both directions and check for resistances while turningp. 855
(Fig. 17)p. 855
+Replace the bearings if they do not perform correctlyp. 855
Replace the bearings if they do not perform correctlyp. 855
+Fig. 18p. 855
Fig. 18p. 855
+29. Unscrew the oil filler plug 1p. 855
+29. Unscrew the oil filler plug 1p. 855
(Fig. 18)p. 855
+30. Fill in oil up to the max. capacity .p. 855
30. Fill in oil up to the max. capacity .p. 855
+For quality and quantity of oil refer to the table of "fuels, lubricants and filling capacities".p. 855
For quality and quantity of oil refer to the table of "fuels, lubricants and filling capacities".p. 855
+31. Turn the oil filler plug into the flange.p. 855
31. Turn the oil filler plug into the flange.p. 855
+Fig. 19p. 856
Fig. 19p. 856
+32. Attach the lifting tackle to the spacer block with longitudinal rubber elementsp. 856
+32. Attach the lifting tackle to the spacer block with longitudinal rubber elementsp. 856
(Fig. 19)p. 856
+Observe the assembly direction, arrow up.p. 856
Observe the assembly direction, arrow up.p. 856
+BW213 = 4 Rectangular rubber buffers.p. 856
BW213 = 4 Rectangular rubber buffers.p. 856
BW226 = 8 Rectangular rubber buffers.p. 856
+Fig. 20p. 856
Fig. 20p. 856
+33. Assemble the rectangular rubber buffer unit to the side plate with screws, washers and nutsp. 856
+33. Assemble the rectangular rubber buffer unit to the side plate with screws, washers and nutsp. 856
(Fig. 20)p. 856
+34. Tighten the screws (1) hand-tight.p. 856
34. Tighten the screws (1) hand-tight.p. 856
+Fig. 21p. 856
Fig. 21p. 856
+Assemble the support.p. 856
Assemble the support.p. 856
+35. Remove the lifting tackle.p. 856
35. Remove the lifting tackle.p. 856
+Fig. 22p. 856
Fig. 22p. 856
+36. Attach the lifting tackle to the second spacer block with longitudinal rubber elementsp. 856
+36. Attach the lifting tackle to the second spacer block with longitudinal rubber elementsp. 856
(Fig. 22)p. 856
+Observe the assembly direction, arrow up.p. 856
Observe the assembly direction, arrow up.p. 856
+BW213 = 4 Rectangular rubber buffers.p. 856
BW213 = 4 Rectangular rubber buffers.p. 856
BW226 = 8 Rectangular rubber buffers.p. 856
+Fig. 23p. 857
Fig. 23p. 857
+37. Assemble the rectangular rubber buffer unit to the side plate with screws, washers and nutsp. 857
+37. Assemble the rectangular rubber buffer unit to the side plate with screws, washers and nutsp. 857
(Fig. 23)p. 857
+38. Tighten the screws (1) hand-tight.p. 857
38. Tighten the screws (1) hand-tight.p. 857
+39. Remove the lifting tackle.p. 857
39. Remove the lifting tackle.p. 857
+40. Remove the support again.p. 857
40. Remove the support again.p. 857
+Fig. 24p. 857
Fig. 24p. 857
+41. Assemble the tool to block the rectangular rubber buffersp. 857
+41. Assemble the tool to block the rectangular rubber buffersp. 857
(Fig. 24)p. 857
+Fig. 25p. 857
Fig. 25p. 857
+42. Tighten the fastening screwsp. 857
+42. Tighten the fastening screwsp. 857
(Fig. 25)p. 857
+43. Disassemble the tool to block the rectangular rubber buffers.p. 857
43. Disassemble the tool to block the rectangular rubber buffers.p. 857
18.6 Changing the rubber buffers and adjusting the pretensionp. 858
+Fig. 1p. 858
Fig. 1p. 858
+Relieve the rubber buffersp. 858
Relieve the rubber buffersp. 858
+1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any loadp. 858
+1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any loadp. 858
(Fig. 1)p. 858
+2. Loosen all fastening screws.p. 858
2. Loosen all fastening screws.p. 858
+Fig. 2p. 858
Fig. 2p. 858
+3. Turn one screw each into the welded nutsp. 858
+3. Turn one screw each into the welded nutsp. 858
(Fig. 2)p. 858
+Fig. 3p. 858
Fig. 3p. 858
+4. Remove the compensation shimsp. 858
+4. Remove the compensation shimsp. 858
(Fig. 3)p. 858
+Fig. 4p. 859
Fig. 4p. 859
+5. Unscrew the screwsp. 859
+5. Unscrew the screwsp. 859
(Fig. 4)p. 859
+Fig. 5p. 859
Fig. 5p. 859
+Check the rectangular rubber buffers, replace if necessary.p. 859
Check the rectangular rubber buffers, replace if necessary.p. 859
Observe the assembly direction, arrow up.p. 859
+Fig. 6p. 859
Fig. 6p. 859
+Changing the rubber buffersp. 859
Changing the rubber buffersp. 859
+6. Unscrew nut 1p. 859
+6. Unscrew nut 1p. 859
(Fig. 3)p. 859
+7. Unscrew screws (2).p. 859
7. Unscrew screws (2).p. 859
+8. Take off rubber buffer (3).p. 859
8. Take off rubber buffer (3).p. 859
+9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.p. 859
9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.p. 859
+10. Turn in and tighten the fastening screws.p. 859
10. Turn in and tighten the fastening screws.p. 859
+11. Assemble the washer, turn on and tighten the nut.p. 859
11. Assemble the washer, turn on and tighten the nut.p. 859
+Fig. 7p. 859
Fig. 7p. 859
+Adjusting the pre-loadp. 859
Adjusting the pre-loadp. 859
+12. Measure distance "X" between spacer piece and side platep. 859
+12. Measure distance "X" between spacer piece and side platep. 859
(Fig. 7)p. 859
+13. Calculate the thickness of the compensation plates. Nominal value: Distance "X" + 2 mmp. 859
13. Calculate the thickness of the compensation plates. Nominal value: Distance "X" + 2 mmp. 859
+Fig. 8p. 860
Fig. 8p. 860
+14. Turn in screws into each welded nut and provide sufficient space to insert the compensation platesp. 860
+14. Turn in screws into each welded nut and provide sufficient space to insert the compensation platesp. 860
(Fig. 8)p. 860
+Fig. 9p. 860
Fig. 9p. 860
+15. Assemble the compensation shimsp. 860
+15. Assemble the compensation shimsp. 860
(Fig. 9)p. 860
+Fig. 10p. 860
Fig. 10p. 860
+16. Unscrew the screwsp. 860
+16. Unscrew the screwsp. 860
(Fig. 10)p. 860
+Fig. 11p. 860
Fig. 11p. 860
+17. Tighten the fastening screwsp. 860
+17. Tighten the fastening screwsp. 860
(Fig. 11)p. 860
+18. Lower the frame again.p. 860
18. Lower the frame again.p. 860
18.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrolp. 861
+Fig. 1p. 861
Fig. 1p. 861
+1. Guide bolt for bearing flange M20 x 200 mm.p. 861
1. Guide bolt for bearing flange M20 x 200 mm.p. 861
+Fig. 2p. 861
Fig. 2p. 861
+2. Tool to block the rectangular rubber buffers.p. 861
2. Tool to block the rectangular rubber buffers.p. 861
+Fig. 3p. 861
Fig. 3p. 861
+3. Tool to the drive disc with gearbox, travel motor and gearbox holder.p. 861
3. Tool to the drive disc with gearbox, travel motor and gearbox holder.p. 861
+Fig. 4p. 862
Fig. 4p. 862
+4. Tool to take up the exciter unit.p. 862
4. Tool to take up the exciter unit.p. 862
+Fig. 5p. 862
Fig. 5p. 862
+5. Mechanical fixation, assembly of gearbox cover with weights pointing downward (vertical amplitude) .p. 862
5. Mechanical fixation, assembly of gearbox cover with weights pointing downward (vertical amplitude) .p. 862
BOMAG part-no.: 955 822 11p. 862
+Fig. 6p. 862
Fig. 6p. 862
+6. Mechanical fixation, adjustment of potentiometer for horizontal amplitude.p. 862
6. Mechanical fixation, adjustment of potentiometer for horizontal amplitude.p. 862
BOMAG part-no.: 955 821 69p. 862
+Fig. 7p. 862
Fig. 7p. 862
+7. Mechanical lock for swashing motorp. 862
7. Mechanical lock for swashing motorp. 862
+Fig. 8p. 863
Fig. 8p. 863
+8. Auxiliary assembly rings, side plate.p. 863
8. Auxiliary assembly rings, side plate.p. 863
BOMAG part-no.: 972 051 73p. 863
+Fig. 9p. 863
Fig. 9p. 863
+9. Assembly device, radial seal.p. 863
9. Assembly device, radial seal.p. 863
+Fig. 10p. 863
Fig. 10p. 863
+10. Pressing tool, inner races of tapered roller bearingsp. 863
10. Pressing tool, inner races of tapered roller bearingsp. 863
BOMAG part-no.: 972 051 76p. 863
+Fig. 11p. 863
Fig. 11p. 863
+11. Pressing tool, outer races of tapered roller bearingsp. 863
11. Pressing tool, outer races of tapered roller bearingsp. 863
BOMAG part-no.: 972 051 75p. 863
+Fig. 12p. 864
Fig. 12p. 864
+12. 3X guide bolts for exciter shaft M27 X 500 mm.p. 864
12. 3X guide bolts for exciter shaft M27 X 500 mm.p. 864
+Fig. 13p. 864
Fig. 13p. 864
+13. 3X guide bolts for installation of exciter housing M18X1,5X 300 mm.p. 864
13. 3X guide bolts for installation of exciter housing M18X1,5X 300 mm.p. 864
+Fig. 14p. 864
Fig. 14p. 864
+14. Assembly mandrel for radial seal in exciter housingp. 864
14. Assembly mandrel for radial seal in exciter housingp. 864
+Fig. 15p. 864
Fig. 15p. 864
+15. Manual screwerp. 864
15. Manual screwerp. 864
+The manual screwer is equipped with a ratchet. Short ratchet movements allow very effective working.p. 864
The manual screwer is equipped with a ratchet. Short ratchet movements allow very effective working.p. 864
+Fig. 16p. 865
Fig. 16p. 865
+16. Assembly mandrel for radial seal in bearing flangep. 865
16. Assembly mandrel for radial seal in bearing flangep. 865
+Fig. 17p. 865
Fig. 17p. 865
+17. Protection cap for assembling the gearp. 865
17. Protection cap for assembling the gearp. 865
+Fig. 18p. 865
Fig. 18p. 865
+18. Puller to disassemble the exciter shaft, exciter housing rightp. 865
18. Puller to disassemble the exciter shaft, exciter housing rightp. 865
+Fig. 19p. 865
Fig. 19p. 865
+19. Puller to disassemble the outer bearing race, exciter housing rightp. 865
19. Puller to disassemble the outer bearing race, exciter housing rightp. 865
+19 Oscillating articulated jointp. 867
19 Oscillating articulated jointp. 867
+19.1 Special toolsp. 868
19.1 Special toolsp. 868
+Fig. 1p. 868
Fig. 1p. 868
+1. Assembly mandrel for rocker bearings (console of articulated joint).p. 868
1. Assembly mandrel for rocker bearings (console of articulated joint).p. 868
BOMAG part-no.: 007 211 55p. 868
+Fig. 2p. 868
Fig. 2p. 868
+2. Assembly mandrel for rocker bearings (steering cylinders).p. 868
2. Assembly mandrel for rocker bearings (steering cylinders).p. 868
BOMAG part-no.: 007 211 56p. 868
Repair overview oscillating articulated joint
Fig. 1 Oscillating articulated jointp. 870
Fig. 2 Cross-sectional drawingp. 871
+1 Four-point bearingp. 871
1 Four-point bearingp. 871
2 Console, frontp. 871
3 Centring discp. 871
4 O-ringp. 871
5 Console, rearp. 871
6 Self-aligning bearingp. 871
7 Spacer ringp. 871
8 Washerp. 871
9 Boltp. 871
Fig. 3p. 872
+1) Assemble with sliding agent OKS 571 00970026p. 872
(Fig. 3)p. 872
2) Clean the grease nipples and lubricate with approx. 10 shots from the grease gun.p. 872
3) Slightly oil the bearing seatp. 872
Fig. 4 electric steeringp. 873
+Assembly of steering angle sensor for electric steering (BVC machines)p. 873
(Fig. 4)p. 873
a) Align the marks for assembly.p. 873
b) The marks must face in travel direction forward (± 15°)p. 873
1) Mounting platep. 873
2) Steering angle sensorp. 873
3) Roll pinp. 873
4) Control leverp. 873
5) Adapter platep. 873
+After assembly perform teaching of the end stops for the steering angle sensor (see electrics of the machine).p. 873
After assembly perform teaching of the end stops for the steering angle sensor (see electrics of the machine).p. 873
19.3 Removing and installing the oscillating articulated jointp. 874
+Fig. 1p. 874
Fig. 1p. 874
+1. Jack the back of the framep. 874
+1. Jack the back of the framep. 874
(Fig. 1)p. 874
+2. Jack the front frame up and secure it with trestles or wooden blocks.p. 874
2. Jack the front frame up and secure it with trestles or wooden blocks.p. 874
+3. Block drums and wheels with suitable chocks .p. 874
3. Block drums and wheels with suitable chocks .p. 874
+Fig. 2p. 874
Fig. 2p. 874
+4. Unscrew fastening screws 1p. 874
+4. Unscrew fastening screws 1p. 874
(Fig. 2)p. 874
+5. Knock out bearing bolt (3).p. 874
5. Knock out bearing bolt (3).p. 874
+6. Retract steering cylinder (4).p. 874
6. Retract steering cylinder (4).p. 874
+Fig. 3p. 874
Fig. 3p. 874
+Danger of accident!p. 874
Danger of accident!p. 874
+7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.p. 874
7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.p. 874
+8. Unscrew fastening screws 1p. 874
+8. Unscrew fastening screws 1p. 874
(Fig. 3)p. 874
+Fig. 4p. 875
Fig. 4p. 875
+9. Unscrew fastening screws 1p. 875
+9. Unscrew fastening screws 1p. 875
(Fig. 4)p. 875
+10. Pull out the oscillating articulated joint.p. 875
10. Pull out the oscillating articulated joint.p. 875
+Fig. 5p. 875
Fig. 5p. 875
+Note on assemblyp. 875
Note on assemblyp. 875
+11. Insert the bolt for the steering cylinder so that groove 2p. 875
+11. Insert the bolt for the steering cylinder so that groove 2p. 875
(Fig. 5)p. 875
19.4 Dismantling the oscillating articulated jointp. 876
+Fig. 1p. 876
Fig. 1p. 876
+1. Unscrew fastening screws 1p. 876
+1. Unscrew fastening screws 1p. 876
(Fig. 1)p. 876
+Danger of squashing!p. 876
Danger of squashing!p. 876
+2. Take out bolt (3).p. 876
2. Take out bolt (3).p. 876
+Fig. 2p. 876
Fig. 2p. 876
+3. Unscrew fastening screws 1p. 876
+3. Unscrew fastening screws 1p. 876
(Fig. 2)p. 876
+Fig. 3p. 876
Fig. 3p. 876
+Danger of squashing!p. 876
Danger of squashing!p. 876
+4. Turn out bolt 1p. 876
+4. Turn out bolt 1p. 876
(Fig. 3)p. 876
+Fig. 4p. 877
Fig. 4p. 877
+5. Take spacer ring 1p. 877
+5. Take spacer ring 1p. 877
(Fig. 2)p. 877
+Fig. 5p. 877
Fig. 5p. 877
+6. Unscrew fastening screws 1p. 877
+6. Unscrew fastening screws 1p. 877
(Fig. 3)p. 877
+Fig. 6p. 877
Fig. 6p. 877
+7. Take the O-ring out of the rocker bearingp. 877
+7. Take the O-ring out of the rocker bearingp. 877
(Fig. 4)p. 877
+Fig. 7p. 877
Fig. 7p. 877
+8. Knock both rocker bearings 1p. 877
+8. Knock both rocker bearings 1p. 877
(Fig. 5)p. 877
+Fig. 8p. 878
Fig. 8p. 878
+9. Knock rocker bearings 1p. 878
+9. Knock rocker bearings 1p. 878
(Fig. 8)p. 878
+Fig. 9p. 878
Fig. 9p. 878
+10. Unscrew fastening screws 1p. 878
+10. Unscrew fastening screws 1p. 878
(Fig. 9)p. 878
+11. Check four point bearing for wear , replace if necessary.p. 878
11. Check four point bearing for wear , replace if necessary.p. 878
19.5 Assembling the oscillating articulated jointp. 879
+Fig. 1p. 879
Fig. 1p. 879
+1. Lay the four point bearing 3p. 879
+1. Lay the four point bearing 3p. 879
(Fig. 1)p. 879
+Fig. 2p. 879
Fig. 2p. 879
+2. Spray the rocker bearings 1p. 879
+2. Spray the rocker bearings 1p. 879
(Fig. 2)p. 879
+Special tools:p. 879
Special tools:p. 879
Assembly mandrel for rocker bearings (steering cylinders).p. 879
+Fig. 3p. 879
Fig. 3p. 879
+3. Slightly lubricate the bearings seats and knock rocker bearings 1p. 879
+3. Slightly lubricate the bearings seats and knock rocker bearings 1p. 879
(Fig. 3)p. 879
+Special tools:p. 879
Special tools:p. 879
Assembly mandrel for rocker bearings (console of articulated joint).p. 879
+Fig. 4p. 880
Fig. 4p. 880
+4. Grease the new O-rings and insert them into the rocker bearingsp. 880
+4. Grease the new O-rings and insert them into the rocker bearingsp. 880
(Fig. 2)p. 880
+Fig. 5p. 880
Fig. 5p. 880
+5. Fasten centring discs 2p. 880
+5. Fasten centring discs 2p. 880
(Fig. 3)p. 880
+Fig. 6p. 880
Fig. 6p. 880
+6. Insert spacer ring 1p. 880
+6. Insert spacer ring 1p. 880
(Fig. 4)p. 880
+Fig. 7p. 880
Fig. 7p. 880
+7. Spray pin 1p. 880
+7. Spray pin 1p. 880
(Fig. 5)p. 880
+Bolt (1) must be knocked in on the side with spacer ring 1p. 880
+Bolt (1) must be knocked in on the side with spacer ring 1p. 880
(Fig. 4)p. 880
+8. Join both consoles (2 and 3) together and knock in bolt (1).p. 880
8. Join both consoles (2 and 3) together and knock in bolt (1).p. 880
+Fig. 8p. 881
Fig. 8p. 881
+9. Assemble disc 2p. 881
+9. Assemble disc 2p. 881
(Fig. 8)p. 881
+Fig. 9p. 881
Fig. 9p. 881
+10. Spray bolt 3p. 881
+10. Spray bolt 3p. 881
(Fig. 9)p. 881
+Fig. 10p. 881
Fig. 10p. 881
+11. Secure bolt 3p. 881
+11. Secure bolt 3p. 881
(Fig. 10)p. 881
+20 Suppliers documentationp. 883
20 Suppliers documentationp. 883
20.4 Axlep. 884
+20.4 Axlep. 885
20.1 Travel and vibration pumpp. 885
20.4 Axlep. 886
20.4 Axlep. 887
+20.4 Axlep. 1039
20.2 Vibration motorp. 1039
20.4 Axlep. 1040
+20.4 Axlep. 1040
This repair manual describes the fixed displacement motor A2FM/E; the repair procedures are identical with the ones for the fixed displacement motor A2FE32, which differs only by a different housing design.p. 1040
20.4 Axlep. 1041
20.4 Axlep. 1069
+20.4 Axlep. 1117
20.3 Axle drive motorp. 1117
20.4 Axlep. 1118
20.4 Axlep. 1119
+20.4 Axlep. 1199
20.4 Axlep. 1199
+21 Circuit diagramsp. 1289
21 Circuit diagramsp. 1289
2p. 1290
+2p. 1291
2p. 1291
21.1 Hydraulic diagram 581 202 08p. 1291
S/N Wiring diagram 582 702 07p. 1292
S/N Wiring diagram 582 702 07p. 1293
S/N Wiring diagram 582 702 07p. 1294
+S/N Wiring diagram 582 702 07p. 1295
21.2 Wiring diagram 582 702 07p. 1295
S/N Wiring diagram 582 702 07p. 1296
+S/N Wiring diagram 582 702 07p. 1296
S/N Wiring diagram 582 702 07p. 1296
+S/N 101 582 121 001p. 1296
Ûp. 1296
+S/N 101 582 641 001p. 1296
Ûp. 1296
+S/N 101 582 651 001p. 1296
Ûp. 1296
+S/N 101 582 771 001p. 1296
Ûp. 1296
+S/N 101 582 781 001p. 1296
Ûp. 1296
+S/N 101 582 861 001p. 1296
Ûp. 1296
+S/N 101 582 881 001p. 1296
Ûp. 1296
+S/N 101 582 891 001p. 1296
Ûp. 1296
+S/N 101 583 141 001p. 1296
Ûp. 1296
+S/N 101 583 151 001p. 1296
Ûp. 1296
+S/N 101 583 161 001p. 1296
Ûp. 1296
+S/N 101 583 191 001p. 1296
Ûp. 1296
+S/N 101 583 061 001p. 1296
Ûp. 1296
S/N Wiring diagram 582 702 32p. 1338
+S/N Wiring diagram 582 702 32p. 1339
21.3 Wiring diagram 582 702 32p. 1339
S/N Wiring diagram 582 702 32p. 1340
+S/N Wiring diagram 582 702 32p. 1340
S/N Wiring diagram 582 702 32p. 1340
+S/N 101 582 121 002p. 1340
Ûp. 1340
+S/N 101 582 131 001p. 1340
Ûp. 1340
+S/N 101 582 641 060p. 1340
Ûp. 1340
+S/N 101 582 651 005p. 1340
Ûp. 1340
+S/N 101 582 771 171p. 1340
Ûp. 1340
+S/N 101 582 781 019p. 1340
Ûp. 1340
+S/N 101 582 861 026p. 1340
Ûp. 1340
+S/N 101 582 881 003p. 1340
Ûp. 1340
+S/N 101 582 891 004p. 1340
Ûp. 1340
+S/N 101 583 141 076p. 1340
Ûp. 1340
+S/N 101 583 151 005p. 1340
Ûp. 1340
+S/N 101 583 161 027p. 1340
Ûp. 1340
+S/N 101 583 191 005p. 1340
Ûp. 1340
+S/N 101 583 201 001p. 1340
Ûp. 1340
+S/N 101 583 371 001p. 1340
Ûp. 1340
+S/N 101 583 061 014p. 1340
Ûp. 1340
+S/N Wiring diagram 582 702 39p. 1381
21.4 Wiring diagram 582 702 39p. 1381
S/N Wiring diagram 582 702 39p. 1382
+S/N Wiring diagram 582 702 39p. 1382
S/N Wiring diagram 582 702 39p. 1382
+S/N 101 582 121 007p. 1382
Ûp. 1382
+S/N 101 582 131 002p. 1382
Ûp. 1382
+S/N 101 582 641 097p. 1382
Ûp. 1382
+S/N 101 582 651 006p. 1382
Ûp. 1382
+S/N 101 582 771 293p. 1382
Ûp. 1382
+S/N 101 582 781 021p. 1382
Ûp. 1382
+S/N 101 582 861 043p. 1382
Ûp. 1382
+S/N 101 582 881 015p. 1382
Ûp. 1382
+S/N 101 582 891 007p. 1382
Ûp. 1382
+S/N 101 583 141 138p. 1382
Ûp. 1382
+S/N 101 583 151 012p. 1382
Ûp. 1382
+S/N 101 583 161 074p. 1382
Ûp. 1382
+S/N 101 583 191 011p. 1382
Ûp. 1382
+S/N 101 583 281 001p. 1382
Ûp. 1382
+S/N 101 583 321 001p. 1382
Ûp. 1382
+S/N 101 583 331 001p. 1382
Ûp. 1382
+S/N 101 583 371 006p. 1382
Ûp. 1382
+S/N 101 583 061 031p. 1382
Ûp. 1382
S/N Wiring diagram 12p. 1383
S/N Wiring diagram 12p. 1424
+S/N Wiring diagram 12p. 1425
21.5 Wiring diagram 12p. 1425
S/N Wiring diagram 12p. 1426
+S/N Wiring diagram 12p. 1426
S/N Wiring diagram 12p. 1426
+S/N 101 582 121 024p. 1426
Ûp. 1426
+S/N 101 582 131 006p. 1426
Ûp. 1426
+S/N 101 582 641 151p. 1426
Ûp. 1426
+S/N 101 582 651 007p. 1426
Ûp. 1426
+S/N 101 582 771 294p. 1426
Ûp. 1426
+S/N 101 582 781 035p. 1426
Ûp. 1426
+S/N 101 582 861 109p. 1426
Ûp. 1426
+S/N 101 582 881 035p. 1426
Ûp. 1426
+S/N 101 582 891 009p. 1426
Ûp. 1426
+S/N 101 583 141 363p. 1426
Ûp. 1426
+S/N 101 583 151 036p. 1426
Ûp. 1426
+S/N 101 583 161 176p. 1426
Ûp. 1426
+S/N 101 583 191 020p. 1426
Ûp. 1426
+S/N 101 583 201 002p. 1426
Ûp. 1426
+S/N 101 583 281 038p. 1426
Ûp. 1426
+S/N 101 583 321 013p. 1426
Ûp. 1426
+S/N 101 583 331 054p. 1426
Ûp. 1426
+S/N 101 583 371 034p. 1426
Ûp. 1426
+S/N 101 583 061 083p. 1426
Ûp. 1426
Chapters Covered
General – introduction, safety regulations, general repair instructions, tightening torques
Maintenance – general notes, fuels and lubricants, table of fuels and lubricants, running-in instructions, maintenance table
Connection overview – travel / vibration pump
Tests and adjustments – special tools, activating service mode, driving against the closed brake, steering against an end stop, pressure tests in the travel circuit, checking and adjusting travel pump neutral positions, pressure measurements in the vibration circuit, checking vibration motor leakage rate, pressure test in the steering circuit
Flushing and bleeding – special tools for flushing, flushing schematics and procedures for travel circuit and vibration drive, bleeding the travel circuit, bleeding the vibration circuit
Electrics – component and terminal designations, battery and analog ground, current and voltage, pulse width modulation, resistance, series and parallel connection, Ohm’s law, metrology, diodes, relays, fuses, plug connectors, Deutsch DT and DTM plugs, spring clamp terminals, inductive proximity switches, angle sensors, acceleration transducer, potentiometer on the slewing motor B62, batteries and battery service, main battery fuse, jump starting, electronic control units, checking the voltage supply, diagnostics concept
Dust protection and gasket assembly
Engine electrics – EMR3 system components, pin assignment of EDC16 / EMR3, camshaft and crankshaft speed sensors, rail pressure sensor, fuel pressure sensor, fuel control unit, injector, oil pressure sensor, charge air temperature and pressure sensor, coolant temperature sensor, glow plugs, water-in-fuel sensor, fuel pre-heating, rotary switch for engine speed, data collector, fault display, diagnosis with SERDIA, diagnosis with CAN-bus, diagnostics interface, EMR3 fault code list, generator, voltage regulator, electric starter
Electronic modules – machine related electrics, electrics MESX, electric module A72, electric module A108
Service Training – BW 216 / 219 / 226 DH / PDH-4 travel system, vibration, steering, and Service Training BVC for Variocontrol machines
Engine – diesel engine, engine description TCD 2012, lubrication oil circuit, coolant circuit, fuel system, Deutz Common Rail injection system, exhaust gas recirculation, wastegate charge pressure control, engine problems, oil level checks, oil and filter changes, fuel pre-filter and fuel filter replacement, water separator, coolant level and change, thermostat testing, combustion air filter service, dust separator, valve clearance adjustment, ribbed V-belt, engine mounts, crank case ventilation valve, engine conservation, special tools
Air conditioning system – physical basics, refrigerant R134a, compressor oil, working principle, monitoring devices, component descriptions, compressor oil level, magnetic clutch, inspection and maintenance, V-belt, service procedures, drying and evacuation, leak test, filling instructions, troubleshooting and steam table
Cabin assembly – preparations, assembly, final function tests and checks
Replacing the cab window panes – assembly of window panes, special tools, auxiliary materials, removal and installation
Drum – repair overview, removing and installing the drum, dismantling the drum, assembling the vibrator unit, installing the exciter unit, changing the rubber buffers and adjusting the pretension, special tools
Oscillating articulated joint – special tools, repair overview, removal and installation, dismantling, assembly
Beyond the chapter list, the document works as a complete workshop reference for one machine rather than a general overview. The repair sections go down to individual bearings, seals, circlips and spacer rings, with assembly sequences, heating and cooling temperatures for bearing races, grease and sealant call-outs, and stated tightening torques for the critical joints on the exciter housing, flanged hub, side plate and clamping ring. The hydraulic chapters walk through the Sauer travel and vibration pump tandem unit, the drum and axle drive motors, the charge and flushing circuits and the steering valve, and they are backed by measurable test points with nominal charge, high-pressure and steering pressures. The electrical half of the manual links the ESX travel control, MESX measuring control, data collector and LC display together, lists ESX and EMR3 fault codes with possible causes, and finishes with the E-Plan and Caddy wiring diagrams plus a full component listing and terminal strip overview.
IMAGES PREVIEW
What This Manual Lets You Do
With the BOMAG BW 226 DH-4 BVC Single Drum Roller Service Manual on hand you can carry out the work the machine actually demands: setting the travel pump neutral position, teaching the electronic steering end stops, reading and clearing ESX and engine fault logs, measuring charge pressure and high-pressure override in the travel and vibration circuits, flushing and bleeding the closed loops after a component change, and verifying vibration motor leakage against the permitted rate. On the mechanical side it supports drum removal, exciter unit dismantling and rebuild, rubber buffer replacement with pretension adjustment, oscillating articulated joint overhaul, and the removal and resealing of the cab window panes.
Correct procedures and the specified values matter here. A hydrostatic roller is unforgiving of a wrong torque, an unbled circuit or a mis-set neutral position, and the service manual supplies the sequence, the measuring points and the nominal figures that keep the machine within its design limits instead of relying on trial and error. Deutz TCD 2012 L06 2V engine maintenance, from valve clearance and ribbed V-belt checks through to Common Rail fuel filter changes and water separator cleaning, is documented with the same level of detail.
Instant PDF Delivery
The BOMAG BW 226 DH-4 BVC Single Drum Roller Service Manual is delivered as an instant PDF download with no shipping and no waiting. Read it on a laptop, tablet or phone in the workshop or print the pages you need for the job in front of you – the wiring diagrams, torque tables and hydraulic schematics are all there to be taken straight to the machine.
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